Download PDF: Repair Manual for BT Forklift SWE Series (100, 120, 120S, 120L, 140, 140L, 200D)

Repair Manual 7519083-040 SWE100, 120, 120S, 120L, 140, 140L, 200D

Document revisions:

Issue date

Order number

Changes

2010-03-26

7519083-040

Completely new issue.

2011-04-04

7519083-040

Updated with S220D.

2013-01-31

7519083-040

Chapter 6 - Parameters Chapter 7 - Troubleshooting: Parameter 3.210 added Chapter 13 - Castor wheel mounts: Adding shims Chapter 14 - Support arm wheels: Adding shims Chapter 21 - Battery weights and hydraulic information

2013-10-01

7519083-040

Chapter 3: General safety rules – Updated Chapter 4: Installation – Updated Chapter 5: Maintenance – Updated Chapter 7: Troubleshooting – Updated Chapter 15: Steering system – 15.5.4 Tiller arm handle updated Chapter 15: Steering system – 15.4 Safety sensor updated Chapter 18: Mast – 18.3 Chain adjustment updated Chapter 21: Technical data – Brake disc tolerances

2014-09-01

7519083-040

Chapter 7 - Troubleshooting - Updated Chapter 10 - Drive gear – 10.4 Replacing wheel hub seal Chapter 25 - Wiring diagrams - Updated

2015-10-01

7519083-040

Chapter 6: Parameters - 1002 updated with more functions Chapter 7: Troubleshooting - 3.003 updated Chapter 7: Troubleshooting - Updated troubleshooting chart Chapter 11: Brakes - New overview Tools 23: Tools - updated

This manual covers following truck models: T-code

Model

Serial number

841

SWE100

6109948-

841

SWE120

6109948-

842

SWE120L

6109948-

841

SWE140

6109948-

842

SWE140L

6109948-

843

SWE120S

6109948-

842

SWE200D

6109948-

Contents Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

1 – Contents 2 – General introduction ......................................................................... 2-1 2.1 How to use this manual .................................................................. 2-1 2.2 Warning symbols ........................................................................... 2-2 2.3 Pictograms ..................................................................................... 2-2 2.3.1 Screws/Nuts .................................................................... 2-2 3 – General safety rules .......................................................................... 3-1 3.1 Work safety .................................................................................... 3-1 3.2 Electrical system ............................................................................ 3-3 3.3 Safe lifting ...................................................................................... 3-4 3.4 Truck modifications ........................................................................ 3-5 4 – Installation ......................................................................................... 4-1 4.1 General .......................................................................................... 4-1 4.2 Transporting the truck .................................................................... 4-1 4.3 Transporting the mast .................................................................... 4-1 4.4 Safe lifting ...................................................................................... 4-2 4.5 Battery installation.......................................................................... 4-3 4.5.1 Safety when handling batteries ....................................... 4-3 4.5.2 Installing the battery ........................................................ 4-4 4.6 Programming PIN codes ................................................................ 4-5 4.6.1 PIN code standard ........................................................... 4-6 4.7 Setting parameters......................................................................... 4-7 4.7.1 Setting the parameters for collision sensor (option) ........ 4-8 Collision sensor parameters 105, 106 and 111 ............... 4-8 Programming the PIN code for resetting the truck .......... 4-9 4.7.2 Setting the parameters for the battery and the battery charger ............................................................................ 4-9 4.7.3 Parameter 107 – Battery size ........................................ 4-11 Verifying the parameter setting for freely ventilated batteries (Lead-acid batteries) ....................................... 4-12 Verifying the parameter setting for valve-regulated batteries (Hawker/Exide) ............................................... 4-12 4.8 Function and safety checks.......................................................... 4-13 5 – Maintenance ....................................................................................... 5-1 5.1 Introduction .................................................................................... 5-1 5.2 Maintenance instructions ............................................................... 5-1 5.2.1 Cleaning and washing ..................................................... 5-1 5.2.2 High-pressure washers .................................................... 5-1 5.2.3 Degreasing agents .......................................................... 5-2 5.2.4 Cleaning the exterior ....................................................... 5-2 5.2.5 Cleaning the chain ........................................................... 5-2 5.2.6 Cleaning the motor compartment .................................... 5-3 5.2.7 Electric components ........................................................ 5-3 5.3 General .......................................................................................... 5-3 5.4 Service intervals............................................................................. 5-4 5.5 Maintenance schedule ................................................................... 5-5

1

Contents T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

6 – Function and parameters .................................................................. 6-1 6.1 General .......................................................................................... 6-1 6.2 Description of the function.............................................................. 6-1 Symbols on keypad and display ...................................... 6-2 6.3 Operating principle......................................................................... 6-3 6.4 Hour meter ..................................................................................... 6-8 6.5 Parameters .................................................................................... 6-9 6.5.1 General ............................................................................ 6-9 6.5.2 Displaying parameters ..................................................... 6-9 6.5.3 Setting parameters ........................................................ 6-10 6.5.4 Operator parameters ..................................................... 6-11 Factory preset operator parameters .............................. 6-12 6.5.5 Service parameters ....................................................... 6-13 6.5.6 Factory parameters ....................................................... 6-17 * Matrix for hardware/software compatibility .................. 6-19 7 – Troubleshooting ................................................................................ 7-1 7.1 General .......................................................................................... 7-1 Software compatibility ...................................................... 7-1 7.2 Emergency driving mode ............................................................... 7-1 7.3 Towing a defective truck ................................................................ 7-2 Tow using a tow truck and tow wagon: ............................ 7-2 7.4 Troubleshooting methods .............................................................. 7-3 7.4.1 General initial troubleshooting ......................................... 7-3 7.4.2 Concluding troubleshooting ............................................. 7-4 7.5 Error code history........................................................................... 7-5 7.6 Error code system.......................................................................... 7-6 7.7 Error codes .................................................................................... 7-7 7.8 Troubleshooting chart .................................................................. 7-25 7.8.1 The truck cannot be driven. ........................................... 7-26 7.8.2 Truck only travels at reduced speed .............................. 7-27 7.8.3 The truck can be driven but behaves abnormally .......... 7-28 7.8.4 The truck can be driven, but some functions do not work ......................................................................... 7-29 Software compatibility .................................................... 7-29 Hardware compatibility matrix ....................................... 7-29 7.8.5 Defective hydraulic functions ......................................... 7-30 7.9 Built-in test function...................................................................... 7-33 7.10 Digital input/output status............................................................. 7-34 7.10.1 Test function “9” – Transistor regulator ......................... 7-34 7.10.2 Test function “10” – Logic card ...................................... 7-37 7.10.3 Test function “12” – Expansion unit SEU (option). ........ 7-38 7.11 Test function for the display ......................................................... 7-39 7.12 Checking the built-in battery charger ........................................... 7-40 8 – Chassis 0000 ...................................................................................... 8-1 8.1 Support arm 0350 .......................................................................... 8-1 8.1.1 Support arm lift, lateral adjustment .................................. 8-1 8.1.2 Adjusting the kneeling action ........................................... 8-2 8.2 Motor mounts 0450 ........................................................................ 8-3 8.2.1 Replacing springs (not applicable for S212S) ................. 8-3 8.3 Removing the platform................................................................... 8-5

1–

Contents Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

9 – Electric drive motor 1700 .................................................................. 9-1 9.1 Components .................................................................................. 9-1 9.2 Removing the motor from the truck ................................................ 9-2 9.3 Drive motor tightening torques ....................................................... 9-4 9.4 Installing the temperature sensor................................................... 9-4 9.5 Cleaning......................................................................................... 9-5 10 – Drive gear 2550 .............................................................................. 10-1 10.1 General ........................................................................................ 10-1 10.2 Components ................................................................................ 10-1 10.3 Removing the gear from the truck (not applicable for S212S)...... 10-2 10.4 Removing the gear from the truck (not applicable for S212S)...... 10-4 10.5 Replacing the wheel hub seal ...................................................... 10-5 Removing the seal ......................................................... 10-5 Fitting the seal ............................................................... 10-6 11 – Brakes 3180 .................................................................................... 11-1 11.1 Components ................................................................................ 11-1 11.2 Releasing the brake ..................................................................... 11-2 11.3 Installing the dust shield............................................................... 11-3 11.4 Installing the dust shield............................................................... 11-5 12 – Drive wheel 3530 ............................................................................ 12-1 12.1 Replacing the drive wheel ............................................................ 12-1 13 – Castor wheels 3540 ....................................................................... 13-1 13.1 Components ................................................................................ 13-1 13.2 Castor wheel mounting ................................................................ 13-2 13.3 Replacing the castor wheel .......................................................... 13-3 14 – Support arm wheel 3550 ............................................................... 14-1 15 – Tiller arm 4000 ............................................................................... 15-1 15.1 Tiller arm components.................................................................. 15-1 15.2 Removing the tiller arm ................................................................ 15-2 15.3 Replacing the gas spring.............................................................. 15-2 15.4 Replacing the safety sensor......................................................... 15-3 15.4.1 Dismantling .................................................................... 15-3 15.4.2 Fitting ............................................................................. 15-3 15.5 Electrical steering system – 4000................................................. 15-5 15.5.1 Tiller arm handle C4110 ................................................ 15-5 15.5.2 Components of the tiller arm handle (new design) ........ 15-5 15.5.3 Components of the tiller arm handle (old design) .......... 15-6 15.5.5 Replacing the signal button/switch .............................. 15-13 15.5.6 Replacement of lift/lower button .................................. 15-13 15.5.7 Replacing the button .................................................... 15-14 15.5.8 Changing the position of the controls - support arm lift/fork lift .............................................................. 15-15 15.5.9 Replacing the safety reversal switch ........................... 15-16

3

Contents T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

16 – Electric components ..................................................................... 16-1 16.1 Replacing the wiring harness ....................................................... 16-1 16.1.1 Replacing the transistor regulator wiring harness ......... 16-2 16.2 Replacing the transistor regulator ................................................ 16-3 17 – Hydraulic system 6000 .................................................................. 17-1 17.1 General ........................................................................................ 17-1 17.2 Hydraulic hygiene ........................................................................ 17-2 17.2.1 Washing ......................................................................... 17-2 17.2.2 Packaging ...................................................................... 17-2 17.2.3 Handling ........................................................................ 17-2 17.2.4 Storage .......................................................................... 17-3 17.2.5 Work procedures ........................................................... 17-3 17.3 Hydraulic unit 6100 ...................................................................... 17-4 17.3.1 Emptying the hydraulic tank .......................................... 17-5 17.3.2 Hydraulic system, bleeding ............................................ 17-5 Cylinders with bleeding valve ........................................ 17-5 Cylinders without bleeding valve ................................... 17-5 17.4 Hydraulic connections 6230......................................................... 17-6 17.4.1 Quick change connector ................................................ 17-6 Connecting the quick change connector ....................... 17-6 Dismantling the quick change connector ....................... 17-7 17.5 Hydraulic calibration..................................................................... 17-8 17.6 Adjusting the pressure limiting valve............................................ 17-9 17.7 Disassembling the hydraulic unit................................................ 17-11 17.8 Hydraulic unit tightening torques................................................ 17-13 18 – Lift mast – 7000 .............................................................................. 18-1 18.1 Main mast 7100 ........................................................................... 18-1 18.1.1 Components .................................................................. 18-1 18.1.2 Maintenance .................................................................. 18-2 Fixing point .................................................................... 18-2 Lubrication ..................................................................... 18-2 18.2 Fork carriage 7420....................................................................... 18-3 18.2.1 Maintenance .................................................................. 18-3 ....................................................................................... 18-3 18.3 Main lift chain system 7120.......................................................... 18-4 18.3.1 Checking the chain setting ............................................ 18-4 18.3.2 Checking the chain ........................................................ 18-4 Noise ............................................................................. 18-4 Surface rust ................................................................... 18-4 Rusty links ..................................................................... 18-4 Stiff links ........................................................................ 18-5 Bolt rotation ................................................................... 18-5 Loose bolts .................................................................... 18-5 Outline wear .................................................................. 18-6 Stretching ...................................................................... 18-7 Damage ......................................................................... 18-7 Damaged plates ............................................................ 18-8 Damaged bolts .............................................................. 18-8 Dirty chain ...................................................................... 18-8 18.3.3 Cleaning ........................................................................ 18-8 18.3.4 Lubrication ..................................................................... 18-9 18.3.5 Adjustment ................................................................... 18-10

1–

Contents Order number 7519083-040

Date 2015-10-01

18.4 18.5 18.6

Valid from serial number 6109948-

T-code 841, 842, 843

Replacing the fork carriage ........................................................ 18-11 Replacement of the mast ........................................................... 18-13 Adjusting the mast...................................................................... 18-17

19 – Accessories ................................................................................... 19-1 19.1 Spider expansion unit................................................................... 19-1 19.2 TLS - Truck log system ................................................................ 19-2 19.3 ID unit........................................................................................... 19-2 19.4 Built-in battery charger ................................................................. 19-3 19.4.1 Technical data ............................................................... 19-3 19.4.2 Charging the battery ...................................................... 19-4 Main charging ................................................................ 19-4 Equalising charging ....................................................... 19-4 Charging completed ...................................................... 19-4 20 – Attachments ................................................................................... 20-1 20.1 General ........................................................................................ 20-1 21 – Technical data ................................................................................ 21-1 21.1 S210, S212, S214 ........................................................................ 21-1 21.2 S212L, S214L, S220D ................................................................. 21-4 21.3 S212S .......................................................................................... 21-7 21.4 Overflow pressure for mast ........................................................ 21-10 22 – General tightening torques ........................................................... 22-1 22.1 General ........................................................................................ 22-1 22.2 Galvanised, non-oiled screws ...................................................... 22-1 22.3 Untreated, oiled bolts ................................................................... 22-1 23 – Tools ............................................................................................... 23-1 23.1 MQS contacts .............................................................................. 23-1 23.2 AMP connectors........................................................................... 23-3 23.2.1 AMP connectors, Multilock series 040 ........................... 23-4 23.3 Molex connectors......................................................................... 23-4 23.4 Grease guns ................................................................................ 23-5 23.5 Other tools ................................................................................... 23-6 24 – Oil and grease specification ......................................................... 24-1 25 – Electrical components and wiring diagram ................................ 25-1 25.1 Electric components..................................................................... 25-1 25.2 Wiring diagram............................................................................. 25-5 25.2.1 List of symbols ............................................................... 25-5 25.2.2 General wiring diagram ................................................. 25-6 25.2.3 Wiring diagram .............................................................. 25-7 26 – Hydraulics chart ............................................................................ 26-1

5

Contents T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

27 – Instructions for disposal ............................................................... 27-1 27.1 General ........................................................................................ 27-1 27.2 Marking of plastics ....................................................................... 27-1 27.2.1 General marking of products and packaging ................. 27-1 27.2.2 Marking according to standard ...................................... 27-2 Abbreviations ................................................................. 27-2 Marking examples ......................................................... 27-2 27.3 Pressure vessels.......................................................................... 27-3 27.3.1 Gas struts ...................................................................... 27-3 27.4 Sorting categories ........................................................................ 27-4

1–

General introduction How to use this manual Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

2 – General introduction 2.1 How to use this manual This service manual is divided into chapers to provide the following information.

• Function and parameters – This chapter provides basic descriptions of the truck's main functions together with the controller system parameters • Installation and commissioning – This chapter describes the work that is necessary for commissioning of the truck • Maintenance – This chapter includes a general diagram for regular maintenance followed by detailed descriptions of required maintenance procedures • Troubleshooting – The troubleshooting chapter describes the error codes that are displayed when the truck is partially or completely disabled. It also describes the cause of the problem together with suggested remedies.

• Service actions – This chapter describes the different parts of the truck, e.g. the hydraulic system, descriptions of components and the service actions that need to be carried out. These descriptions are divided according to the C code system of the truck manufacturer.

• Appendices - The appendices include: - Instructions for disposal - Information about electrical components and wiring diagrams - Hydraulics diagram - List of required tools - Information about general tightening torques - Oil and grease specifications - Technical data

1

General introduction Warning symbols T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

2.2 Warning symbols The following warning symbols are used throughout the service manual: DANGER! DANGER! means there is a risk of accident potentially leading to death or serious injury and material loss or damage. This is always indicated by the warning symbol.

WARNING! WARNING! means that there is a risk of damage to components that are sensitive to electrostatic discharge.

Heed applicable ESD safety precautions.

NOTE: Note: means there is a risk of material loss or damage if the instructions are not followed. Also used to call attention to various points.

2.3 Pictograms 2.3.1 Screws/Nuts Wherever possible, pictograms have been used to describe certain work operations.

Pictograms are primarily used for operations that require loosening or tightening of screws:

×n s mm

The pictograms contain information about the screw head type and have arrows that show if the screw should be loosened or tightened.

The text below the pictograms provide additional information, such as: ‘s’: spanner size, ‘n’: number of screws and, where required, ‘T’: the recommended tightening torque.

2–

General safety rules Work safety Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

3 – General safety rules Only personnel trained in servicing and repair of this type of truck are authorised to carry out service and repair activities.

3.1 Work safety To make work safer and prevent accidents, always keep the following in mind: • Keep the maintenance work site clean. Oil and water on the floor will make it slippery.

• Use the correct working posture. Service work often involves sitting on your knees or bending over forwards. Try sitting on a toolbox, for example, to relieve the strain on your knees and back.

• Loose items and jewellery can get caught in moving parts of the truck. So never wear loose articles or jewellery while working on the truck.

• Exercise caution and always follow applicable local regulations when working at high heights.

• Use the correct tools for the work you are carrying out.

• Keep all tools well maintained.

• Make sure that all safety equipment including guards and covers are properly secured and that they work as intended before starting the repair work. If a guard or cover must be removed in order to perform the repair work, extra care must be taken, and when the repair work is finished the guard or cover must be refitted.

• Relieve the system pressure slowly before starting work on the truck’s hydraulic system.

• Use paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your hands.

• Drive unit oil and the hydraulic system oil may be hot.

DANGER! Risk of burn injury.

Hot drive unit and hydraulic oil.

Allow the truck to cool down before changing the oil.

• Only fill the hydraulic system with new and clean oil.

DANGER! Risk of damage to the hydraulic system.

If the oil is contaminated, the hydraulic components will suffer damage.

Always use new and clean oil in the hydraulic system.

• Store and transport changed oil according to applicable local directions.

1

General safety rules Work safety T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

• Do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way.

Follow local disposal regulations.

• Disconnect the battery prior to performing any welding work on the truck.

NOTE: The battery could be damaged.

When welding with an electric welding unit, welding current may enter the battery.

The battery must be disconnected.

• Prior to welding or grinding on painted surfaces, be sure to remove the paint at least 100 mm around the welding/grinding area by using sandblasting equipment or paint remover.

DANGER! Harmful gasses.

Heated paint gives off harmful gases.

Remove paint 100 mm around the welding/grinding location.

3–

General safety rules Electrical system Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

3.2 Electrical system When working on the electrical system of the truck, remember the following: • Never wear loose items or jewellery when working with the truck.

DANGER! Short-circuiting/Burn injury.

Short circuits and burn injuries can occur if metal objects come into contact with live electrical connections when working on the truck's electrical system.

Remove wristwatches, rings and other metal objects beforehand.

• Always use insulated tools when working on the electrical system.

• Always disconnect the battery before opening any covers to drive units or the electrical system.

• Always disconnect the battery prior to welding work using an electric welding unit. The welding current may damage the battery.

• Always disconnect the battery when carrying out maintenance or repair work on the truck unless otherwise stated in this repair manual.

• Clean electric motors using a rag or a vacuum cleaner.

• Clean electrical panels, electronic cards, contactors, contacts, magnetic valves, etc. with a dampened cloth and a cleaning agent that will not damage the part.

NOTE: Risk of short-circuiting that may damage electrical components.

Do not break the warranty seal on the logic cards.

3

General safety rules Safe lifting T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

3.3 Safe lifting 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 chocked to stop the truck from moving.

Select the lifting point so that the lift is as easy as possible, for example lifting one corner at a time. If the truck has marked lifting points 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.

DANGER! Risk of crushing since a poorly supported truck could fall down.

Never work under a truck that is not supported by trestles and secured by a lifting device.

Support the truck: • as close to the lifted part of the chassis as possible in order to reduce the falling height if the truck should collapse • so the truck cannot move.

Never support the jack on trestles to achieve a higher lift.

Never work under a raised truck without it being properly supported on trestles.

3–

General safety rules Truck modifications Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

3.4 Truck modifications Any modification of the truck must be approved beforehand. No modification of truck may be performed that may influence the capacity, stability and safety of the truck without prior written approval from the manufacturer, 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 designs, tests and implementation of the modification, • approves and makes the applicable changes to the capacity plate, adhesive labels, markings and operator’s manual 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 modification work.

— End of section —

5

General safety rules Truck modifications T-code 841, 842, 843

3–

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Installation General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4 – Installation 4.1 General This section describes the work that is necessary before the truck can be put into use.

4.2 Transporting the truck When transporting the truck on a lorry or the like, the truck must be properly anchored with stropping (A). Use inserts and sheets of shockabsorbing material to prevent damage to the truck during lashing and transport.

A

4.3 Transporting the mast When transporting the mast alone, you must properly anchor all loose parts. The guides must be secured so that they cannot glide apart.

Chains and any hoses must be fastened so that they cannot come loose or be damaged. The entire mast is then strapped to load pallets or another suitable support for transport.

A

1

Installation Safe lifting T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

4.4 Safe lifting

• Lift the truck at its centre of gravity using another fork lift truck.

• Secure the truck to the forks of the lifting truck.

• Lift it very carefully.

WARNING! Risk of tipping.

The truck may tip over if it is lifted incorrectly.

Always lift the truck when it has been fastened to the forks of the lifting truck and its centre of gravity between the forks.

• Only lift the truck at the indicated lifting points using suitable lifting equipment.

WARNING! Risk of tipping.

The truck may tip over if it is lifted in the wrong places.

Always lift the truck in the indicated lifting points.

4–

Installation Battery installation Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4.5 Battery installation 4.5.1 Safety when handling batteries Keep the following safety precautions in mind when working with the battery: • Gel batteries are only intended for use at room temperature within the interval +15 to +30°C. Otherwise, there is a risk of the battery being damaged or its service life being shortened.

• Always use protective gear to protect the eyes, head and skin when checking, handling or filling up batteries.

WARNING! Battery acid causes burns. If battery acid gets onto your skin or clothes, immediately flush the area with cold water. If you get battery acid in the face or the eyes, flush the area with cold water and immediately seek medical assistance.

• Always make sure to have a shower and eye flushing emergency aid close to the work place in case an accident should happen.

• Batteries generate explosive gases. Never use an open flame or other sources of ignition in close vicinity to a battery.

• Do not place tools or other metal objects on the battery. This can cause a short-circuit and even an explosion.

3

Installation Battery installation T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

4.5.2 Installing the battery The battery to be installed in the truck must be of the right size. If the battery is too small in terms of size and weight, it can seriously affect the truck's braking ability and truck stability when lifting goods. See the truck's identification plate for the correct battery data.

1. Lift the battery into place using an approved lifting device and a suitable battery lifting yoke or lifting loops.

WARNING! To prevent the battery from falling down when it is released from the lifting device, prepare trestles or other suitable supports of the right height to support it. Check the height of the supporting material before releasing the lifting hook.

2. Check the electrolyte level in the battery. Normally, the level should be around 10-15 mm above the cell plates.

3. Connect the battery cables/battery connector.

WARNING! Check that the polarity is correct when connecting the battery cables.

Compare the markings on the cables with those on the battery terminals. An incorrectly connected battery may cause short-circuiting.

4. Close the battery compartment cover.

5. Replace the battery plug.

6. Check and if required reset the parameters for the battery and battery charger. See the "Setting the parameters for the battery and battery charger" section in this chapter.

7. Test the truck before using it.

4–

Installation Programming PIN codes Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4.6 Programming PIN codes A number of PIN codes can be made accessible by activating so called blocks. By default, block 0 (zero) is activated, which means that the truck has 3 ready-to-use operator profiles from the beginning. Activation of other blocks means that all PIN codes for the block are accessible. If all 10 blocks are activated, there will be 10 PIN codes available for the operator profile.

The truck software stores a standard set of PIN codes according to the “Standard assignment of PIN codes”. These PIN codes can be changed to any value, but please avoid use of the same PIN code in different operator profiles.

There are two possible methods for programming PIN codes. The first and the simplest is to use TruckCom, which provides clear instructions. Se separate manual for using TruckCom. The other alternative is to use the truck keypad.

To start programming, proceed as follows: 1. Connect the CAN service key to connector [X41].

2. Enter code 341671 and press the ON button.

3. Select programming commands from the table below:

Function

Programming

Remarks

Restore factory settings.

Press 1 + the ON button

Blocks 1-9 are disabled.

The original PIN codes are reset according to the Standard assignment of PIN codes table.

PIN codes in the block can be used.

Press 2 + b + the ON button

B = Block 0-9

The PIN-codes in the block cannot be used

Press 3 + b + the ON button

B = Block 0-9

Programming a new PIN code

Press 4 + b + P + NNNN + the ON button Note: The block that should apply must first be activated (see function 2 in the table above).

B = Block 0-9 P = Operator profile 1-10 NNNN = PIN code Note: It is only possible to assign one digit to an operator profile. As a result, operator profile 10 should be assigned as 0 (zero).

4. Switch off the truck by pressing the OFF button.

Programming of PIN codes is now complete. Verify that programming has been done correctly by logging in using one of the new PIN codes.

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

Installation Programming PIN codes T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

4.6.1 PIN code standard The table below shows the PIN codes that are found as standard in the programme. PIN codes can be activated or changed according to the preferences of the operator. An operator profile is activated upon normal log-in by all PIN codes whose block number is activated.

The truck program does not approve log-in using the PIN code “0000”.

Note: Service personnel is urged to keep written records of activated blocks, changed PIN codes and specially set operator profiles.

Standard assignment for PIN codes Operator profile no.

1

Block 0

0001

0002

0003

0000

0000

0000

0000

0000

0000

0000

Block 1

7901

1437

3731

1049

9439

7265

1322

2869

1574

5421

Block 2

4854

2907

9175

5799

1490

3031

7392

5622

5023

1787

Block 3

3174

1026

3815

6703

1179

5152

7514

5668

3215

4659

Block 4

7110

5477

3846

9491

5918

8222

6923

8139

7025

9197

Block 5

6276

9879

9658

1690

4042

5201

9807

4332

9715

2549

Block 6

4142

8620

3754

8432

8788

7430

1948

2595

8527

7474

Block 7

1482

7135

2395

7365

7092

4611

2831

4185

6067

1930

Block 8

4731

1022

5377

3257

7334

9009

7881

8843

7436

2876

Block 9

3162

5878

2828

1910

6907

2136

5730

2957

7691

3242

4–

2

3

4

5

6

7

8

9

10 Note: Enter ed as 0

Installation Setting parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4.7 Setting parameters This chapter covers only those parameters that need to be set upon commissioning of the truck and which, as a result, require detailed descriptions. Fore more information on the parameters, please refer to the Function and parameters chapter.

Check to make sure all parameters are set to the desired values in terms of • maximum travel speed, operator parameter – see the Function and parameters chapter • acceleration, operator parameters – see the Function and parameters chapter • braking, operator parameters – see the Function and parameters chapter • collision sensor (option) • battery • battery charger (option) 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.

7

Installation Setting parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

4.7.1 Setting the parameters for collision sensor (option) Be sure to set the parameters for collision sensitivity upon installation of the truck.

If a collision sensor is installed on the CAN bus, this registers when the truck bumps against something. If a collision exceeds a certain force, set by parameters 105 and 106, it is interpreted as a collision, and the truck travel speed is reduced to creep speed, a signal is heard and error code 8.001 is displayed.

Information about the collision is stored in the truck's internal memory.

The last ten registered collisions can be displayed together with operator identity via the PIN code. Additional information is available via TruckCom where collision levels and time indications can also be read.

Collision sensor parameters 105, 106 and 111 See the table below for information about the possible values:

Service parameters Parameter

Designation/unit

Min./ Max.

Incr eme nt

Std .

Description

105

Collision sensor X level

0/100

1

0

Indicates the degree of sensitivity for what should be interpreted as a side impact.

106

Collision sensor Y level

0/100

1

0

Indicates the sensitivity for generating a front or rear collision report.

111

Reset following a collision

0/1

1

0

0 = A special PIN code to reset the truck after a collision is required.

1 = The truck can be reset using all the activated PIN codes.

Note: If the parameter value for the collision sensor is set to 0 (zero), this will disable the collision sensor function as well the logging function.

4–

Installation Setting parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Programming the PIN code for resetting the truck 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 upon installation of the truck.

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, and it needs to be changed to a desired PIN code by the service technician.

Note: The PIN code cannot contain the same combination of digits as any of the other programmed PIN codes.

4.7.2 Setting the parameters for the battery and the battery charger Upon installation of the battery, the following parameters must be set or verified.

Note: Even if the battery has been supplied with the truck from the factory, the parameters still need to be set or verified.

Note: Ensure that service parameter 109 is set to the value for the installed battery and that the right battery capacity is set in parameter 110.

Note: For Hawker Evolution batteries, only battery sizes 134Ah, 174Ah and 201Ah may be used.

9

Installation Setting parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Parameter

Designation/unit

Min. / Max .

Incr eme nt

Std.

Description

107 service parameter

Battery setting, Ah

1/20

1

9

9 = Large battery 13 = Medium battery 17 = Small battery For more information, see the text below the table. See section "4.7.3 Parameter 107 – Battery size".

109 service parameter

Battery charger, battery type

0/3

1

0

Determines the battery type.

0 = No charging. Default setting An error code is displayed if this parameter has been set to 0 when a battery charger has been installed and factory parameter 1101 has been set to 1.

1 = Lead/acid battery 2 = Hawker Evolution battery. Size 134Ah, 174Ah, 201Ah 3 = Exide gel-battery

110 service parameter

Built-in battery charger, battery capacity, Ah

0/300 (100/ 300)

1

0 (100)

Specifies the battery capacity.

0 (100) = No charging. Default setting An error code is displayed if this parameter has been set to 0 (100) when a battery charger has been installed and factory parameter 1101 has been set to 1.

The value in brackets () indicates if the truck has software version -006 or newer.

Factory parameter 1101

Built-in battery charger

0/1

1

0

0 = No battery charger 1 = Battery charger installed

Note: If factory parameter 1101 has been set to 0 (zero), service parameters 109 and 110 should also be set to 0 (zero). If the truck has software version -006 or newer, and if factory parameter 1101 has the value 0 (zero) the service parameter 109 must have the value 0 (zero) and service parameter 110 must have the value 100 (one hundred). The values of service parameters 109 and 110 only need to be changed if the truck is equipped with a built-in charger and the value of factory parameter 1101 has been set to 1.

4–

Installation Setting parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4.7.3 Parameter 107 – Battery size It is necessary to specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid density when the battery is fully charged, to check the quality of battery. This value should be in the range 1.27-1.29.

Please note that the acid density may vary between different battery brands.

• When the lifting capacity is disabled (battery 80% discharged), the value must be close to, but not below, 1.14.

Refer to the table below for recommended parameter settings.

Parameter 107

Slight discharge

Deeper discharge

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Battery size Lead-acid battery

286-320 Ah 251-285 Ah 221-250 Ah 206-220 Ah 191-205 Ah 176-190 Ah 161-175 Ah 146-160 Ah 131-145 Ah 115-130 Ah

Battery size Hawker Evolution

Battery size Exide gel battery

271-280 Ah 251-270 Ah 231-250 Ah 211-230 Ah 191-210 Ah 171-190 Ah 151-170 Ah 131-150 Ah 120-130 Ah

271-290 Ah 251-270 Ah 231-250 Ah 211-230 Ah 191-210 Ah 171-190 Ah 151-170 Ah 131-150 Ah 110-130 Ah

WARNING! Battery service life will be reduced if the value of parameter 107 is set too high. The standard setting of parameter 107 is set for normal truck handling. Other applications may require a different setting of parameter 107. Check that the parameter setting is the correct one using the instructions below.

11

Installation Setting parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Verifying the parameter setting for freely ventilated batteries (Lead-acid batteries) 1. Charge the battery.

2. Operate the truck in its normal application until the battery indicator indicates a discharged battery (0% in the display).

3. Disconnect the battery from the truck and allow it to rest for at least two hours.

Note: Do not allow any charging or discharging during this time.

4. Measure the acid weight of the battery at room temperature.

If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value is considerably higher than 1.15 g/ cm3 the risk of damage to the battery is reduced. At the same time, however, the operating time of the truck decreases. If extended operating time is desired, then increase the parameter value, but maximum by one unit.

Note: Each change should be followed up by a new verification of the parameter setting.

Verifying the parameter setting for valve-regulated batteries (Hawker/Exide) 1. Charge the battery.

2. Operate the truck in its normal application until the battery indicator indicates a discharged battery (0% in the display).

3. Disconnect the battery from the truck and allow it to rest for at least two hours.

Note: Do not allow any charging or discharging during this time.

4. Measure the battery voltage at room temperature.

If the voltage is less than Uend (see the table below) the parameter value must be reduced. If the value is considerably higher than Uend the risk of damage to the battery is reduced. At the same time, however, the operating time of the truck decreases. If extended operating time is desired, then increase the parameter value, but maximum by one unit.

Note: Each change should be followed up by a new verification of the parameter setting.

4–

Battery type

Battery voltage while resting, Uend

Hawker Evolution/Exide

24.24 V

Installation Function and safety checks Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4.8 Function and safety checks

a,e b

q

c

n

d m f k j

g h

p o

j

Prior to putting the truck into use, check the following items:

Pos. Inspection point

Procedure

Completion

a b

Check the function Check the function

2:25 minutes

c d e f g h j k m n o p q

Operating control Switch for safety reversing Horn Steering Brakes Emergency switch off Hydraulic system Drive unit Wheels Chassis Battery cover and locking action Battery Fork carriage Support arms Mast

Check the function Check the function Check the function Check the function Check all components Check for any noise or oil leakage Inspect for any damage, remove dirt etc.

Inspect for any damage, remove dirt etc.

Check the function Inspect the battery acid level and charge level Inspect for any damage, remove dirt etc.

Inspect for any damage, remove dirt etc.

Inspect for any damage, remove dirt etc.

13

Installation Function and safety checks T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

4–

Order number 7519083-040

Maintenance Introduction Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

5 – Maintenance 5.1 Introduction To maintain a high level of truck safety and to minimise downtime, all the points specified in the service programme must be carried out.

The intervals specified are those that fulfil the truck manufacturer's requirements for a truck used in standard applications. The local operating environment may require service intervals that differ from those specified.

Once a truck's service intervals have been determined, the hour recorder is primarily used for determining when servicing is to be carried out.

To maintain truck safety, only spare parts approved by the truck manufacturer may be used for servicing and repairs.

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

5.2 Maintenance instructions 5.2.1 Cleaning and washing Cleaning and washing the truck is an important factor in maintaining truck reliability.

• Carry out general cleaning and washing each week.

Note: Risk of short-circuiting.

Risk of damage to the electrical system.

Disconnect the battery before washing by pulling out the battery connector.

5.2.2 High-pressure washers High-pressure washers may only be used on metal surfaces.

Under no circumstances may high-pressure washers be used in the truck's motor compartment.

When using a high-pressure washer, the jet must be directed in such a way that it does not damage electric cables, electric sensors, hydraulic hoses or decals.

1

Maintenance Maintenance instructions T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Lifting chains, piston rods and end pieces of hydraulic cylinders, ball and roller bearings – including those that are fully enclosed – must not be exposed to the jet, as there is a risk that water may penetrate and cause corrosion.

After washing with a high-pressure washer, all the truck bearings and chains must be lubricated/greased as specified in the maintenance instructions.

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

5.2.4 Cleaning the exterior • Remove rubbish, etc. from the wheels daily • Degreasing agents can be used as needed, in line with the previous section.

• Rinse off loose dirt using lukewarm water.

Note: Seizing, corrosion.

Risk of damage to mechanical parts.

Once washed, the truck should be lubricated as set out in the maintenance instructions.

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

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.

The chain should be blown dry using compressed air and lubricated directly after cleaning.

Note: Exercise care with degreasing agents as these can contain abrasives.

5–

Maintenance General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

5.2.6 Cleaning the motor compartment • Cover electric motors, connectors and valves prior to washing.

Note: Risk of short-circuiting.

Risk of damage to the electrical system.

Electrical components must not be washed with high-pressure washers.

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration • Rinse off loose dirt using lukewarm water.

5.2.7 Electric components • Clean electric motors using vacuum cleaner or a rag.

• Clean electric panels, logic cards, contactors, connectors, magnetic valves, etc. with a rag moistened with water and a suitable detergent.

Note: Risk of short-circuiting.

Risk of damage to electrical components.

Do not break off any warranty seals on the logic cards.

5.3 General This chapter includes a survey diagram for regular maintenance followed by detailed descriptions of required maintenance procedures.

3

Maintenance Service intervals T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

5.4 Service intervals The service intervals are for guidance only and do not need to be followed strictly. The service technician should adapt these to local requirements, however, it is important that the intervals coincide with the minimum requirements of the truck manufacturer.

The service intervals are based on operating hours and can be adapted to most normal 8-hour shifts. The following operating hours have been used when calculating the interval: Daytime: 08.00-17.00 (20 hrs/week) 2 shifts: 06.00-14.00, 14.00-22.00 (40 hrs/week) 3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hrs/week) Make sure regular maintenance service is performed on the truck every 750 operating hours. Truck safety, truck efficiency and the truck's expected service life depend on the service and maintenance the truck receives.

Once service is complete, the truck must be test driven and a function check must be carried out. See the Installation chapter under the heading Function and safety checks.

Use only spare parts approved by truck manufacturer for service and repairs.

5–

Maintenance Maintenance schedule Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

5.5 Maintenance schedule Service maintenance should be performed in intervals of 750 operating hours or every 12 months, whichever occurs first.

The order in the maintenance schedule is not optimal for the working order; it is simply sorted according to the C codes.

Truck area

Pos.

Procedure

750h/12m

Estimated time

0000 Chassis

a

Inspect cover mountings.

X

b

Check signs and adhesive labels.

X

c

Check for cracks and damage

X

5:20 minutes including removal of covers.

d

Check the mast fixing bolts.

X

e

Check for cracks and damage to the motor fixing points.

X

f

Secure the paper holder strap if necessary

X

b

b

b

d Qmax XXXX kg

a

b

a f

b

d b

b e

M-PLATE

c

A B C D E

b

A B C

b

D

E F G

*The M-label is only affixed on specially produced trucks.

5

Maintenance Maintenance schedule T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Truck area

Pos.

Procedure

750h/12m

Estimated time

Support arms – 0350

a

Check for cracks and damage.

X

b

Inspect bushings and links for possible playa.

X

1:30 minutes.

c

Check for cracks and damage to the push rodsa.

X

d

Check all shafts, links and spring pinsa.

X

a.Only applies to trucks with support arm lift (S212L, S214L and 220D)

g

e

c a

f

b b

d

5–

d

Truck area

Pos.

Procedure

750h/12m

Estimated time

0380 Fork carriage –

e

Check for cracks and damage.

X

f

Check the rollers for looseness.

X

1:30 minutes.

g

Check the load support (Option).

X

Inspect the fork stop screws (S212S)

X

Check that the battery locks are attached and work properly, also check the bracket on the battery tray.

X

Maintenance Maintenance schedule Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Truck area

Pos. Procedure

750h/12m

Estimated time

0560 Platform and mountings

a

Check for cracks and damage

X

b

Check the spring and that the platform returns to the upright position from the lowered position

X

1:30 minutes.

b a

7

Maintenance Maintenance schedule T-code 841, 842, 843

5–

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Truck area

Pos. Procedure

750h/12m Estimated time

1700 Drive motor

a

Check the drive motor's attachment.

X

b

Clean the drive motor.

X

c

Inspect for abnormal noise in the drive motor bearings.

X

2550 Drive gear

d

Check for abnormal noise

X

e

Check the mountings and play in the steering bearings.

X

3180 Brakes

f

Check for wear on the brake disc.

Minimum brake disc thickness: 7.9 mm

X

g

Check the air gap in the released position.

Nominal brake air gap: 0.3 mm Minimum permitted gap: 0.2 mm Maximum permitted gap: 0.5 mm.

Measuring must be done around the entire pressure disc, both on the inside and the outside.

X

h

Clean the brake.

X

4:30 minutes.

Maintenance Maintenance schedule Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

f,g,h c b a e d

Truck area

Pos.

Procedure

750h/12m

Estimated time

3500 Wheels

a b c

Check for wear on the drive wheel.

Check the nuts.

X X X

2 minutes

d e

Inspect castor wheel wear.a Check for wear on support arm wheels Check whether the castor wheels swivel freelya

X X

a.Not applicable for S212S

9

Maintenance Maintenance schedule T-code 841, 842, 843

Valid from serial number 6109948-

e

d

c

b

Order number 7519083-040

a

Wheels

Standard measurements, mm

Minimum dimensions, mm

Drive wheel

30 10

15 5

11

5.5

Castor wheela Support arm wheels

a.Not applicable for S212S

5–

Date 2015-10-01

Maintenance Maintenance schedule Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Truck area

Pos.

Procedure

750h/12m

Estimated time

4110 Tiller arm

a

Check for proper attachment.

X

1:45 minutes

b

Inspect the operating console for correct mounting.

X

c

Check the mounting of the handle.

X

d

Check the force and locking of the gas spring.

The tiller arm should return to the top position both from the bottom position and from the lower position where the brake is applied.

X

Check that the braking function is activated in both upper and lower tiller arm positions.

c

a d

b

11

Maintenance Maintenance schedule T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Truck area

Pos.

Procedure

750h/12m

Estimated time

5000 Electrical system

a

Inspect the contacts, wiring harness (including the battery cables), cable insulation and that all cables can move freely.

X

4:30 minutes

b

Inspect the contactors for correct operation.

X

c

Check error code log, operating times and all the segments on the display.

X

d

Clean and check that there is no play between the steering box and the heat dissipation plate.

X

e

Check and tighten the cable connections.

X

f

Check all switches and sensors.

X

a

a,e b d

c

f a,e a,e

5–

Maintenance Maintenance schedule Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Truck area

Pos. Procedure

750h/12m Estimated time

6000 Hydraulic system

a b

X X

Check wear on hoses and pipes.

Check the oil level.

(Recommended window for the oil level when forks are lowered according to illustration) Check the mountings of the hydraulic unit.

Inspect the hydraulic system for possible leakage.

Change the oil and clean the oil tank.

Note: Initially after 750 h/12 m, then every 4500 h/36 m.

Clean the oil strainer.

Note: Initially after 750 h/12 m, then every 4500 h/36 m.

Inspect the lifting cylinder for leakage.

Inspect the lifting cylinder for correct mounting Inspect the lifting cylinder (support arm lift) for leaks Inspect the cylinder (support arm lift) for correct mounting

c d e

f

6600 Lift cylinder

g h j k

16 minutes

X X X

X

X X X X

g,h

j,k

b a,c,d,e,f

20 mm

13

Maintenance Maintenance schedule T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Truck area

Pos. Procedure

750h/12m

Estimated time

7100 Mast

a b

X X

16 minutes

c d e

f

g

Check for any cracks or damage.

Check that there is no looseness in the mast's mounting points.

Check for play between the mast beam and the inner runner's rollers.

Check the inner runner's side play.

Check for wear on lifting chains and sprockets. See section "18.3 Main lift chain system 7120".

Check the adjustment of the lifting chains.

See section "18.3 Main lift chain system 7120".

Lubricate the inside surfaces of beam flanges

d

X X 500 h

500 h

X

g

c

e

e

f a

b b

e e b b

— End of section —

5–

Function and parameters General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6 – Function and parameters 6.1 General The “Function and parameters” chapter provides basic descriptions of the truck's main functions together with the control system parameters.

6.2 Description of the function The Function description section provides a basic description of the truck's main functions.

• Event – Use of one of the truck's main functions is referred to as an event. All events are indicated by a number.

• 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 parameter 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 show what is expected when no error conditions are present.

Text within square brackets [ ] refer to the electrical component names in the truck's electrical diagram.

Unless otherwise stated, {high} is ≈ 24 V and {low} is ≈ 0 V.

1

Function and parameters Description of the function T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Symbols on keypad and display Symbol

Description The ON switch This button is used to both start the truck and to confirm the settings made The OFF switch

Error code

Battery charge as a percentage

Parameter

Hour meter

6–

Function and parameters Operating principle Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6.3 Operating principle Event:

1. Battery is connected

Action(s)

Connect the truck battery [G1]

Influencing elements

Main power fuses OK [F1] Operating circuit fuses OK [F50, F51]

Resulting conditions

The status LED for the transistor regulator lights continuously [T1].

Event:

2. Starting the Truck

Preceding event(s)

The battery is connected.

Action(s)

Enter a valid PIN code and press the ON button on the keypad [S223].

Influencing elements

The emergency stop [S21] has not been activated [T1:INP. SUPPLY+24V DC] {high}.

Resulting conditions

The power light is lit. Main display shows the hour counter for 4 seconds and after this the battery charge level as a percentage of full charge.

The mechanical brake remains applied [Q1] [T1:OUT.BRAKE RELEASE] {high}.

Event:

3. The tiller arm is lowered to the drive position

Preceding event(s)

Start the truck.

Action(s)

Lower tiller arm

Influencing elements

Tiller arm sensor in drive position [B60].

Resulting conditions

Tiller arm sensor in drive position activates [B60] [T1:INP. TILLER ARM IN DRIVE POS] {low}.

The main contactor output voltage goes {low} [T1:OUT. MAIN CONTACTOR] The main contactor closes [Q10].

Function and parameters Operating principle T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Event:

4. Driving in the fork direction

Preceding event(s)

Tiller arm is lowered to the drive position.

Action(s)

Turn the speed control in the fork direction.

Influencing elements

Speed control with Hall sensor [A5:S10-18] Settings of operator parameters 4, 5 and 6 determine truck travel performance.

Resulting conditions

[T1:OUT.BRAKE RELEASE] goes {low}.

Brake coil [Q1] is activated, and the mechanical brake is released.

The pulsed current fed to the drive motor is proportional to speed control actuation.

Event:

5. Driving in drive wheel direction

Preceding event(s)

Tiller arm is lowered to the drive position.

Action(s)

Turn the speed control in the drive wheel direction.

Influencing elements

Speed control with Hall sensor [A5:S1-9] Settings of operator parameters 4, 5 and 6 determine truck travel performance.

Resulting conditions

[T1:OUT. BRAKE RELEASE] goes {low}.

Brake coil [Q1] is activated, and the mechanical brake is released.

The pulsed current fed to the drive motor is proportional to speed control actuation.

Event:

6. Neutral braking

Preceding event(s)

Truck travels in fork or drive wheel direction.

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 [T1] 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 [G1] helping to recharge it. The mechanical brake [Q1] is applied when the truck stops. [T1:OUT.BRAKE RELEASE] goes {high}.

6–

Function and parameters Operating principle Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Event:

7. Reversing braking

Preceding event(s)

Truck travels in fork or drive wheel direction.

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 [T1] 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 [G1] helping to recharge it. The braking effect increases the more the speed control is turned.

The mechanical brake [Q1] [T1:OUT. BRAKE RELEASE] is applied when the truck stops.

Event:

8. Mechanical braking

Preceding event(s)

Truck travels in fork or drive wheel direction.

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 [T1: 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 below 0.8 m/s. After this, the mechanical brake [Q1] is applied. [T1:OUT.BRAKE RELEASE] {high}.

Event:

9. Anti-collision safety switch

Preceding event(s)

Truck travels in drive wheel direction.

Action(s)

When driving in the drive wheel direction, the anti-collision safety switch [A5:S17] is pressed.

Influencing elements

Safety switch [A5:S17].

Resulting conditions

The Hall sensor [A5:S17] is immediately activated. The logic card [A5] interprets this signal as a command to the transistor regulator [T1] to operate the drive motor at reduced speed in the fork direction for as long as the safety switch against collision [A5:S17] is pressed. The command signal for normal travel operation of the drive motor from the speed control is blocked until the speed control is released and returned to the neutral position.

Function and parameters Operating principle T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Event:

10. Fork lifting

Preceding event(s)

Start the truck.

Action(s)

Press the fork lift button [A5:S19].

Influencing elements

Main contactor [Q10].

Fuse [F1].

Fork lift button [A5:S19].

Battery status OK (battery discharge indicator > 0 or battery charge > 20 %).

Resulting conditions

[T1:OUT. P-] goes {low}.

Pump motor [M3] starts.

Event:

10. Fork lifting (SWE100)

Preceding event(s)

Start the truck.

Action(s)

Press the fork lifting button [A5:S19].

Influencing elements

Main contactor [Q10].

Fuse [F1].

Fork lift button [A5:S19].

Battery status OK (battery discharge indicator > 0 or battery charge > 20 %).

Resulting conditions

[T1:OUT. PUMP CONTACTOR] goes {low}.

The pump contactor [Q25] closes, the pump motor [M3] starts.

Event:

11. Fork lowering

Preceding event(s)

Start the truck or commence fork lifting.

Action(s)

Press the fork lowering button [A5:S20].

Influencing elements

Main contactor [Q10].

Fork lowering button [A5:S20].

Resulting conditions

[T1:OUT. LOWER VALVE] goes {low}, proportional valve [Q4] opens.

Event:

12. Support arm lift (SWE120L, 140L, 200D)

Preceding event(s)

Start the truck.

Action(s)

Press the button for support arm lift [A5:S21].

Influencing elements

Main contactor [Q10].

Fuse [F1].

Button for support arm lift [A5:S21].

Battery status OK (battery discharge indicator > 0 or battery charge > 20 %).

Resulting conditions

[T1:OUT. PUMP CONTACTOR] goes {low}.

The pump contactor [Q25] closes, the pump motor [M3] starts.

Event:

13. Support arm lowering (SWE120L, 140L, 200D)

Preceding event(s)

Start the truck or commence support arm lift.

Action(s)

Press the button for support arm lowering [A5:S22].

6–

Function and parameters Operating principle Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Influencing elements

Main contactor [Q10].

Button for support arm lowering [A5:S22].

Resulting conditions

[T1:OUT. LOWER VALVE] goes {low}, proportional valve [Q4] opens.

Event:

14. Click-2-Creep

Preceding event(s)

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 low speed (2.5 km/h).

Influencing elements

Main contactor [Q10].

Setting of factory parameter 1002.

Resulting conditions

[T1:OUT.BRAKE RELEASE] goes {low}.

Brake coil [Q1] is activated, and the mechanical brake is released.

The pulsed current fed to the drive motor is proportional to speed control actuation. “SLO” is displayed (flashes).

Event:

15. Turtle function (option)

Preceding event(s)

Tiller arm is lowered to the drive position.

Action(s)

Press [S206] to activate this function.

Turn the speed control in either direction.

Influencing elements

Option button 1 [S206].

Setting of operator parameter 7 and service parameter 202.

Resulting conditions

[T1: OUT. BRAKE RELEASE] goes {low}.

Brake coil [Q1] is activated, and the mechanical brake is released.

The pulsed current fed to the drive motor is proportional to speed control actuation. The maximum travel speed is determined by operator parameter 7. “SLO” is displayed (lit continuously).

Function and parameters Hour meter T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

6.4 Hour meter When switching on the truck, the hour counter is displayed and the hour meter symbol is lit for 4 seconds.

The truck’s control system stores five different time values. The time values are controlled by parameter 103. To display a desired value, proceed as follows: 1. Ensure that the battery is connected.

2. Ensure that the truck is switched off. Press the OFF switch.

3. Enter the appropriate PIN code. Note: Do not press the ON button.

4. Keep the horn button depressed until “H” is displayed, then release the button. The hour counter symbol is lit.

Press the speed control repeatedly to cycle through the different hour counter values. The current time value will be displayed a short while after this mode has been selected.

Hour meter values Value 1 = Key time The total time for which the truck has been in use.

Value 2 = Operating time Combined time that either the pump motor or the drive motor has been in operation.

Default display.

Value 3 = Drive motor time The total time the drive motor has been in operation.

Value 4 = Pump motor time Total time the pump motor has been in operation.

Value 5 = Remaining time until next service.

Parameter 101 controls the initial value.

6–

Display

Function and parameters Parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6.5 Parameters 6.5.1 General The truck's control system stores a number of parameters. These parameters are used to configure the truck for correct operation in specific settings and for a particular application. The parameters are divided into three groups: • Operator parameters – Adapts truck travel performance for a specific operator or application. Operator parameters can be changed at any time without the need for a CAN service key.

• Service parameters – Used to adapt functional performance of the truck. Service parameters can only be adjusted when a suitable CAN service key is plugged into the truck. Please note that the service parameters can be checked without any need for plugging in a CAN service key, however it is not possible to change the values.

• Factory parameters – Parameters pre-set at the factory, which in case of special requirements can be changed by a service technician. As an example, these parameters indicate the truck model and which controls to use for the hydraulic function. The factory parameters cannot be changed with the CAN service key.

All parameters can be changed via a PC/PDA running TruckCom.

6.5.2 Displaying parameters To only display and verify the various truck settings, proceed as follows: 1. Connect the CAN key or enter a PIN code, then press the horn button and keep the button depressed.

The indicator shows: - Operating times and time remaining to the next service (H) - Error codes (E) - Parameters (P) - Hardware and software numbers (Pn) - Test function display (d) - Collision sensor log (c) - Emergency travel mode (Ed) - Calibration (CAL). Shortcut for setting parameter 108 = 1 2. Release the horn button to selected what you wish to view.

3. To scroll between the settings for each mode above, turn the speed control.

Function and parameters Parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

6.5.3 Setting parameters To set parameters, proceed as follows: 1. Connect the CAN key or enter a PIN code, then press the horn button and keep the button depressed. Release the horn button when the display shows “P”.

The parameter symbol lights continuously.

2. Turn the speed control to scroll to the desired parameter. Release the control when the display shows the correct parameter number.

3. Press once on the horn button to change the value.

The parameter symbol starts blinking.

4. Change the value by turning the speed control level.

5. Confirm the setting by pressing the horn button once more.

The parameter symbol lights continuously once again.

6. Complete programming by pressing the OFF button.

6–

Function and parameters Parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6.5.4 Operator parameters Note: Changing specific truck parameters changes the truck's driving properties. Do not change any parameter values without the necessary know-how.

Parameter

Designation/ Min./ unit Max.

Incr eme nt

Std .

Description

4

Acceleration, %

10/100

5

70

Determines the truck's acceleration capacity. The lower the value of this parameter, the longer time it takes for the truck to accelerate to top speed.

5

Braking, %

10/100

5

90

Determines the braking force when the speed control is returned to neutral position. The lower the value of this parameter, the longer the time to decelerate.

6

Maximum speed, %

30/100

5

90

Determines the maximum travel speed.

7

Maximum speed in turtle mode, %

30/100

5

50

Determines the truck's maximum travel speed when the turtle mode has been activated.

Function and parameters Parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Factory preset operator parameters Upon delivery from the factory, the various operator profiles have different values for operator parameters 4, 5 and 6. See the table below.

The values for operator profile 1 and 4-10 are the default values.

Operator profile Operator profile 1

Operator profile 2

Operator profile 3

Parameter

Factory setting

4

70

5

90

6

90

4

50

5

90

6

80

4

100

5

100

6

100

PINcode 1

2

3

Note: When replacing the firmware, the factory settings of operator profiles 2 and 3 are lost. In this case, all operator profiles are assigned the same default values, i.e. the default values of operator profiles 1 and 4-10. To regain the factory settings, these values must be entered anew, either manually or via a PC/PDA.

6–

Function and parameters Parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6.5.5 Service parameters Note: Changing specific truck parameters changes the truck's driving properties. Do not change any parameter values without the necessary know-how.

Note: Parameter 201 must be set to a value equal to or larger than the value of parameter 5. If a value of any parameter is changed causing the value of parameter 201 to become smaller than that of parameter 5, then the value of parameter 201 will automatically be reset to 100. When this parameter value is changed automatically, error code 2.002 is generated.

Note: Ensure that service parameter 109 is set to the value for the installed battery and that the right battery capacity is set in parameter 110.

Note: For Hawker Evolution batteries, only battery sizes 134Ah, 174Ah and 201Ah may be used.

Before any service parameter can be changed, the CAN service key must be connected to the contact [X41].

Param eter

Designation/ Min./ unit Max.

Incr eme nt

Std.

Description

101

Service interval, hours

0/ 2000

50

0

Determines the limit when the next service visit is required. When the next service is required, error code 2.003 is displayed.

0 = Service prompting switched off.

102

Operator access

1/10

1

3

Determines the login method to be used and whether the operator should be able to change operator parameter settings.

Values 1 and 2 = Key Values 3 and 4 = Keypad with 100 PIN codes Values 5 and 6 = Keypad with DHU Values 7 and 8 = ID unit Values 9 and 10 = ID unit with DHU Odd values = Open operator parameters Even values = Operator parameters can only be changed with a CAN key.

103

Hour meter selection

1/5

1

2

Specifies a time value for the hour counter.

For more information, see the Hour counter section in this chapter.

104

Automatic logout, minutes

0/20

1

20

Specifies the time until the truck is switched off when the keypad is used.

Time is counted from when the latest power consumer is used. The value 0 gives 4 hours.

Function and parameters Parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Param eter

Designation/ Min./ unit Max.

Incr eme nt

Std.

Description

105

X-level collision sensor

0/100

1

0

Option. Indicates the degree of sensitivity for what should be interpreted as a frontal/ rear-end impact. Be sure to set this parameter when installing the truck. For more information, see the Installation chapter.

106

Y-level collision sensor

0/100

1

0

Option. Indicates the degree of sensitivity for what should be interpreted as a side impact. Be sure to set this parameter when installing the truck. For more information, see the Installation chapter.

107

Battery setting, Ah

1/20

1

9

9 = Large battery 13 = Medium battery 17 = Small battery For more information See section "4.7.3 Parameter 107 – Battery size".

108

Calibration

1

1

1 = Calibration of proportional valve. Automatically reset to zero after completed calibration. See the chapter on hydraulics for complete instructions on how to perform the calibration.

109

Battery charger, battery type

0/3

1

0

Specifies what type of battery will be charged.

0 = No charging. Default setting An error code is displayed if this parameter has been set to 0 when a battery charger has been installed and factory parameter 1101 has been set to 1.

1 = Lead/acid battery 2 = Hawker Evolution battery. Size 134Ah, 174Ah, 201Ah. 3 = Exide gel-battery For more information, see the Installation chapter.

110

Battery charger, battery capacity, Ah

0/300 (100/ 300)

1

0 (100)

Specifies the battery capacity.

0 (100) = No charging. Default setting An error code is displayed if this parameter has been set to 0 (100) when a battery charger has been installed and factory parameter 1101 has been set to 1.

The value in brackets () indicates if the truck has software version -006 or newer.

For more information, see the Installation chapter.

6–

Function and parameters Parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Param eter

Designation/ Min./ unit Max.

Incr eme nt

Std.

Description

111

Reset following a collision

0/1

1

0

0 = A special PIN code to reset the truck after a collision is required.

1 = The truck can be reset using all the activated PIN codes.

2 = Horn sounds once every five seconds.

3 = Options 1 and 2 combined.

201

Reverse braking

70/ 100

5

100

Determines how hard the truck should brake when the speed control is turned fully in the opposite direction.

Note: This value must not be set lower than the value of parameter 5. If it is lower, error code 2.002 is shown at start-up and the value is not changed.

202

Creep speed

-200/ 200

5

0

Determines the speed the truck will have when it reaches the value set for the first travel speed sensor.

-200 = Low speed at the first speed sensor.

200 = High speed for the first speed sensor.

203

Maximum speed, %

10/ 100

5

45

Specifies the truck's maximum speed with forks above 1.8m.

204

Acceleration, %

10/ 100

5

45

Specifies the truck's acceleration capacity with forks above 1.8m. The lower the value of this parameter, the longer time it takes for the truck to accelerate to top speed.

205

Reversing braking, %

10/ 100

5

80

Specifies how hard the truck is decelerated with forks over 1.8m when the speed control is turned all the way in the direction opposite to the direction of travel.

206

Braking, %

10/ 100

5

60

Specifies the motor's braking force when the speed control is set to the neutral position with the forks over 1.8m. The lower the value of this parameter, the longer the time to decelerate.

301

Lowering stop ramp

3/20

1

7

Determines the closing ramp of the proportional valve.

302

Fork lowering speed

70/ 255

5

190

Determines the maximum lowering speed of the forks. This parameter can be adjusted manually or can be set by using the calibration function (parameter 108 = 1).

303

EVP start position

30/ 150

5

90

Determines the start position of the proportional valve. This parameter can be adjusted manually or can be set by using the calibration function (parameter 108 = 1).

Function and parameters Parameters T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Param eter

Designation/ Min./ unit Max.

Incr eme nt

Std.

Description

304

EVP support arms lowering speed

50/ 220

5

130

Specifies the lowering speed of the support arms. This parameter can be adjusted manually or can be set by using the calibration function (parameter 108 = 1).

305

EVP slow lowering speed

40/ 220

5

105

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 (parameter 108 = 1).

306

Activate two lifting/lowering speeds

0/1

1

1

Activate “Click-2-Creep” lifting/lowering 0 = Off 1 = On

307

Activate automatic lowering of the support arms

0/1

1

1

Activate automatic lowering of the support arms 0 = Off 1 = On

6–

Function and parameters Parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6.5.6 Factory parameters The truck's factory parameters are preset in the truck during production at the factory. Factory parameters can only be changed using the TruckCom software application in a PC or PDA. Note: Remember that a change of specific truck parameters changes the truck's properties. Do not change any parameter values without the necessary know-how. Only authorised service technicians with personal TruckCom user identities have the rights to change factory settings. The parameters should only be changed when a specific need for this arises.

The user ID and time of changing parameters will be logged in the logic card housed in the tiller arm handle.

Param eter

Designation/ unit

Min./ Max.

Incr eme nt

Std .

Description

1001

Truck type

0/8

1

0

0 = Unknown truck type 1 = SWE100 2 = SWE120 3 = SWE140 4 = SWE120L 5 = SWE140L 6 = SWE200D 7 = SWE080L 8 = SWE120S

1002

Non-configurable options

0/7

1

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.

0 = No option 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

ConfOption Func1

0/13

1

0

Requires SEU

1004

ConfOption Func1Arg1

0/255

1

0

Requires SEU

Function and parameters Parameters T-code 841, 842, 843

6–

Valid from serial number 6109948-

Date 2015-10-01

Param eter

Designation/ unit

Min./ Max.

Incr eme nt

Std .

Description

1005

ConfOption Func1Arg2

0/255

1

0

Requires SEU

1006

ConfOption Func1Arg3

0/255

1

0

Requires SEU

1007

ConfOption Func1Arg4

0/255

1

0

Requires SEU

1008

ConfOption Func2

0/13

1

0

Requires SEU

1009

ConfOption Func2Arg1

0/255

1

0

Requires SEU

1010

ConfOption Func2Arg2

0/255

1

0

Requires SEU

1011

ConfOption Func2Arg3

0/255

1

0

Requires SEU

1012

ConfOption Func2Arg4

0/255

1

0

Requires SEU

1013

ConfOption Func3

0/13

1

0

Requires SEU

1014

ConfOption Func3Arg1

0/255

1

0

Requires SEU

1015

ConfOption Func3Arg2

0/255

1

0

Requires SEU

1016

ConfOption Func3Arg3

0/255

1

0

Requires SEU

1017

ConfOption Func3Arg4

0/255

1

0

Requires SEU

1018

ConfOption Func4

0/13

1

0

Requires SEU

1019

ConfOption Func4Arg1

0/255

1

0

Requires SEU

1020

ConfOption Func4Arg2

0/255

1

0

Requires SEU

1021

ConfOption Func4Arg3

0/255

1

0

Requires SEU

1022

ConfOption Func4Arg4

0/255

1

0

Requires SEU

Order number 7519083-040

Function and parameters Parameters Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Param eter

Designation/ unit

Min./ Max.

Incr eme nt

Std .

Description

1023

Controls for hydraulic functions

1/4

1

1

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 = Rear lift and lowering control connected to the first hydraulic function and forward control connected to second hydraulic function.

3 = Both lift and lowering controls are connected to the first hydraulic function. There are no other hydraulic functions.

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.

1024

Brake configuration * see below

0/1

1

0

0 = 1.5 kHz brake frequency 1 = 8 kHz brake frequency

1101

Battery charger, onboard

0/1

1

0

0 = No battery charger installed 1 = Battery charger installed

* Matrix for hardware/software compatibility See the matrix below for the correct setting of factory parameter 1024.

The setting depends on which version of transistor regulator is installed on the truck.

• Value 0 = 1.5 kHz (default value) • Value 1 = 8 kHz

Transistor regulator Factory parameter 1024 243428-001/-002 246889-001/-002 246890-001/-002

Value = 0

Value = 1

OK

Not permitted

7513528-001/-newer Not recom7513526-001/-newer mended 7513527-001/-newer

OK

Function and parameters Parameters T-code 841, 842, 843

6–

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Troubleshooting General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7 – Troubleshooting 7.1 General The troubleshooting section describes the error codes that are displayed when the truck is partially or completely disabled. It also describes the cause of the problem together with corrective remedies.

The electronic control system of the truck has built-in error code display and logging. When an error occurs, the error code is shown on the display and the error code LED flashes.

The first time an error code is displayed, try to restart the truck to check whether the error condition remains.

Note: The request "Restart the truck" means that the battery connector must be disconnected before attempting to start the truck again.

If the error cannot be remedied through troubleshooting, contact the supplier for more information.

Software compatibility Ensure that the logic card ICH [A5], transistor regulator ACT [T1] and battery charger BCU [A30] have software from the same software package.

Download and install the latest software package in order to maintain full functionality.

7.2 Emergency driving mode If the truck for some reason stops operating and remains immobile in an unsuitable place, it is possible to active the emergency travel mode to move the truck out of the way.

1. Enter your PIN code.

2. Press the horn button and keep it depressed.

“Ed” is displayed.

3. Release the horn button.

All lamps flash and “SLO” is displayed.

It is now possible to drive the truck, but exercise extreme caution. It is not possible to brake by raising the tiller arm.

If the truck is on an incline, be even more careful when using the emergency travel mode. If too much acceleration is used, there is a risk the truck can roll away. To stop the truck, change the travel direction to the opposite direction.

With some errors, the emergency travel mode will not operate. In

Troubleshooting Towing a defective truck T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

such cases, it is not possible to receive information about the error.

7.3 Towing a defective truck The towed truck shall always have an operator who can steer and apply the brake when towing using a tow-truck and tow-rope.

Always remove the load before towing or transporting the truck to the specified repair site.

Tow or transport a defective truck as follows: • Start the truck, move the tiller arm to the drive position and push the truck by hand.

DANGER! The truck can start to roll when the parking brake function is disabled.

Never leave the truck with the parking brake disconnected, chock the wheels in a satisfactory manner.

Tow using a tow truck and tow wagon: 1. Lift the truck onto the tow wagon. See the instructions under Lifting a truck.

2. Connect the truck to the wagon.

3. Drive with care.

4. Lift off the truck according to the instructions under Lifting a truck.

7–

Troubleshooting Troubleshooting methods Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.4 Troubleshooting methods 7.4.1 General initial troubleshooting Begin the troubleshooting

Was an error code displayed?

Follow the instructions in the chapter Troubleshooting

Eliminate improbable errors

Follow the instructions in the troubleshooting chart

Select and prioritize the most likely causes

Yes

Are the symptoms mentioned in the troubleshooting chart?

Yes No

What is the problem?

Collect as much information as possible about the problem Where at the place of work did the problem occur?

Identify all parts that may have caused the problem. Use the wiring chart if needed

When did the problem occur?

Which functions are affected?

What conditions triggered the problem?

When the error is localized, see the instructions in the section for procedures

Troubleshooting Troubleshooting methods T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.4.2 Concluding troubleshooting End the troubleshooting

Drive the truck in the same way it was driven when the problem occurred. Verify that the problem does not occur again.

Make sure all wiring and hoses are refitted in the correct manner

Make sure that parts that have been emptied of fluids are refilled to the correct level

Recreate the same conditions as when the problem first occurred

7–

Let the operator drive the truck. Verify that the problem does not occur again.

If you previously contacted the department for technical support to discuss the problem, we ask you to please get in touch again to tell us how the problem was resolved.

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.

Troubleshooting Error code history Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.5 Error code history Up to 50 of the most recent error code events can be stored in a log along with the hour meter reading when the error occurred. The error code log displays error codes in chronological order starting with the most recent error code.

To display the error code log, proceed as follows: 1. Ensure that the battery is connected.

2. Ensure that the truck is switched off. Press the OFF button.

3. Enter the appropriate PIN code. Note: Do not press the ON button.

4. Keep the horn button depressed until “E” is displayed, then release the horn button. The error code symbol lights up.

The most recent error is then displayed. The display alternates between the error code and the hour counter reading when the error occurred. If the error code log contains more than one error code, the codes can be displayed by repeatedly pressing on the speed control.

Troubleshooting Error code system T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.6 Error code system See the tables below for an explanation of the error code system.

Structure

Description

G.ANN G (3)

NN (10)

Example: 3.510 Group. Indicates which truck system is affected by the error.

Error category. Describes the type of error that has occurred and what happened.

Error code

Group.

Description

1 2 3 4 5 6 7 8

Not used.

Main control system and other Drive system Hydraulic system Not used.

Not used.

Not used.

Option

A (5)

Error category.

Description

0

Proceed with caution. This is primarily an information code that indicates that some of the truck functions have been reduced or do not operate.

Minor error. The lifting and lowering of the forks is disabled and the truck travel speed is reduced to safety speed.

Not used.

Critical error. The main contactor is open. The truck stops.

Critical error. The main contactor is open. The truck stops.

1-2

3 4 5

7–

Code

Description

00-09 10-19 20-39 40-59 60-79 80-99

Miscellaneous error codes.

CAN related error codes.

Error codes for specific components.

Error code for short-circuited outputs.

Error codes for open circuits.

Incorrect signals received from the sensors.

Troubleshooting Error codes Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.7 Error codes Please note that some error codes are stored in the firmware and disappear from the display, while other error codes remain on the display and require switch-off of the truck and subsequent restart in order for the error code to disappear from the display.

Code

Event

Possible cause Measure

Main controller unit E141

Software download interrupted

Transmission cable disconnected.

Restart the download in "Emergency download" mode.

2.001

Transistor regulator stops all functions.

Emergency switch off pressed.

Check: • that the emergency switch off is not actuated.

• cable 24.

• fuse [F51]

2.002

No event. Truck can be operated as usual.

Some parameter values may be outside the pre-set values. The parameters are reset to the default values.

• Check the parameter settings.

• If the code is immediately followed by error code 2.004, copy the configuration to the transistor regulator [T1] via TruckCom.

2.003

No event. Truck can be operated as usual.

Time for service.

Check the service meter (S hour counter). Maybe it was not reset after the latest service.

2.004

No event. Truck can be operated as usual.

The values in the transistor regulator's backup file differ from the values in the handle's logic card with regards to parameters, hour counters and/or serial number.

Use TruckCom to check where the correct data are stored. See section "7.8.4 The truck can be driven, but some functions do not work".

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

2.101

Safety speed, raising and lowering the forks not working.

The truck type has not been set.

Alternatively, the values in the handle logic card [A5] differ from the values in the transistor regulator [T1].

Reset data from backup, See section "15.5.4 Disassembling/assembling the steering unit handle". If this does not help, indicate the type of truck by entering factory parameter 1001 (Truck type), or see table 7.6.4.

2.102

Safety speed, raising and lowering the forks not working.

The indicated truck type does not support analogue lifting and lowering operations.

Check the settings of factory parameters 1001 (Truck type) and 1023 (Controls for hydraulic functions).

2.501

Main contactor opens.

Low battery voltage <16.8V> for more than 2 seconds Charge the battery. Inspect all cables and connectors

2.511

The main contactor is open.

CAN communication error.

Check: • connections and wiring harness • cables 119 and 120 • logic card in tiller arm handle.

2.514

The main contactor is open.

CAN communication error.

Check: • connections and wiring harness • cables 119 and 120.

• logic card in tiller arm handle.

2.515

The truck cannot be started

CAN communication error.

Check: connectors and wiring harness between the DHU [K110] and the ICH logic card [A5]

2.520

The main contactor is open.

Errors in software for tiller arm handle or in the microprocessor.

Download new software.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

2.521

The main contactor is open.

Defective safety reversing function.

Mechanical error or defective Hall sensor that regulates the safety reversing function.

Use TruckCom to check whether the Hall sensor is working properly.

2.522

The main contactor is open.

Incorrect power supply to the Hall sensor.

Use TruckCom to check whether the Hall sensors are defective.

2.523

The main contactor is open.

Main contactor is not activated.

• Check whether the main contactor is defective.

• Open the main contactor.

Drive system 3.001

Travel disabled until the speed control is reset to the neutral position.

• The speed control was not in the neutral position during start-up.

• Defective Hall-sensors.

Check: • speed control functionality • via TruckCom that the Hall-sensors work.

3.002

The transistor regulator reduces power supply to 50%.

The transistor regulator's temperature exceeds +85°C. The driving may be too intensive.

• Drive the truck less intensively.

• Check whether dirt has built up around the transistor regulator. Too much dirt can cause insufficient cooling of the transistor regulator.

3.003

The transistor regulator reduces the maximum current linearly from 100% at 145°C to 0% at 160°C.

The engine's temperature exceeds +145°C. The driving may be too intensive.

• Drive the truck less intensively.

• Check whether dirt has built up around the motor. Too much dirt can cause insufficient cooling of the motor.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

3.040

No event. Truck can be operated as usual.

Incorrect power saving function in the standby mode.

• Internal transistor regulator error.

• Restart the truck.

• If the error persists, replace the transistor regulator.

3.080

The transistor regulator reduces power supply to 50%.

The temperature sensor for the transistor regulator shows abnormal values.

• Internal transistor regulator error.

• Restart the truck.

• If the error persists, replace the transistor regulator.

3.081

The transistor regulator reduces power supply to 50%.

The motor temperature sensor shows abnormal values. The sensor could be defective.

Inspect the cables (63/64) to the motor temperature sensor.

3.101

Safety speed, raising and lowering the forks not working.

The transistor regulator is using pre-set power amplification. Internal error • Internal transistor regulator error.

• Restart the truck.

• If the error persists, replace the transistor regulator.

3.120

Safety speed, raising and lowering the forks not working.

Incorrect checksum for the transistor regulator parameters.

• Internal transistor regulator error.

• Restart the truck.

• Reprogram the truck.

• If the error persists, replace the transistor regulator.

3.121

Safety speed, raising and lowering the forks not working.

The transistor regulator cannot use the internal memory.

• Internal transistor regulator error.

• Restart the truck.

• Reprogram the truck.

• If the error persists, replace the transistor regulator.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

3.140

Horn disabled. Safety speed.

The horn circuit has short-circuited.

Check: • connections and wiring harness • cable 50 • the horn.

3.210

Safety speed, raising and lowering the forks not working.

CAN communication error with tiller arm logic card Check: • connections and wiring harness • wires 119 and 120, 60 ohms • the logic card in the tiller arm handle and replace the card if necessary.

3.501

The main contactor is open.

Faulty transistor regulator.

Check: • the transistor regulator.

• factory parameter 1001 (Truck type).

If the error persists, replace the transistor regulator.

3.502

The main contactor is open.

The logic card in the tiller arm handle cannot download parameters to the transistor regulator.

• Restart the truck.

• Replace the logic card in the tiller arm handle.

• If the error persists, replace the transistor regulator.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

3.510

The main contactor is open.

CAN communication problem with the transistor regulator at start-up.

In the following order, check: • the connection. Disconnect the battery connector [X1] and reconnect it.

Start the truck.

• the unit. Connect TruckCom to load the truck's software. If the node/unit ACT [T1] does not respond, try to start downloading software in “Emergency download” mode.

• the software. Ensure that ICH [A5] and ACT [T1] have software from the same software package.

• connections and wiring harness • cables 119 and 120 • the transistor regulator [T1]; replace it if necessary.

If the error persists, refit the transistor regulator [T1] and replace the logic card [A5] in the tiller arm handle.

3.511

The main contactor is open.

The logic card in the tiller arm handle does not receive CAN data from the transistor regulator.

Check: • connections and wiring harness • cables 119 and 120 • the logic card in the tiller arm handle and replace the card if necessary.

If the error persists, replace the transistor regulator.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

3.512

Transistor regulator stops all functions.

The transistor regulator does not receive CAN data from the logic card in the tiller arm handle.

Check: • connections and wiring harness • cables 119 and 120 • the logic card in the tiller arm handle and replace the card if necessary.

If the error persists, replace the transistor regulator.

3.514

The main contactor is open.

The logic card in the tiller arm handle cannot send CAN data to the transistor regulator.

Check: • connections and wiring harness • cables 119 and 120 • the logic card in the tiller arm handle and replace the card if necessary.

If the error persists, replace the transistor regulator.

3.515

Transistor regulator stops all functions.

The transistor regulator has detected a CAN communication error.

Check: • connections and wiring harness • cables 119 and 120 • the logic card in the tiller arm handle and replace the card if necessary.

If the error persists, replace the transistor regulator.

3.520

Transistor regulator stops all functions.

The transistor regulator has detected a short-circuit in the power supply unit.

Check: • the motor wiring harness • the motor • the transistor regulator.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

3.521

Transistor regulator stops all functions.

The transistor regulator has detected low motor voltage.

Check: • the motor wiring harness • the motor • the transistor regulator.

3.522

Transistor regulator stops all functions.

The transistor regulator has detected high motor voltage.

Check: • the motor wiring harness • the motor • the transistor regulator.

3.523

Transistor regulator stops all functions.

The transistor regulator has detected an internal problem in its own software or hardware.

Internal transistor regulator error.

Reprogram the truck, both in the tiller arm handle and the transistor regulator.

3.524

Transistor regulator stops all functions.

The transistor regulator has detected an internal problem in its own software or hardware.

Internal transistor regulator error.

Reprogram the truck, both in the tiller arm handle and the transistor regulator.

3.525

Transistor regulator stops all functions.

The transistor regulator has detected that the motor phase remains 0 (zero) continuously.

Check: • the motor wiring harness • the motor • the transistor regulator.

3.526

Transistor regulator stops all functions.

Defective current measuring in the transistor regulator.

Internal transistor regulator error.

Replace the transistor regulator.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

3.527

Transistor regulator stops all functions.

Defective software in the transistor regulator.

Internal transistor regulator error.

Check that the latest software has been downloaded to the transistor regulator.

3.528

Transistor regulator stops all functions.

Internal problem in the transistor regulator microprocessor.

• Internal transistor regulator error.

Check that the latest software for the transistor regulator has been downloaded.

• If the error persists, replace the transistor regulator.

3.529

Transistor regulator stops all functions.

The transistor regulator has detected an internal problem.

• Internal transistor regulator error.

Check the software.

• If the error persists, replace the transistor regulator.

3.530

Transistor regulator stops all functions.

The transistor regulator has detected an internal problem.

• Internal transistor regulator error.

Check the software.

• If the error persists, replace the transistor regulator.

3.531

Transistor regulator stops all functions.

The transistor regulator has detected an internal problem.

• Internal transistor regulator error.

Check the software.

• If the error persists, replace the transistor regulator.

3.532

Transistor regulator stops all functions.

The transistor regulator has detected an internal problem in the AD converter.

• Internal transistor regulator error.

• Replace the transistor regulator.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

3.533

Transistor regulator stops all functions.

The charging voltage for the transistor regulator capacitor indicates abnormal values.

Check: • connections and wiring harness • cable 20 • the transistor regulator.

• pump contactor If the error persists, replace the transistor regulator.

3.534

Transistor regulator stops all functions.

The transistor regulator has detected a problem with the speed sensor. Excessive frequency fluctuations.

• Inspect the connections and wiring harness.

• Remove and clean the speed sensor.

• Replace the speed sensor if the actions stated above do not work.

3.535

Transistor regulator stops all functions.

Incorrect checksum for the transistor regulator parameters.

Download the software to the handle and the transistor regulator.

3.536

Transistor regulator stops all functions.

The transistor regulator current sensor is outside the valid range.

Internal transistor regulator error.

Replace the transistor regulator.

3.537

Transistor regulator stops all functions.

Multi-direction command issued by handle.

Internal error in handle.

3.538

The main contactor is open.

Unknown transistor regulator error.

• Internal transistor regulator error.

Reprogram the transistor regulator.

• If the error persists, replace the transistor regulator.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

3.539

Transistor regulator stops all functions.

The transistor regulator detects that battery voltage is between 18 V and 28.8 V. Check: • the cabling between the battery and the transistor regulator.

• the battery.

3.540

Transistor regulator stops all functions.

The transistor regulator output to the main contactor has short-circuited.

Check: • connections and wiring harness • the main contactor.

3.541

Transistor regulator stops all functions.

The transistor regulator output to the parking brake has short-circuited.

Check: • connections and wiring harness • the parking brake.

3.542

Transistor regulator stops all functions.

One of the transistor regulator's circuits to the main contactor, parking brake or lowering valve has short-circuited to +24 V at start-up.

Check • connections and wiring harness • main contactor • parking brake • the lowering valve.

3.560

Transistor regulator stops all functions.

The transistor regulator output to the main contactor has short-circuited.

Check: • connections and wiring harness • the main contactor.

3.561

Transistor regulator stops all functions.

The circuit between the transistor regulator and the main contactor coil is open.

Check: • connections and wiring harness • the main contactor.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

3.562

Transistor regulator interrupts all functions.

The transistor regulator output to the parking brake is open.

Check: • connections and wiring harness • parking brake.

3.563

Transistor regulator stops all functions.

The transistor regulator coil circuit to the parking brake is open.

Check: • connections and wiring harness • parking brake.

3.564

Transistor regulator stops all functions.

The circuit between the transistor regulator and the main contactor coil is open.

Check: • connections and wiring harness • the main contactor.

3.565

Transistor regulator stops all functions.

The circuit between the transistor regulator and the main contactor coil is open.

Check: • connections and wiring harness • the main contactor.

3.566

Transistor regulator stops all functions.

The circuit between the transistor regulator and the main contactor coil is open.

Check: • connections and wiring harness • the main contactor.

3.567

Transistor regulator stops all functions.

The circuit between the transistor regulator and the main contactor coil is open.

Check: • connections and wiring harness • the main contactor.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

3.568

Transistor regulator stops all functions.

The circuit between the transistor regulator and the main contactor coil is open.

Check: • connections and wiring harness • the main contactor.

3.580

Transistor regulator stops all functions.

The main contactor is closed.

Check: • connections and wiring harness • the main contactor.

3.581

Transistor regulator stops all functions.

Main contactor open.

Check: • connections and wiring harness • the main contactor.

• the main fuse [F1]

3.582

Transistor regulator stops all functions.

The transistor regulator's output for power supply has the wrong voltage level.

Check: • connections and wiring harness • main contactor • lowering valve • brake • the pump contactor.

Internal transistor regulator Change transistor regulator.

3.583

Transistor regulator stops all functions.

error.

Internal transistor regulator voltage supply has not been switched on.

Internal transistor regulator error.

Change transistor regulator.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

Hydraulic system 4.001

Lifting is prevented until the analogue controller for lifting and lowering has been returned to the neutral position.

The analogue controller for lifting and lowering was not set to the neutral position at start-up. (Not applicable for SWE100).

Do not actuate the speed control when starting the truck.

Check: • wiring in the handle • the potentiometer. If defective, replace the potentiometer.

4.101

Safety speed, raising and lowering the forks not working.

The analogue control signals for lifting and lowering show abnormal values.

Do not actuate the speed control when starting the truck.

Check: • wiring in the handle • the potentiometer. If defective, replace the potentiometer.

4.102

Safety speed, raising and lowering the forks not working.

The handle type does not match the setting of factory parameter 1023 “Controls for hydraulic functions”.

Check the setting of factory parameter 1023 and compare with the handle type used on the truck.

4.125

Safety speed, raising and lowering the forks not working.

Pump motor current feedback remains zero when the pump motor operates.

Defective current sensor in the transistor regulator. Change transistor regulator.

4.126

Safety speed, raising and lowering the forks not working.

Excessive pump motor current feedback at start-up and in the standby mode.

Defective current sensor in the transistor regulator. Change transistor regulator.

4.521

The main contactor is open.

Pump motor voltage too low.

Check: • the wiring harness between the transistor regulator and pump motor.

• the pump motor.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

4.522

The main contactor is open.

Pump motor voltage too high.

Check: • the wiring harness between the transistor regulator and pump motor.

• the pump motor.

4.540

Transistor regulator stops all functions.

• The transistor regulator output to the lowering valve has short-circuited.

• Internal short-circuit in the transistor regulator.

• Inspect the connections and wiring harness.

• Disconnect the lowering valve and try restarting the truck.

• If the error remains, replace the lowering valve of the transistor regulator.

4.541

Transistor regulator stops all functions.

The transistor regulator output to the lowering valve has short-circuited with B-.

Inspect the connections and wiring harness.

4.560

Transistor regulator stops all functions.

The transistor regulator output to the lowering valve is open.

Check: • connections and wiring harness • the safety valve coil.

Option 8.001

Safety speed, raising and lowering the forks not working.

The collision sensor has registered collision levels that are above the stated limits.

• Drive carefully.

• Check the limit values for registering collisions (service parameters 105 and 106).

8.002

Safety speed, raising and lowering the forks not working.

The truck has intentionally been disabled by TLS. Reset the truck to normal operation.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

8.003

No event. Truck can be operated as usual.

Argument warning from Spider expansion unit.

Check option parameters for correct settings.

8.010

No event. Truck can be operated as usual.

CAN communication problem with the battery charger at start-up.

• Inspect the connections and wiring harness.

• Make sure that ICH [A5] and BCU [A30] have compatible software. See section "7.1 General".

8.011

No event. Truck can be operated as usual.

The logic card in the tiller arm handle is not receiving CAN data from the battery charger.

Inspect the connections and wiring harness.

8.014

No event. Truck can be operated as usual.

The logic card in the tiller arm handle cannot send CAN data to the battery charger.

Inspect the connections and wiring harness.

8.020

No event. Truck can be operated as usual.

The battery charger is not connected to the battery.

Inspect the connections and wiring harness.

8.021

No event. Truck can be operated as usual.

The battery charger has detected too low battery voltage.

Check battery status.

8.022

No event. Truck can be operated as usual.

The battery charger has detected excessively high battery voltage.

Check battery status.

8.023

No event. Truck can be operated as usual.

The battery charger has detected low charging temperature.

Charge the battery at normal temperature.

8.024

No event. Truck can be operated as usual.

The battery charger has detected high charging temperature.

Check: • that the fan is operating.

7–

Troubleshooting Error codes Order number 7519083-040

Code

Date 2015-10-01

Valid from serial number 6109948-

Event

T-code 841, 842, 843

Possible cause Measure

8.027

No event. Truck can be operated as usual.

Serious error in the battery charger.

Replace the battery charger.

8.028

No event. Truck can be operated as usual.

The battery charger has exceeded the charge time limit.

Inspect the battery.

8.029

No event. Truck can be operated as usual.

The battery charger overcharges beyond maximum capacity.

Check: • battery • service parameter 110.

8.030

No event. Truck can be operated as usual.

The battery charger is installed in the truck, but it is not activated via factory parameter 1101.

Check factory parameter 1101.

8.031

No event. Truck can be operated as usual.

Incorrect setting of the battery charger parameter.

Restart the truck. Check that the truck and battery charger use the correct software.

8.032

No event. Truck can be operated as usual.

If the error code is displayed during charging with the built-in charger, parameter 109 has the wrong setting.

Check service parameter 109.

8.110

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 1 when starting.

Inspect the connections and wiring harness.

8.111

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 1.

Inspect the connections and wiring harness.

8.114

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 2 when starting.

Inspect the connections and wiring harness.

8.115

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 2.

Inspect the connections and wiring harness.

Troubleshooting Error codes T-code 841, 842, 843

Code

Valid from serial number 6109948-

Event

Date 2015-10-01

Order number 7519083-040

Possible cause Measure

8.123

Safety speed, raising and lowering the forks not working.

Spider expansion unit 1 programming warning.

Check option parameters.

8.124

Safety speed, raising and lowering the forks not working.

Spider expansion unit 2 programming warning.

Check option parameters.

7–

Troubleshooting Troubleshooting chart Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.8 Troubleshooting chart The following section describes the type of errors that can occur together with a description of the cause.

Troubleshooting is divided into groups according to truck symptoms: • The truck cannot be driven.

• The truck can be driven but only at reduced speed • The truck can be driven but behaves abnormally • Defective hydraulic functions.

Troubleshooting Troubleshooting chart T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.8.1 The truck cannot be driven.

Symptom

Influencing elements

Possible cause

Mechanical brake cannot be applied.

Sensor [B60]

• Sensor in wrong position or disrupted by metal • Defective sensor

Mechanical brake cannot be released.

Tiller arm handle always "On" in travel mode

Damaged wiring harness or incorrect plus/minus current supply

Transistor regulator, input [T1:95].

Defective transistor regulator

Brakes

If the gap is greater than 0.6 mm, the brakes may be difficult to apply.

Sensor [B60]

• Sensor in wrong position or cannot be normally actuated • Defective sensor • Break in sensor wiring harness.

Truck cannot travel after start-up although tiller arm handle was in raised position.

7–

Transistor regulator, input [T1:95].

Transistor regulator, output [T1:90].

Defective transistor regulator

Corrosion

Brake has seized due to corrosion

Sensor [B60]

• Sensor in wrong position and affected by metal • Defective sensor

Tiller arm handle always "On" in travel mode

Damaged wiring harness or incorrect plus/minus current supply

Transistor regulator, input [T1:95].

Broken transistor regulator.

Troubleshooting Troubleshooting chart Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.8.2 Truck only travels at reduced speed Symptom

Influencing elements

Possible cause

Speed always reduced

Click-2-Creep function

Click-2-Creep function activated

Turtle function

Turtle function activated

Operator parameter 6 - speed

Operator parameter 6 has not been set to the maximum value

Pulse transducer [B11]

Defective or disconnected pulse transducer [B11]

Motor cable connections

• One of the phases U, V, W has been disconnected • Broken wiring

Mechanical brake

• Partially applied brake • Incorrect gap.

Troubleshooting Troubleshooting chart T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.8.3 The truck can be driven but behaves abnormally Symptom

Influencing elements

Possible cause

Truck travels in wrong direction.

Motor cable connections

Incorrect U, V, W connections

Acceleration always reduced

Driver parameter 4

Value setting low.

Reversing braking always reduced.

Service parameter 201

Value setting low.

Neutral braking always reduced

Driver parameter 5

Value setting low

The truck cannot be switched off.

Parameter 102. The Red off key on the keypad does not work.

Parameter 102 has been incorrectly set for the log-in unit installed in the truck.

Speed always reduced

Pulse transducer [B11]

Defective or disconnected pulse transducer [B11]

Motor cable connections

• One of the phases U, V, W has been disconnected • Broken wiring

7–

Troubleshooting Troubleshooting chart Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.8.4 The truck can be driven, but some functions do not work Software compatibility Ensure that the correct software for logic card [A5], transistor regulator [T1] and battery charger [A30] is installed on the truck. See section "7.1 General".

Hardware compatibility matrix Make sure the correct software of the logic card [A5] and the transistor regulator [T1] have been installed in the truck by referring to the matrix below.

Transistor regulator ACT [T1] not replaced

Transistor regulator ACT [T1] replaced

OK ICH logic card [A5] activated

Warning 2.004. Use TruckCom to download new backup values.

Open TruckCom, and select “Copy configuration to secondary unit: ACT”

ICH logic card [A5] replaced

Replace one node at a time and implement the corresponding measure. See 17.2 and 16.5.2

Error code 2.101. Use TruckCom to upload new backup values.

Select “Copy configuration to primary unit: ICH”

Troubleshooting Troubleshooting chart T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.8.5 Defective hydraulic functions Symptom

Influencing elements

Possible cause/Remedy

The forks can be lowered but not raised.

Low or no hydraulic pressure

• Low oil level • Clogged suction filter • Defective or incorrectly adjusted pressure limiting valve • Defective hydraulic pump; replace the hydraulic unit

Pump motor [M3] does not work

• Hydraulic unit fuse [F1] has blown; replace fuse.

For more information, see the following table Pump motor [M3] does not work: • Measure current and voltage through and across the pump motor [M3].

• Pump motor [M3] voltage/current normal • No current or voltage through/ across the pump motor [M3] • Voltage across the pump motor [M3], but no current through it

7–

Troubleshooting Troubleshooting chart Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Symptom

Influencing elements

Possible cause/Remedy

Forks can be raised but not lowered.

The proportional valve [Q4] for lowering the forks does not open:

• Measure current and voltage through and across the valve coil.

For more information See “ Cont'd. The proportional valve [Q4] for lowering the forks does not open:” on page 32.

• Solenoid valve voltage/current normal • No current or voltage through/ across the solenoid valve coil • Voltage across solenoid valve coil, but no current through the coil.

Forks can neither be raised nor lowered

Defective fuse [F50] 7.5 A

Replace the fuse

Logic card [A5] faulty

Replace the logic card

Defective transistor regulator [T1]

Replace the transistor regulator.

Factory parameter 1023

Check the parameter value settings

Troubleshooting Troubleshooting chart T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Cont'd. Pump motor [M3] does not operate: Symptom

Influencing elements

Possible cause/Remedy

Pump motor [M3] voltage/current normal

Mechanical fault in the pump

Replace the hydraulic unit

No current or voltage through/ across the pump motor [M3]

Damaged wiring harness or connections in the pump motor [M3]

Check the wiring harness for interruptions or short-circuits to other electric components

Voltage across the pump motor [M3], but no current through it

Open circuit in the pump motor [M3]

Replace the hydraulic unit

Cont'd. The proportional valve [Q4] for lowering the forks does not open: Symptom

Influencing elements

Possible cause/Remedy

The proportional valve's [Q4] current/voltage is normal

Mechanical fault in the proportional valve [Q4]

Replace the hydraulic unit

No or low current/voltage through/across the proportional valve's coil [Q4]

Damage to the proportional valve's [Q4] wiring harness or connections

Check the wiring harness for interruptions or short-circuits to other electric components

Tiller arm Hall sensor for fork lowering defective

Replace the logic card [A5]

Transistor regulator [T1], output 108 “OUT.LOWER VALVE” defective

Replace the transistor regulator [T1]

Transistor regulator [T1], output 82 “OUT. +24 V HIGH SIDE DRIVER” defective

See the troubleshooting chart The truck cannot be driven

Break in the proportional valve's coil [Q4]

Replace the hydraulic unit

Voltage across the proportional valve's coil [Q4], but no current through it

7–

Troubleshooting Built-in test function Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.9 Built-in test function The truck control system has a number of built-in test functions that can be used to aid the troubleshooting process. To active the test functions, proceed as follows: 1. Connect the CAN service key to [X41] and log in.

2. Battery status symbol is lit.

3. Press the horn button [S18] repeatedly to choose the integrated test mode.

Note: All truck functions work as normal while the integrated test function is active. Care should be taken when operating the truck and reading the display at the same time.

Mod e

Flashing symbol

Data shown in the display

Normal value

1

Battery voltage (V)

2

Current across battery (A)

-

3

The set speed value that is sent to the transistor regulator

Min: -142 Max: 142

4

Travel speed value from travel speed sensor

Min: approx. -140 Max: approx. 140

5

Fork lowering on/off Fork lifting on/off

On: 1 Off: 0 On: 2 Off: 0

6

Fork under mast sensor #1

On (0V): Down Off (>5V): Up

7

N/A

-

8

N/A

-

9

Input/output status, transistor regulator [T1]

-

10

Input/output status, logic card [A5]

-

Troubleshooting Digital input/output status T-code 841, 842, 843

Mod e

Valid from serial number 6109948-

Flashing symbol

Date 2015-10-01

Order number 7519083-040

Data shown in the display

Normal value

11

Maximum value registered by the collision sensor (option)

Min: 0 Max: 100

12

Status of inputs/outputs, expansion unit 1 (optional)

-

13

Status of inputs/outputs, expansion unit 2 (optional)

-

7.10 Digital input/output status 7.10.1 Test function “9” – Transistor regulator In this setting, the digital inputs and outputs are tested by checking specific segments on the display according to the following tables.

A F G B C

E

1

2

3

4

D

H

Position: 1 and 2: The transistor regulator's current value. What is the current value in each input/output.

3 and 4: The transistor regulator's set point. Relating to what the software value should be.

A – H: Reference to segment One or more segments may be lit continuously at each position. The indications can also be combined across several positions. [xxx] in the table indicates the component designation {nn} in the table indicates the cable number in the electrical wiring diagram.

7–

Troubleshooting Digital input/output status Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Current values Function Fork under mast sensor #2 [B64] INP. MAST SWITCH 2 Main contactor [Q10] Parking brake [Q1] Tiller arm in drive position [B60] INP. TILLER ARM IN DRIVE POS.

Pos 1

Pos 2

Pos 3

Pos 4

A

*

*

*

Lit: Forks lowered Extinguished: Forks up

B

*

*

*

Lit: Contactor closed Unlit: Contactor open

C

*

*

*

Lit: Brake released Unlit: Brake applied

D

*

*

*

Lit: Tiller arm in drive position Unlit: Tiller arm in one of the end positions

-

E

*

*

*

Not assigned

Support arm in lower position.

[B62] INP. SUPPORT ARM IN LOWEST POS

F

*

*

*

Lit: Down Extinguished: Up

Forks below mast sensor #1 [B63] INP. MAST SWITCH 1

G

*

*

*

Lit: Down Extinguished: Up

-

H

*

*

*

Not assigned

-

*

A

*

*

Not assigned

-

*

B

*

*

Not assigned

-

*

C

*

*

Not assigned

-

*

D

*

*

Not assigned

-

*

E

*

*

Not assigned

Fork valve active.

[Q22] OUT. FORK VALVE

*

F

*

*

Lit: Valve open Unlit: Valve closed

Support arm valve active.

[Q23] OUT. SUPPORT ARM VALVE

‘

G

*

*

Lit: Valve open Unlit: Valve closed

-

*

H

*

*

Not assigned A F G B C

E D

H

Troubleshooting Digital input/output status T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Set points Function

Pos 1 Pos 2

Pos 3

Pos 4

-

*

*

A

*

Not assigned

Main contactor [Q10] OUT. MAIN CONTACTOR

*

*

B

*

Lit: Contactor closed Unlit: Contactor open

-

*

*

C

*

Not assigned

Parking brake [Q1] OUT. BRAKE RELEASE

*

*

D

*

Lit: Brake released Unlit: Brake applied

-

*

*

E

*

Not assigned

Pump motor [M3] active

*

*

F

*

Lit: Active Unlit: Not active

Proportional valve [Q4]

*

*

G

*

Lit: Affected Unlit: Not affected

-

*

*

H

*

Not assigned

Pump contactor [Q25].

OUT. PUMP CONTACTOR1

*

*

*

A

Lit: Contactor closed Unlit: Contactor open

Fork valve [Q22] OUT. FORK VALVE2

*

*

*

B

Not assigned

Support arm valve [Q23] OUT. SUPPORT ARM VALVE2

*

*

*

C

Not assigned

Spare (Digital out 4)

*

*

*

D

Not assigned

-

*

*

*

E

Not assigned

-

*

*

*

F

Not assigned

-

*

*

*

G

Not assigned

-

*

*

*

H

Not assigned A F G B C

E D

1.Only applies to SWE100.

2.Applies only to SWE120L, 140L and 200D.

7–

H

Troubleshooting Digital input/output status Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.10.2 Test function “10” – Logic card

Function

Pos 1

Pos 2

Pos 3

Pos 4

-

A

*

*

*

Not assigned

-

B

*

*

*

Not assigned

-

C

*

*

*

Not assigned

Front fork lift button [A5:S19]

D

*

*

*

Lit: Button depressed

Front fork lowering button [A5:S20]

E

*

*

*

Rear fork lift button [A5:S21]

F

*

*

*

Rear fork lowering button [A5:S22]

G

*

*

*

Sound signal control [S18]

H

*

*

*

Outermost option button, right side [S116]

*

A

*

*

Centre option button, right side [S115]

*

B

*

*

Innermost option button, right side [S114]

*

C

*

*

Outermost option button, left side [S113]

*

D

*

*

Centre option button, left side [S206]

*

E

*

*

Innermost option button, left side [S111]

*

F

*

*

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned

Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed Lit: Button depressed

A F G B C

E D

H

Troubleshooting Digital input/output status T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.10.3 Test function “12” – Expansion unit SEU (option).

Function

Pos 1

Pos 2

Pos 3

Pos 4

Digital input 1

A

*

*

*

-

Digital input 2

B

*

*

*

-

Digital input 3

C

*

*

*

-

Digital input 4

D

*

*

*

-

Digital input 5

E

*

*

*

-

Digital input 6

F

*

*

*

-

Digital input 7

G

*

*

*

-

Digital input 8

H

*

*

*

-

Digital output 1

*

A

*

*

-

Digital output 2

*

B

*

*

-

Digital output 3

*

C

*

*

-

Digital output 4

*

D

*

*

-

-

*

E

*

*

Not assigned

-

*

F

*

*

Not assigned

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned A F G B C

E D

7–

H

Troubleshooting Test function for the display Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

7.11 Test function for the display The digital display itself can be tested to verify all segments of the display function correctly.

To the test the display, proceed as follows: 1. Ensure that the battery is connected.

2. Ensure that the truck is switched off. Press the OFF switch.

3. Enter the appropriate PIN code. Note: Do not press the ON button.

4. Keep the horn button depressed until “d” is displayed, then release the horn button.

All segments and symbol icons must flash sequentially.

Troubleshooting Checking the built-in battery charger T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

7.12 Checking the built-in battery charger This checklist must be filled in and sent in together with the replaced charger.

Applies to the following part numbers: 7513327 7513328 7539122 7539123 The unit must not be opened under any circumstances.

• Connect the charger to mains voltage and ensure the battery connector is connected.

Check 1

Are all of the charger's connectors properly connected?

2

Does the fan blow air out of the charger? (it should begin running at start-up)

3

Does battery voltage increase when the charger is connected to mains voltage?

(Measure across the battery terminals)

4

Are the parameter settings for the battery set as specified in the repair manual?

5

If any parameter setting was incorrect, does it have the correct setting now?

6

Is the correct software completely downloaded?

If not, follow the emergency downloading instructions found in the TruckCom manual.

Yes

No

---------

If you answered Yes to all of the questions, the charger is functioning properly and does not require replacement.

If not, fill in the rest of the checklist on the next page.

7–

Troubleshooting Checking the built-in battery charger Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

This part of the checklist is intended to help us in our improvement work.

Check 1

Is there any evidence of moisture on the inside or outside?

(Investigate for interior moisture through the perforated sides.)

2

Has the truck been used in an environment with a temperature below 0° Celsius?

3

Has the truck been used outdoors?

4

Are there signs of mechanical damage?

5

Has the truck travelled over uneven floors or loading ramps?

6

Are there any error codes? If yes, please specify.

Yes

No

Troubleshooting Checking the built-in battery charger T-code 841, 842, 843

7–

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Chassis 0000 Support arm 0350 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

8 – Chassis 0000 8.1 Support arm 0350 8.1.1 Support arm lift, lateral adjustment b

a

1. Loosen the locking nut 2. Adjust the lateral guides using the adjustment screw (b). There are four adjustment screws.

3. Adjust the lateral guides so that there is no play but so that the lowering does not jam.

4. Lock the adjustment screws position with the locking nut.

Chassis 0000 Support arm 0350 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

8.1.2 Adjusting the kneeling action

a

The gap between the chassis pressure plate and the support arm link roller must be between the minimum value of 0.4 and the maximum of 2.0.

1. Check the gap. A precondition for checking the gap is that the roller is fitted and that they are in the lowered position.

2. Loosen the cylinder (a) if the gap is incorrect (6 mm Allen) 3. Place a suitable number of shims 7501642 under the cylinder (a).

4. Tighten the cylinder.

5. Check that the gap is correct.

8–

Chassis 0000 Motor mounts 0450 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

8.2 Motor mounts 0450 8.2.1 Replacing springs (not applicable for S212S) Proceed as follows to replace the springs that press the drive unit against the ground: 1. Remove the covers and the battery door.

The top cover is secured with Velcro tape. Be careful when detaching the cover. Use of a suitable tool is recommended.

2. Lift out the battery.

3. Disconnect the cables to the drive motor and the pump motor and also the wiring harness.

4. Disconnect the cable duct.

5. Unfasten the battery connector and the battery cable bracket.

6. Install the threaded M16 bar. See section "Tools".

1

2

7. (1) Washer and nut on the top side. (2) Screw the shaft into the threaded hole and tighten with the nut.

3

Chassis 0000 Motor mounts 0450 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

8. Change the upper stop screws for M8 x 120, washers are not needed.

9. Remove and discard the screws to the upper bracket.

10. Remove the lower screws.

11. Compress the spring assembly using the threaded bar until the lips are clear.

12. Unload the springs by prying up the bracket using the threaded bar.

Note: Check that the bushings do not get stuck or become damaged during reassembly.

8–

Chassis 0000 Removing the platform Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

8.3 Removing the platform 1. Apply a load on the platform and loosen the upper dampening stop together with the spring cover plate.

2. Disassemble the platform from the truck by loosening the four bolts.

3. Put the platform on the floor behind the truck with the spring facing you and placing the other edge under the truck's foot guard.

4. Loosen all 8 screws securing the bracket, which the spring clamp is pushing against.

Chassis 0000 Removing the platform T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Note: Pay utmost attention when working with tensioned springs.

5. Relieve the spring using a crowbar or a large screwdriver and carefully remove the bracket.

6. Pull out the axle and replace the part(s) that should be replaced.

7. Install in reverse order.

8–

Electric drive motor 1700 Components Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

9 – Electric drive motor 1700 9.1 Components E D A

B

C

Pos.

Description

A B C C D E

Speed sensor Connection, motor cables Motor: S212L/214/214L/220D 1.5kW Motor: S210/212/212S 1.0kW Temperature sensor Dust guard

Electric drive motor 1700 Removing the motor from the truck T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

9.2 Removing the motor from the truck 1. Remove the covers.

The top cover is secured with Velcro tape. Be careful when detaching the cover. Use of a suitable tool is recommended.

2. Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X60.

a 3. Loosen the operating console's mounting screws (a) and remove the operating console and tiller arm.

4. Remove the brake's cable connection Q1.

5. Remove the speed sensor's cable connector B11.

9–

Electric drive motor 1700 Removing the motor from the truck Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

6. Remove the temperature sensor B1 7. Disconnect the motor cables and unscrew the motor retaining screws.

8. Lift out the motor from the truck.

9. If needed, remove the brake and the speed sensor.

Note: Cover the drive gear to prevent loose items from falling into the drive gear after the drive motor has been removed.

Install the motor in the reverse order.

See section "9.3 Drive motor tightening torques".

Note: During installation, it is very important for the motor to be adjusted so that the grooves in the motor and motor bracket face each other before the retaining screws are tightened. See the illustration below.

Tighten the 4 drive motor mounting screws (a). The screws must be tightened crosswise and in two stages. In other words, do not tighten to full torque during the first stage. See section "9.3 Drive motor tightening torques".

a

Electric drive motor 1700 Drive motor tightening torques T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

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

3.5Nm T30

3 + 0,5 Nm 10 mm

8 Nm T30

9.4 Installing the temperature sensor 1. Cut off the wiring to the broken temperature sensor, and splice on 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.

8. Following curing, it is recommended to apply another layer of plastic steel.

9–

Electric drive motor 1700 Cleaning Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

9.5 Cleaning Keep the motor as clean as possible since this is a decisive factor for correct operation. Regularly inspect 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 not for longer than 6 hours.

Electric drive motor 1700 Cleaning T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

9–

Order number 7519083-040

Drive gear 2550 General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

10 – Drive gear 2550 10.1 General The drive gear is combined with the motor and brake assembly in a complete drive unit.

The complete overhaul of the drive gear must be performed by the supplier.

10.2 Components

b

a

Pos.

Description

a b

Drive gear Screw

Drive gear 2550 Removing the gear from the truck (not applicable for S212S) T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

10.3 Removing the gear from the truck (not applicable for S212S) 1. Remove the covers.

The top cover is secured with Velcro tape. Be careful when detaching the cover. Use of a suitable tool is recommended.

2. Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X60.

3. Unscrew the retaining screws of the steering console and remove the steering console and the tiller arm.

4. Disassemble the speed sensor and disconnect the cable connections Q1 and B1.

5. Disconnect the motor cables and unscrew the motor retaining screws.

6. Lift out the motor from the truck.

7. Insert a 30 mm plug in the hole in the gear housing to prevent oil leakage when the gear is removed from the truck.

8. Disconnect the cable duct.

9. Install the threaded M16 bar.

10 –

Drive gear 2550 Removing the gear from the truck (not applicable for S212S) Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

10. Lift the motor bracket using the threaded rod until the drive wheel is lifted approx. 4 mm from the floor.

11. Unscrew the retaining screws of the gear box.

12. Lift carefully approx. 125 mm lay the gear down on the floor.

13. Lift a further 100 mm, a total of 225 mm and pull it out to the rear edge.

Steps 12, 13 Install in reverse order.

Please note the risk of crushing when installing the unit.

Drive gear 2550 Removing the gear from the truck (not applicable for S212S) T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

10.4 Removing the gear from the truck (not applicable for S212S) 1. Elevate the drive unit approx 190 mm.

2. Loosen the drive wheel.

3. Remove the covers.

The top cover is secured with Velcro tape. Be careful when detaching the cover. Use of a suitable tool is recommended.

4. Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X60.

5. Unscrew the retaining screws of the steering console and remove the steering 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 retaining 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. Put down the gear and pull it out to the rear edge.

Install in reverse order.

Put a wooden block under the gearbox to facilitate reassembly.

10 –

Drive gear 2550 Replacing the wheel hub seal Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

10.5 Replacing the wheel hub seal Removing the seal

• Remove the drive wheel. See section "12.1 Replacing the drive wheel".

1:

Remove the cover ring using a screwdriver or similar.

2:

Remove the seal using a screwdriver or similar.

Drive gear 2550 Replacing the wheel hub seal T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Fitting the seal

Step 1

Step 2

1:

Fit a new seal. Tap lightly to get it into the right position.

2:

Fit a new cover ring. Tap it lightly into place.

• Fit the drive wheel. See section "12.1 Replacing the drive wheel".

10 –

Brakes 3180 Components Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

11 – Brakes 3180 In normal work environments, the brake should not require any maintenance.

11.1 Components I H

B

A

C

F D

J

E

Pos. no.

Description

A

Circlip

B

Complete brake assembly

C

Screw

D

Key

E

Hub

F

Brake disc

G

Flange

H

Dust guard

I

Cable grommet

J

Dust guard

G

Brakes 3180 Releasing the brake T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

11.2 Releasing the brake Note: The brakes should only be released when the truck needs to be moved in connection with service and repair work.

A

A 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 operating the truck again.

11 –

Brakes 3180 Installing the dust shield Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

11.3 Installing the dust shield Applies to serial numbers up to 6140925

Step 3

Step 2

Step 1

Steps 4, 5 and 6 Gap=Min 0.2mm

Step 7

Step 9

Step 8

Steps 10 and 11

Step 12 T=23Nm

Brakes 3180 Installing the dust shield T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

DANGER! Risk of brake function being lost.

When work is done in the brake system, there is a risk of brake function being partly or completely lost.

Method Preconditions: • Truck switched off and the battery disconnected • Motor compartment open 1.

2.

3.

4.

5.

6.

Remove the steering yoke from the truck together with the tiller arm (see the repair manual). Note the position of the conduit entry so that refitting is done correctly.

Unscrew the retaining screws of the brake and disconnect the cable connection.

Remove the brake unit from the truck. Note the position of the brake so that refitting is done correctly.

Place the parking brake on a workbench with the magnet housing facing downwards.

Clean the brake using compressed air. Clean from the inside outwards.

Repeat the cleaning as necessary until a 0.2 mm feeler gauge can be inserted. If there are particles that cannot be cleared away with compressed air, these may be carefully scraped away.

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

Note: It is extremely important that an air gap of min. 0.2 mm is maintained all around the brake. If the prescribed measurement cannot be maintained, the brake must be replaced

7.

8.

Turn over the parking brake and press the dust guard into place.

Turn the brake back with the magnet housing positioned downwards. Using a suitable blunt tool, press on the dust guard until it is edge-to-edge with the upper part of the magnet housing.

9. Check the position of the dust guard.

10. Reinstall the brake as noted and connect the connector unit.

11. Torque tighten the brake retaining screws to 5 Nm. 12. Refit the tiller arm and the steering yoke and tighten the screws to 23Nm Make sure the wire grommet is placed according to the notes and properly secured when fitting it to the brake.

Concluding procedures: • Connect the battery and close the motor compartment cover.

• Start the truck and check that the brake works correctly.

11 –

Brakes 3180 Installing the dust shield Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

11.4 Installing the dust shield Applies to serial numbers from 6140927

Step 1

Steps 4, 5 and 6 Gap=Min 0.2mm

Step 3

Step 2

Step 7

Step 8

Steps 9 and 10 T=5Nm

Step 12 T=23Nm

Brakes 3180 Installing the dust shield T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

DANGER! Risk of brake function being lost.

When work is done in the brake system, there is a risk of brake function being partly or completely lost.

Method Preconditions: • Truck switched off and the battery disconnected • Motor compartment open 1.

2.

3.

4.

5.

6.

Remove the steering yoke from the truck together with the tiller arm (see the repair manual). Note the position of the conduit entry so that refitting is done correctly.

Unscrew the retaining screws of the brake and disconnect the cable connection.

Remove the brake unit from the truck. Note the position of the brake so that refitting is done correctly.

Place the parking brake on a workbench with the magnet housing facing downwards.

Clean the brake using compressed air. Clean from the inside outwards.

Repeat the cleaning as necessary until a 0.2 mm feeler gauge can be inserted. If there are particles that cannot be cleared away with compressed air, these may be carefully scraped away.

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

Note: It is extremely important that an air gap of min. 0.2 mm is maintained all around the brake. If the prescribed measurement cannot be maintained, the brake must be replaced

7. Turn over the parking brake and press the dust guard into place.

8. Check the position of the dust guard.

9. Reinstall the brake as noted and connect the connector unit.

10. Torque tighten the brake retaining screws to 5 Nm. 11. Refit the tiller arm and the steering yoke and tighten the screws to 23Nm Make sure the wire grommet is placed according to the notes and properly secured when fitting it to the brake.

Concluding procedures: • Connect the battery and close the motor compartment cover.

• Start the truck and check that the brake works correctly.

11 –

Drive wheel 3530 Replacing the drive wheel Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

12 – Drive wheel 3530 12.1 Replacing the drive wheel

Step 1

Step 2

Step 4 Step 5 Method DANGER! Risk of crushing since a poorly supported truck could fall down.

1. Pull out the battery.

2. Lift up the truck about 100 mm and support it with trestles.

3. Turn the drive wheel diagonally from one of the sides.

4. Unscrew the 5 nuts, and remove them along with the washers.

5. Pull out the wheel.

Drive wheel 3530 Replacing the drive wheel T-code 841, 842, 843

Valid from serial number 6109948-

Step 1

Date 2015-10-01

Order number 7519083-040

Step 2

Step 3 Step 4

Step 5

Installing the drive wheel on the truck

×n

1. Fit the drive wheel.

2. Fasten the screws and washers.

3. Tighten the screws crosswise - tightening torque 81 ±19 Nm

s mm

Step 3: s = 17, n = 5 Mv = 81Nm

12 –

4. Remove the trestles and lower the truck to the ground.

5. Connect the battery.

Castor wheels 3540 Components Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

13 – Castor wheels 3540 This chapter does not apply to S212S

13.1 Components

Pos.

Description

Pos.

Description

A B C D E F G

Circlip Washer Screw Bracket Washer Bearing Circlip

H I J I L M

Screw Spacer Spacer Bearing Guard Nut

Castor wheels 3540 Castor wheel mounting T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

13.2 Castor wheel mounting 11 12

13

14 15 21

20 19 18 17 16

13 –

Pos.

Description

Pos.

Description

11

Nut

17

Screw

12

Steering

18

Washer

13

Spring

19

Bracket

14

Steering

20

Bushing

15

Cradle

21

16

Screw

Shims, max 1mm gap. Add as needed.

Castor wheels 3540 Replacing the castor wheel Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

13.3 Replacing the castor wheel

Step 2

Steps 3 and 4 Step 1

Step 5 Step 6 Method DANGER! Risk of crushing since a poorly supported truck could fall down.

1. Secure the truck on support trestles.

2. Disconnect the truck battery.

3. Unscrew the castor wheel.

4. Refit the castor wheel and its four fastening screws and washers.

5. Connect the battery.

6. Remove the support trestles.

Castor wheels 3540 Replacing the castor wheel T-code 841, 842, 843

13 –

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Support arm wheel 3550 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

14 – Support arm wheel 3550 c

b

a

f g

e

d

Pos.

Description

a

Screw

b

Bracket

c

Bogie wheel

d

Single wheel

e

Shaft

f

Circlip

g

Shim

Remarks

Use the required amount to achieve a gap between 0.5 and 1.5 mm

Support arm wheel 3550 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

14 –

Order number 7519083-040

Tiller arm 4000 Tiller arm components Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

15 – Tiller arm 4000 15.1 Tiller arm components A

U

T

B

C E

S

D

I

J

F G

R H

K

Q L

w P

M N

V

O

O

Pos.

Description

Pos.

Description

A B C D E F G H I J I

Tiller arm: Rubber buffer Cylindrical bolt Gas strut Circlip Rubber buffer Bushing Threaded insert Spring pin Holder Safety sensor B60

M N O P Q R S T U V W

Indicator sleeve Plate Yoke Cable clamp Screw Yoke Screw Cover Cover Cable clamp Cable clamp retaining screw

L

Shaft

Tiller arm 4000 Removing the tiller arm T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

15.2 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 steering console.

Note: Do not try to prise away the cable clamp with a screwdriver.

5. Cut off the cable ties of the cable duct on the transistor regulator side and disconnect cable connections X5 and X60.

Install in reverse order.

15.3 Replacing the gas spring 1. Remove the cover (T).

2. Remove the cable clamp retaining screw (W) 3. Unscrew the adjusting screw (Q).

4. Remove the locking mechanism (E) from the gas strut lock shaft (C) 5. Detach the gas strut lock shaft (C).

6. Remove the gas strut.

Install in reverse order.

Note: Pay attention during assembly and make sure no cables are pinched.

15 –

Tiller arm 4000 Replacing the safety sensor Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

15.4 Replacing the safety sensor 15.4.1 Dismantling Beginning with serial number ????, the spring pin has been replaced with a stop screw. Both procedures are described here.

1. Remove the gas strut. See section "15.3 Replacing the gas spring".

2. Unscrew the stop screw (I) of the shaft (L). See figure. Skip to step 5.

3. Tap the spring pin (I) of the shaft (L) into place. Use a suitable implement and tap the spring pin so deep that the spring pin is fully in the shaft.

4. Tap out the shaft (L) approx. 5 mm so that the spring pin hole becomes accessible. Use care to prevent the indicator sleeve (M) from becoming pinched.

5. Turn the shaft (L) until the back of the indicator sleeve (M) becomes accessible.

6. Loosen the indicator sleeve (L).

To prevent damage to the sleeve, pry the indicator sleeve loose from both sides at the same time.

7. Tap out the shaft (L).

Note: Make sure that the handle does not drop down and damage the cables.

8. Remove the cable clamp retaining screw (W).

9. Remove the sensor retaining screw (S).

10. Detach contact B60 from the sensor (K).

11. Remove the sensor.

15.4.2 Fitting Beginning with serial number ????, the spring pin has been replaced with a stop screw. Both procedures are described here.

1. Fit the sensor (K) 2. Attach connector B60 to the sensor.

3. Apply Loctite to the sensor retaining screw (S) or replace it. Fasten the screw.

4. Fasten the cable clamp retaining screw (W).

Note: The cable must be routed to the right of the sensor (K), towards the spring pin.

5. Screw the stop screw (I) into the shaft (L). See figure. Skip to step 9.

Tiller arm 4000 Replacing the safety sensor T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

6. Tap the spring pin (I) out of the shaft (L) and fit the shaft.

7. Fit the indicator sleeve and turn the shaft so that the sleeve faces in towards the sensor. Turn just far enough for the spring pin to be able to run into the shaft.

8. Use an implement and tap the spring pin into the yoke (O) and shaft (L). The spring pin must be tapped in deep enough that the implement goes approx. 19 mm into the yoke. See figure.

m 19 m

15 –

9. Fit the gas spring. See section "15.3 Replacing the gas spring".

10. Check for correct operation of the safety sensor.

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

15.5 Electrical steering system – 4000 15.5.1 Tiller arm handle C4110 15.5.2 Components of the tiller arm handle (new design) G

H

C I

F

B

Y D

A

E K

S

K

J

L

T

M

X L R N

Q

P O

U

V

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

15.5.3 Components of the tiller arm handle (old design) H G

A

I

F C A

B

D

E

K

J

L

S

T

M

X K L R

N

Q

P

O

U

V

15 –

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Pos.

Description

Pos.

Description

A

Symbol board

M

Speed control/travel direction selector

B

Push-button

N

Display

C

Push-button

O

Cable clip

D

Safety reversing push button

P

Cable clip

E

Spring

Q

Cover

F

Logic card

R

Plug

G

Seal

S

Cover, transparent plastic

H

Spring

T

Seal

I

Cover

U

Handle

J

Seal

V

Cover

I

Horn button

X

Wiring harness

L

Signal switch

Y

Butterfly switch

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

15.5.4 Disassembling/assembling the steering unit handle

Step 2 Step 3

Step 5

Step 4

B

Step 6

15 –

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Warning!

Static electricity!

Risk of static discharge that can damage the electronics.

Make sure you take the necessary steps to prevent static electricity, ESD protection, before starting work on the steering module.

Disassembly 1:

Disconnect the truck battery.

2:

Detach the keypad and disconnect it from the logic card

3:

Remove the screws holding the upper cover and keep hold of the upper cover to prevent damage to the logic card cable

4:

Disconnect the CAN connection to the logic card

5:

Remove the screws holding the cover over the logic card and carefully lift away the cover.

Hint: Hold a finger between the cover and the shaft for the speed control buttons to prevent the speed control assembly from falling down.

6:

Lift off the speed control assembly

7:

If the logic card is to be replaced, disconnect its connectors and lift out the logic card.

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Assembly 1:

Fit the new logic card in place and connect it.

2:

Check the cable connection on the logic card and that the connectors are correctly connected.

3:

Fit the speed control assembly in position. Hook the ends of the spring around two the lugs in the cover

B

15 –

4:

Fit the cover in place and screw it down. Make sure the conduit entry is intact and correctly positioned.

5:

Check that the conduit entry is also correctly positioned in the cover.

6:

Connect the CAN bus connection to the logic card

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

7:

Valid from serial number 6109948-

T-code 841, 842, 843

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.

x5

8.

Turn the screws crosswise as depicted below a further four complete turns (a total of nine turns, which corresponds to 1 Nm).

2

4

3 1

x4

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

Valid from serial number 6109948-

9.

Date 2015-10-01

Order number 7519083-040

Check that there is no space between the tiller arm and the steering head.

10: Make sure that the control can be moved back and forth without difficulty, and that the control returns to the neutral position.

If the control shows signs of being difficult to move: Re-adjust the screws according to step 8.

11: Connect the keypad and screw it in position

12: Connect the truck battery 13: Test drive the truck and check the functions of the handle 11. If a new logic card without software has been installed, use TruckCom to download software and reset the parameters.

See the TruckCom manual.

15 –

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

15.5.5 Replacing the signal button/switch 1:

Disassemble the tiller arm handle.

See section "15.5.4 Disassembling/assembling the steering unit handle".

2:

Remove the button using a screwdriver as illustrated

3:

Remove the connection for the switch on the logic card

4:

Press out the switch from its bracket

5:

Fit the new switch and connect the cable to the logic card

6:

Align the button with the catch and secure it by hand.

7:

Assemble the tiller arm handle.

See section "15.5.4 Disassembling/assembling the steering unit handle".

15.5.6 Replacement of lift/lower button 1:

Disassemble the tiller arm handle.

See section "15.5.4 Disassembling/assembling the steering unit handle".

2:

Remove the button by placing a screwdriver in the holes (A):

A

A

3:

Unscrew the plate holding the arm and remove the arm

4:

Compress the springs and fit the button in place. Snap the button in place by hand.

5:

Assemble the tiller arm handle.

See section "15.5.4 Disassembling/assembling the steering unit handle".

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

15.5.7 Replacing the button 1. Press out the button laterally with the fingers.

2. Position a screwdriver as illustrated and carefully pry out the button.

3. Unscrew the button-holder and arm.

Assembly is done in reverse.

15 –

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

15.5.8 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 the lips catch when the new buttons are inserted.

3. Connect a PDA or PC and use TruckCom to change parameter 1023 to 2.

4. Start the truck and make sure the change is correct.

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

15.5.9 Replacing the safety reversal switch 1. Remove the keypad by undoing the screw and disconnecting the connector.

×1 2,5 mm

2. Loosen the screws securing the upper part of the tiller arm.

×4 4 mm

3. Disconnect the CAN connector.

15 –

Tiller arm 4000 Electrical steering system – 4000 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

4. Loosen the screws until the switch brackets come loose.

×3 3 mm

5. Remove the button by unhooking the locks on both sides.

6. Install in reverse order.

Tiller arm 4000 Electrical steering system – 4000 T-code 841, 842, 843

15 –

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Electric components Replacing the wiring harness Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

16 – Electric components 16.1 Replacing the wiring harness

A B X5 X21

C

X60

D

Pos.

Description

A

Connector clamp

B

Connector, female part

C

Bracket

D

Connector, male part

Proceed as follows when replacing the wiring harness: 1. When prying the X connectors apart, press in the connector lock (A) of the female part (B) and pull upwards.

2. Disconnect the female part (B) of the connector from the male part (D).

3. Then disconnect the male part (D) by pulling it downwards.

The bracket (C) remains on the connector panel.

Electric components Replacing the wiring harness T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

16.1.1 Replacing the transistor regulator wiring harness

A

B

C

Keep the following in mind if it becomes necessary to disconnect the connector (A) of the transistor regulator: • First press down on the bracket clamp (B).

• Then lift up the connector lever (C).

16 –

Electric components Replacing the transistor regulator Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

16.2 Replacing the transistor regulator Note: This action requires access to TruckCom!

A

D

C

1. Remove the inspection cover.

2. Cut off the cable ties of the cable duct on the transistor regulator side.

3. Disconnect the connectors (A) from the connector bracket.

4. Undo the screws (D) and move the connector bracket aside.

5. Disconnect all cables and connectors from the transistor regulator.

6. Loosen the fastening nuts (B) of the fixing plate.

7. Remove the transistor regulator.

Angle out the top edge of the fixing plate and turn it in the drive wheel direction in order to remove it from the truck.

8. Unscrew the transistor regulator from the fixing plate (C).

Assembly is done in reverse.

After installation of the new transistor regulator, the truck will display error code 2.004.

1. Connect TruckCom. 2. Select “Copy truck configuration”.

3. Select “Copy configuration to secondary unit: ACT”

Electric components Replacing the transistor regulator T-code 841, 842, 843

16 –

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Hydraulic system 6000 General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

17 – Hydraulic system 6000 17.1 General Always take the following safety precautions prior to commencing work on the truck's hydraulic systems: • Slowly depressurise system pressure.

• Use paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your hand.

• Be careful since the oil in the transmission and hydraulic systems can be scalding hot.

WARNING! Risk of burns if hot transmission oil or hydraulic oil gets onto the skin. Allow the truck to cool down before changing the oil.

Hydraulic system 6000 Hydraulic hygiene T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

17.2 Hydraulic hygiene Note: Risk of malfunction.

If impurities get into the hydraulic system, there is a risk of malfunctions in part or all of the hydraulic system. There is also a risk of severe damage to components.

For all work on the hydraulic system, the following instructions must be followed.

Note: Use only new and clean oil when refilling the hydraulic oil system. If the oil is contaminated, the hydraulic components will suffer damage.

17.2.1 Washing Hydraulic components, including hydraulic hoses and pipes, must be cleaned with a filtered washing fluid using a method suitable for the components concerned.

The washing fluid must have purity code 19/16/13 in accordance with ISO4406:1999 or 16/13 in accordance with ISO4406:1987.

Blowing clean with dry filtered air may be done when this is the only practical method to carry out cleaning.

17.2.2 Packaging After cleaning, all openings must be sealed with protective plugs. Connecting surfaces must be protected against handling damage and dirt penetration.

Completely dry components can be packed in plastic bags or boxes with lids.

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 components.

Tape must never be used without cleaning afterwards.

Protective plugs must be stored in plastic bags or boxes with lids until they are used.

After use, discard the plugs and plastic bags.

17.2.3 Handling Hydraulic components must be handled and transported with the greatest care.

Transportation packaging must be used throughout the entire handling chain.

This packaging must be clean and free from dust, etc.

17 –

Hydraulic system 6000 Hydraulic hygiene Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

17.2.4 Storage Hydraulic components must be handled and stored so that: • no rusting can occur • dust and dirt particles are shielded out • no mechanical deformation can occur

17.2.5 Work procedures When working on the hydraulic system, great cleanliness must be observed so that no impurities can enter the system.

No work that generates particles may be carried out in the same workplace or close to where work is being carried out on the hydraulic system.

The service technician must ensure that the components to be used are carefully deburred and cleaned.

Couplings for pipe ends or other openings must never be removed until the part is to be fitted to the receiving component.

Note: All hydraulic components that have not been cleaned, e.g. pipe couplings and nipples, must be blown clean before fitting.

Hydraulic system 6000 Hydraulic unit 6100 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

17.3 Hydraulic unit 6100 o

n m

a

k b i c

d

h g f

e

Pos.

Description

Pos.

Description

a

Pump motor [M3]

h

Hydraulic fork connection

b

Solenoid valve, support arm selection [Q23]1

i

Pressure limiting valve

c

Solenoid valve, fork selection [Q22]1

k

Max. oil level

d

Proportional valve, lowering [Q4]

m

Filling cap

e

Tank (suitable oil volume 5 l)

n

Pump motor cable connection

f

Screw

o

Pump motor cable connection

g

Hydraulic connection, support arm 1.Only applies to S212L, S214L and S220D

17 –

Hydraulic system 6000 Hydraulic unit 6100 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

17.3.1 Emptying the hydraulic tank 1. Loosen all cables and tubes to the hydraulic unit.

2. Loosen the hydraulic unit from the truck by releasing the clamps that surround the pump motor.

3. Loosen the tank from the hydraulic unit by loosening screw (f).

17.3.2 Hydraulic system, bleeding Cylinders with bleeding valve 1. Loosen all bleeding screws 2 revolutions.

2. Lift slowly at a constant rate until the forks begin to rise (30-40 cm).

3. Close the bleeding screws.

4. Lower the forks and continue to press the lowering button for 10-15 s.

5. Top up with oil.

6. Lift the forks to max.

7. Lower and check the oil level.

Cylinders without bleeding valve 1. Lift slowly at a constant rate until the forks begin to rise.

2. Lower the forks and continue to press the lowering button for 10-15 s.

3. Repeat a couple of times.

4. Fill with oil.

5. Lift the forks to max.

6. Lower to min.

7. Allow to stand approx. 30 min (info for customer).

Hydraulic system 6000 Hydraulic connections 6230 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

17.4 Hydraulic connections 6230 17.4.1 Quick change connector Connecting the quick change connector

1. Place the assembly stop (1) on the male fitting and make sure that the dismantling ring (2) runs freely in the groove.

2. Push the male fitting into the female fitting until the assembly stop makes contact with the female fitting.

3. The coupling is now made and locked.

17 –

Hydraulic system 6000 Hydraulic connections 6230 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Dismantling the quick change connector

1. Remove the assembly stop (with the aid of a screwdriver or similar tool).

2. Push the male fitting all the way into the female fitting.

3. Pull the male fitting out of the female fitting.

4. Refit the assembly stop on the male fitting.

5. Place protective plugs on the valve and hose.

Hydraulic system 6000 Hydraulic calibration T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

17.5 Hydraulic calibration A calibration function can be used to handle the proportional valve's [Q4] tolerance. Service mode “cal” must have the setting “1” and the truck must be restarted in order to activate the calibration mode. When performing a calibration, the service key must be connected, and the maximum rated load must be loaded onto the forks.

In the calibration mode, “strt” is shown on the display, waiting for one of the two horn buttons to be pressed. The calibration begins when one of the two horn buttons is pressed. The lowering valve is then opened slowly. As soon as the operator notices the movement of the forks, the horn button must be released. Wait until the display shows “end” and then restart the truck. Service parameter 108 s re-set automatically when the calibration is finished.

The calibration process affects the following parameters: • Maximum lowering speed of the fork (parameter 302) • Starting position of the proportional valve (parameter 303) • Lowering speed of the support arms (parameter 304) • Slow lowering speed (parameter 305) All parameters may be adjusted manually after calibration.

17 –

Hydraulic system 6000 Adjusting the pressure limiting valve Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

17.6 Adjusting the pressure limiting valve

Valve location 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:

c b

a

1. Pry off the sealing cap (a) attached to the pressure limiting valve using a screwdriver.

2. Remove the protective cover (b) (17 mm) by turning it anti-clockwise. Remove the protective cover and the washer housed inside it.

Hydraulic system 6000 Adjusting the pressure limiting valve T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

3. Loosen the locking nut (c) (17 mm) by turning it anti-clockwise.

4. Turn the adjusting screw clockwise until the truck is able to lift the load without any problem.

5. Tighten the locking nut (c) clockwise.

6. Refit the washer and protective cover (b) 7. Push a new sealing cap (a) onto the pressure limiting valve Once the truck is able 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. Pry off the sealing cap (a) attached to the pressure limiting valve using a screwdriver.

2. Remove the protective cover (b) (17 mm) by turning it anti-clockwise. Remove the protective cover and the washer housed inside it.

3. Loosen the locking nut (c) (17 mm) by turning it anti-clockwise.

4. Turn the adjusting screw counter-clockwise until the truck cannot lift the load.

5. Tighten the locking nut (c) clockwise.

6. Refit the washer and protective cover (b) 7. Push a new sealing cap (a) onto the pressure limiting valve

17 –

Hydraulic system 6000 Disassembling the hydraulic unit Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

17.7 Disassembling the hydraulic unit Before commencing any work on the hydraulic unit, make sure the forks have been fully lowered.

Step 1.

Step 2.

×n s mm

s: 13mm, n: 2

Step 3.

1. Disconnect the hydraulic hose. See section "17.4.1 Quick change connector".

2. Disconnect the motor cables using a wrench.

3. Disconnect the electric connection to the lowering valve.

Hydraulic system 6000 Disassembling the hydraulic unit T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Step 5.

×n s mm

Step 4.

s: 7mm, n: 1

×n s mm

s: 6mm, n: 1 each

Step 6.

4. Loosen the hydraulic unit bracket and lift out the unit from the truck.

5. Undo the clamp to be able to detach the tank from the motor and lift the valve unit away from the tank.

6. Remove and clean the strainer, then reattach it in the correct position.

7. Change the oil and clean the tank.

8. Reassemble everything in reverse order. See section "17.8 Hydraulic unit tightening torques".

Note: Be careful with the hydraulic unit seals when re-installing

17 –

Hydraulic system 6000 Hydraulic unit tightening torques Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

17.8 Hydraulic unit tightening torques The hydraulic unit tightening torques are depicted in the picture below:

10 + 2 Nm 10 mm

8,5 +- 0,5 0,5 Nm 13 mm

45 + 5 Nm 24 mm

45 + 5 Nm 24 mm

0,8 Nm 5 +- 0,8

4 +- 0,5 0,5 Nm 7 mm

Hydraulic system 6000 Hydraulic unit tightening torques T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

17 –

Order number 7519083-040

Lift mast – 7000 Main mast 7100 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

18 – Lift mast – 7000 18.1 Main mast 7100 18.1.1 Components

a a

b b

Pos .

Description

Tightening torque

a

Upper mast fixing points.

189 ± 8 Nm

b

Lower mast fixing points.

83 ± 4 Nm

Lift mast – 7000 Main mast 7100 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

18.1.2 Maintenance Fixing point According to the maintenance chart, the mast mounting bolts (8) should only be visually inspected and not re-tightened on inspection. If the mast needs to be replaced or if the bolts have come loose, then be sure to use new bolts and washers. The tightening torque should be according to the torque table.

Lubrication Lubricating the beam 1

18 –

The inside of the beam flanges are lubricated with (Q8 Rembrandt EP2).

Lift mast – 7000 Fork carriage 7420 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

18.2 Fork carriage 7420

a b

c

Pos.

Description

a

Shim

b

Roller

18.2.1 Maintenance • Check that the play in the fork carriage is not excessive.

• Adjust with shims (a) if needed.

• There are rollers with different diameters (c) to compensate for any wear on the guide rails.

Lift mast – 7000 Main lift chain system 7120 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

18.3 Main lift chain system 7120 18.3.1 Checking the chain setting The lifting chains must be adjusted at regular periods due to stretching; see below. The chain is checked during servicing as set out in the maintenance schedule.

Any adjustment is made with the chain mounting bolts.

Adjust the fork height according to C code 7100, 7420, 7700 and 7800 as applicable.

18.3.2 Checking the chain The chains are subjected to two types of wear – outline wear and stretching. Wear to the bolts and plate holes causes the chain to stretch. The chains are also affected by the environment in which they are used.

Noise If there has been insufficient lubrication, there will be metallic friction on the chain and this will result in noise.

Replace the chain.

Surface rust Surface rust is easy to recognise as the chain will be reddish brown.

Deep-seated rust has generally started and the strength of the chain is impaired.

Replace the chain

Rusty links Fretting corrosion results in a reddish-brown powder being visible on the outer plates. It can also appear as if the chain is bleeding if lubricated.

Replace the chain.

18 –

Lift mast – 7000 Main lift chain system 7120 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Stiff links If it is not possible to pull out the chain to its normal position this can be because of link rust or seizing.

Replace the chain

Bolt rotation Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when comparing with a new chain. .

Replace the chain

Loose bolts If a bolt is loose it will protrude from the side of the chain, and this is due to a stiff link or bolt rotation.

Replace the chain

Lift mast – 7000 Main lift chain system 7120 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Outline wear P

H2

H3

P = Pitch.

H2 = Nominal plate height.

H3 = Minimum plate height.

A new lifting chain has a specific nominal plate height (defined as H2 in the figure). As the truck is used, the lifting chain wears radially on the side that rolls over the chain wheel. The minimum plate height (defined as H3 in the figure) denotes the minimum permitted value of the plate height.

Maximal permitted outline wear is 5% of the height H2. If a lifting chain reaches the maximum level of wear, the chain must be replaced.

The nominal and minimum Plate heights for respective lift chains are stated in the table in the section “Stretching”.

18 –

Lift mast – 7000 Main lift chain system 7120 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

Stretching The amount of stretch on a lifting chain is measured on the part of the chain that runs over the chain roller. The amount of stretch may, at the most, be 2% on the most worn section of the chain.

The measurement is best made over 300-1000 mm of chain.

The nominal and maximum permitted chain lengths for lifting chains are stated in the table below.

Type of chain

Nominal disc height H2 (mm)

Minimum plate height H3 (mm)

Pitch P (mm)

Nominal chain length for 20/30/ 50 plates (mm)

Maximum permitted chain length for 20/30/50 plates (mm)

3/4", 2x3

17.8

16.9

19.05

381/572/953

389/583/972

3/4", 3x4

17.8

16.9

19.05

381/572/953

389/583/972

3/4", 4x6

17.8

16.9

19.05

381/572/953

389/583/972

1", 4x4

23.6

22.4

25.4

508/762/1270

518/777/1295

1", 6x6

23.6

22.4

25.4

508/762/1270

518/777/1295

Wear to the bolts and around the holes on the discs is one reason why the chain stretches. The chain should be replaced if stretching is more than 2%.

Damage

The chain should be replaced if damaged in any way.

Lift mast – 7000 Main lift chain system 7120 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Damaged plates If a plate has broken on the chain, this may be due to overloading or corrosion.

Replace the chain.

Damaged bolts It can be difficult to determine whether a bolt has broken. It can appear as bolt rotation and/or that the outer plate is loose.

Replace the chain.

Dirty chain If a chain is very dirty replacement is recommended first and foremost.

It can also be removed and cleaned as set out in the chapter “Cleaning”.

18.3.3 Cleaning If a chain is very dirty, replacement is recommended.

Dirty chains should be cleaned before they are lubricated, e.g. by washing with solvent such as diesel or petrol.

The chain should be blown dry using compressed air and lubricated directly after cleaning.

NOTE: Exercise care with degreasing agents as these can contain abrasives.

18 –

Lift mast – 7000 Main lift chain system 7120 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

18.3.4 Lubrication Both mineral and synthetic oils can be used to re-lubricate Rexnord chains.

NOTE: Lubricants must not contain substances such as molybdenum disulphide, PTFE or such.

A lift chain should be offloaded from the weight of the fork carriage (hanging free) when lubricated.

• Lubrication intervals: - 500 hours with normal operations - 100 hours when operating in rugged environments such as cold stores and corrosive environments.

The chains are sprayed with lubricant. Please note that the entire chain must be lubricated, even the fastening bolts. It is particularly important that the part of the chain that runs over the chain wheel is well lubricated.

The lubricate must comply with the viscosity demands at respective temperatures as set out in the table below. The following lubricants are recommended:

Ambient temperature

Viscosity class

Recommended products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

> + 5°C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

* Similar products from other manufacturers may be used.

NOTE: Do not use a special rust protective agent to prevent rust on the lifting chains.

These agents impair lubrication of the chains. Regular lubrication is the best method to prevent rusting.

Lift mast – 7000 Main lift chain system 7120 T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

18.3.5 Adjustment The lifting chains must be adjusted at regular periods due to stretching.

This is to be done when other service work with chains is performed.

The lock nuts on the lift chains are to be tightened with 50 Nm (+12.5 Nm / -5 Nm). .

a 1.

2.

b Make sure that the thinner nut (b) is placed closest to the chain fitting.

Use a fixed spanner and a torque wrench set to 50 Nm to ensure the correct torque.

Using the main lifting chains, the mast guides must be adjusted so that the bottom part of the mast is level. .

18 –

Lift mast – 7000 Replacing the fork carriage Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

18.4 Replacing the fork carriage 1. Lift the fork carriage with an overhead crane or with another truck to take the load off the chain.

2. Remove the chain bolt.

3. Lower the fork carriage.

Lift mast – 7000 Replacing the fork carriage T-code 841, 842, 843

Valid from serial number 6109948-

4. Lift the inner guides.

5. Remove the fork carriage.

6. Install in reverse order.

18 –

Date 2015-10-01

Order number 7519083-040

Lift mast – 7000 Replacement of the mast Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

18.5 Replacement of the mast We use a Duplex Hilo mast in this example.

1. Start by disconnecting the fork carriage according to the example above.

2. Disconnect all connectors to the lift height switches.

3. Remove the spiral hose.

4. Disconnect the main hydraulic hose from the T-connector.

Lift mast – 7000 Replacement of the mast T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

5. Connect a hose plug in the hose to stop the oil flow.

6. Lift out the battery.

7. Lower the mast and secure it in both lifting points with an overhead crane or using another truck.See section "23.5 Other tools".

18 –

Lift mast – 7000 Replacement of the mast Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

8. Remove the lower finger protectors and the bracket for the hydraulic hose on the cylinder.

9. Remove the four bolts holding the mast.

Lift mast – 7000 Replacement of the mast T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

10. Make sure that the mast is freed, and lift it past the guide lugs.

11. Attach the new mast in reverse order.

18 –

Lift mast – 7000 Adjusting the mast Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

18.6 Adjusting the mast The angle of the mast must be checked after replacement. Make sure that the truck is standing on a level surface when checking. Fit shims according to the instructions below if needed.

Lift mast – 7000 Adjusting the mast T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Tighten the screws that hold the mast See section "18.1.1 Components".with the correct tightening torque.

18 –

Accessories Spider expansion unit Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

19 – Accessories 19.1 Spider expansion unit The spider expansion unit, called SEU, allows the main logic card to handle a greater number of inputs and outputs. The SEU does not have its own truck controller logic, which means that a defective SEU can be replaced without the replacement affecting any truck functions.

The SEU is used for modification of the truck to meet special customer requirements. .

Electronic card

Truck Log System

Pump controller

Extra/Customised function(s)

CAN bus

Spider Expansion Unit

CAN service connector

Motor Controller

The picture above 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.

Accessories TLS - Truck log system T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

19.2 TLS - Truck log system See the separate manual that is included with the truck log system.

19.3 ID unit See the separate manual that is included with the software.

19 –

Accessories Built-in battery charger Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

19.4 Built-in battery charger Note: If retrofitting the built-in battery charger, TruckCom is required to be able to set all necessary parameters. TruckCom is not needed if replacing an existing charger. When installing the charger, torque tighten nuts (A) to max. 1.6 Nm.

If the truck is factory-fitted with a battery, the battery charger is adjusted to suit the battery.

If the truck is delivered from the factory without a battery, the customer/ technician must set the right parameters based on battery type and size

A

B

19.4.1 Technical data Designation

SMCO 24/30

Dimensions, mm

240x111x77

Weight, kg

1.7

Ambient temperature, ºC

-25 - +40 (freely vented batteries) +15 - +30 (valve regulated batteries)

Mains voltage, V AC

195-264

Rated voltage, V DC

24

Rated current, A

30

Maximum output, W

800

Accessories Built-in battery charger T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

19.4.2 Charging the battery To start charging, open the battery compartment cover and connect the charger connector to a wall outlet.

Note: Prior to commencing charging, switch off the truck and disconnect all other electrical connections to the truck.

When the truck is charging, the following is indicated on the display:

Main charging During the charging process, lines appear sequentially from left to right as the battery is charged. The battery symbol and the OFF button flash.

Equalising charging Four lines at the left in the display light continuously while four lines on the right appear sequentially. The battery symbol and the OFF button flash.

Charging completed The battery capacity value and unit (Ah) appear alternately in the display. The battery symbol is lit continuously, while the OFF button flashes.

Disconnect the contact from the wall socket once the battery has been charged. The OFF button then lights continuously. The truck is now ready for use.

19 –

Attachments General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

20 – Attachments 20.1 General The Attachments section provides instant access to the following information: • Technical data • general tightening torques • tools • Oil and grease specifications • electric components and wiring diagrams • hydraulics schematics • disposal instructions.

Attachments General T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

20 –

Order number 7519083-040

Technical data S210, S212, S214 Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

21 – Technical data 21.1 S210, S212, S214 Model

SWE100

SWE120

SWE140

Truck traction Type Power, kW Duty cycle Weight, kg

Iskra AML7108 1.0 S2-60 min 9

10.5

Brakes Type Braking force, Nm Power, W Resistance, coil, Ω Nominal gap in actuated position, mm Minimum thickness of brake disc, mm Thickness of new brake disc, mm

Warner PK10 15 51/13 10.5-12.0 0.2-0.55

7.9 8.2

Transmission/gear mechanism Type Gear ratio Oil volume, litres Oil type

Iskra AML7109 1.5

Kordel Genius 5.72.02.1 30.204 0.8 100 % synthetic API GL-5,SAE 75W-90

Technical data S210, S212, S214 T-code 841, 842, 843

Valid from serial number 6109948-

Model

SWE100

Date 2015-10-01

SWE120

Order number 7519083-040

SWE140

Wheels Drive wheel, mm Wheel pressure (kg/mm²) Axle pressure without load, kg Axle pressure at rated load, kg Tightening torque, wheel bolts, Nm Support arm wheels, mm Axle pressure without load, kg Axle pressure at rated load kg Castor wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg

0.2 350 350

235 1185 230 280

230 0.22 400 400 81±19 125 285 1445 85 250 290

0.24 450 450

285 1640 200 245

Hydraulic system Power, kW Duty factor, % Minimum brush length, mm Min. commutator thickness/diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, litres/minute Tank volume, litres Oil type Normal temperature < 0o C

2.2 S2, 60 min -

See section "21.4 Overflow pressure for mast".

4.5 ISO VG32 ISO 6743-4 category HM ISO VG27.5 ISO 6743-4 category HV

Fuses Drive motor circuit, A Pump motor circuit, A Control circuit, A

21 –

125 125 7.5

Technical data S210, S212, S214 Order number 7519083-040

Date 2015-10-01

Model

Valid from serial number 6109948-

SWE100

T-code 841, 842, 843

SWE120

SWE140

Battery compartment, Batteries Capacity, Ah Weight, kg min/max

150 189/280

225 189/280

189/280

Truck travel speeds Unloaded, km/h Unloaded, m/s With rated load, km/h With rated load, m/s

6.0 1.7 6.0 1.7

Lifting/lowering speed Lift without load, m/s Lift with rated load, m/s Lowering without load, m/s Lowering with rated load, m/s

0.28 0.14 0.38 0.38

0.28 0.12 0.38 0.38

0.25 0.11 0.38 0.37

8

8

8

1831 1888 1938 3300

1906 1956 4500

1901 1951 4755

650

715

715

Gradient capability With rated load, %

Dimensions Short Medium Long Lifting height

Weight Truck without battery, Medium

Technical data S212L, S214L, S220D T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

21.2 SWE120L, SWE140L, SWE200D Model

SWE120L

SWE140L

SWE200D

Truck traction Type Power, kW Duty cycle Weight, kg

Iskra AML7109 1.5 S2-60 min 10.5

Brakes Type Braking force, Nm Power, W Resistance, coil, Ω Nominal gap in actuated position, mm Minimum thickness of brake disc, mm Thickness of new brake disc, mm

Warner PK10 15 51/13 10.5-12.0

0.2-0.55 7.9 8.2

Transmission/gear mechanism Type Gear ratio Oil volume, litres Oil type

21 –

Kordel Genius 5.72.02.1 30.204 0.8 100 % synthetic API GL-5,SAE 75W-90

Technical data Order number 7519083-040

Date 2015-10-01

Model

Valid from serial number 6109948-

SWE120L

SWE140L

T-code 841, 842, 843

SWE200D

Wheels Drive wheel, mm Wheel pressure (kg/mm²) Axle pressure without load, kg Axle pressure at rated load, kg Tightening torque, wheel bolts, Nm Support arm wheels, mm Axle pressure without load, kg Axle pressure at rated load kg Castor wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg

0.24 450 450

265 1345 220 340

230 0.24 450 450 81±19 125 265 1525 85 220 360

0.27 570 570

215 1155 100 360

Hydraulic system Power, kW Duty factor, % Minimum brush length, mm Min. commutator thickness/diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, litres/minute Tank volume, litres Oil type Normal temperature < 0oC

2.2 S2, 60 min -

See section "21.4 Overflow pressure for mast".

4.5 ISO VG32 ISO 6743-4 category HM ISO VG27.5 ISO 6743-4 category HV

Fuses Drive motor circuit, A Pump motor circuit, A Control circuit, A

125 125 7.5

Technical data S212L, S214L, S220D T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Model

SWE120L

SWE140L

Order number 7519083-040

SWE200D

Battery compartment, Batteries Capacity, Ah Weight, kg min/max

225 189/280

Truck travel speeds Unloaded, km/h Unloaded, m/s With rated load, km/h With rated load, m/s

6.0 1.7 6.0 1.7

Lifting/lowering speed Lift without load, m/s Lift with rated load, m/s Lowering without load, m/s Lowering with rated load, m/s

0.39

0.25 0.11 0.28 0.38

9

8

9

3300

1910 1960 3255

2100

715

715

665

0.12

0.12 0.39

Gradient capability With rated load, %

Dimensions Short Medium Long Lifting height

Weight Truck without battery, Medium

21 –

Technical data Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

21.3 SWE120S Model Truck traction Type Power, kW Duty cycle

Iskra AML7108 1.0 S2-60 min

Weight, kg

9

Brakes Type Braking force, Nm Power, W Resistance, coil, Ω Nominal gap in actuated position, mm Minimum thickness of brake disc, mm Thickness of new brake disc, mm

Warner PK10 15 51/13 10.5-12.0 0.2-0.55

7.9 8.2

Transmission/gear mechanism Type Gear ratio Oil volume, litres Oil type

Kordel Genius 5.72.02.1 30.204 0.8 100 % synthetic API GL-5,SAE 75W-90

T-code 841, 842, 843

Technical data S212S T-code 841, 842, 843

Valid from serial number 6109948-

Model

Date 2015-10-01

Order number 7519083-040

SWE120S

Wheels Drive wheel, mm Wheel pressure (kg/mm²) Axle pressure without load, kg Axle pressure at rated load, kg Tightening torque, wheel bolts, Nm Support arm wheels, mm Axle pressure without load, kg Axle pressure at rated load kg Castor wheel, mm Axle pressure without load, kg Axle pressure at rated load, kg

230 0.32 675 635 81±19 100 340 1580 -

Hydraulic system Power, kW Duty factor, % Minimum brush length, mm Min. commutator thickness/diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, litres/minute Tank volume, litres Oil type Normal temperature < 0oC

2.2 S2, 60 min -

See section "21.4 Overflow pressure for mast".

4.5 ISO VG32 ISO 6743-4 category HM ISO VG27.5 ISO 6743-4 category HV

Fuses Drive motor circuit, A Pump motor circuit, A Control circuit, A

21 –

125 125 7.5

Technical data Order number 7519083-040

Date 2015-10-01

Model

Valid from serial number 6109948-

SWE120S

Battery compartment, Batteries Capacity, Ah Weight, kg

225 214

Truck travel speeds Unloaded, km/h Unloaded, m/s With rated load, km/h With rated load, m/s

6.0 1.7 6.0 1.7

Lifting/lowering speed Lift without load, m/s Lift with rated load, m/s Lowering without load, m/s Lowering with rated load, m/s

0.21 0.11 0.24 0.33

Gradient capability With rated load, %

8

Dimensions Short Medium Long Lifting height

1946 1996 4755

Weight Truck without battery, Medium

795

T-code 841, 842, 843

Technical data Overflow pressure for mast T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

21.4 Overflow pressure for mast Mast (rated load)

Pressure at rated load (on main lift for HiLomast)

Pump flow at rated load (from graph for hydraulic unit)

Recommended overflow pressure

Simplex (1000kg)

140 bar

7.1

165 bar

Simplex (1200kg)

165 bar

6.5

190 bar

Tele (1000kg)

145 bar

7.0

170 bar

Tele (1200kg)

170 bar

6.4

195 bar

Tele ClearView (1000kg)

150 bar

6.8

175 bar

Tele ClearView (1200kg)

175 bar

6.3

200 bar

Tele ClearView (1400kg)

200 bar

5.9

225 bar

Duplex HiLo (1200kg)

150 bar

6.8

170 bar

Duplex HiLo (1400kg)

170 bar

6.4

190 bar

Triplex HiLo (1200kg)

185 bar

6.2

210 bar

Triplex HiLo (1400kg)

210 bar

5.8

235 bar

21 –

General tightening torques General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

22 – General tightening torques 22.1 General Millimetre threads M3 to M24. The following applies in the case of good conditions, e.g. steel against steel.

Note: Experience has shown that if the torque wrench is adjusted to the values for untreated screws, the correct torque value for galvanised screws will also be obtained. Do not tighten more than the values indicated in the tables, otherwise the bolts can be destroyed.

22.2 Galvanised, non-oiled screws Tightening torque (Nm) Strength class: M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24

8.8

10.9

12.9

1.1 2.8 5.5 9.5 23 45 78 123 189 370 638

1.6 3.8 7.7 13 32 62 109 174 266 519 898

2.0 4.7 9.3 16 38 76 130 208 320 623 1075

22.3 Untreated, oiled bolts Tightening torque (Nm) Strength class: M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24

8.8

10.9

12.9

1.2 2.9 5.7 9.8 24 47 81 128 197 385 665

1.7 4.0 8.1 14 33 65 114 181 277 541 935

2.1 4.9 9.7 17 40 79 136 217 333 649 1120

General tightening torques Untreated, oiled bolts T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

22 –

Order number 7519083-040

Tools MQS contacts Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

23 – Tools 23.1 MQS contacts

Tools

Number

Use

257841

MQS Basic toolbox.

The box contains: 1 set pliers with tools 25 x splice 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.

Tools MQS contacts T-code 841, 842, 843

Tools

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

Number

Use

257842

MQS refill box.

Use to refill the “MQS 257843 Complete toolbox”.

The refill box contains: 200 x sleeves 0.2-0.5 mm2 200 x sleeves SWS 0.2-0.5 mm2 400 x sleeves SWS 0.5-0.75 mm2 100 x sleeves S"Clean body" 0.5-0.75 mm2 200 x pins SWS 0.2-0.5 mm2 400 x pins SWS 0.5-0.75 mm2 1200 x seals 200x blind plugs

257843

MQS Complete toolbox.

Contains 4 pliers with tools: 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.

23 –

Tools AMP connectors Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

23.2 AMP connectors PT = Power Timer (4.8. 5.8. 6.3 mm) JPT = Junior Power Timer (2.8 mm) MPT = Micro Power Timer (1.5 mm)

Figure

2

1

Number

Use

151080 (PT)

Removal tool for pins/ sleeves

213296 (JPT)

Removal tool for pins/ sleeves

213298 (MPT)

Removal tool for pins/ sleeves

1=163787 (JPT) 2=163788 (JPT)

Crimping tool (sleeves only)

1=213336 (MPT) 2=213337 (MPT)

1=213336 (JPT) 2=213549 (JPT)

2

1

Crimping tool for fitting pins, For 0.5–2.5 mm2

Tools Molex connectors T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

23.2.1 AMP connectors, Multilock series 040

Figure

Number

Use

213130

Pin removal tool

213129

Crimping tool for pins

23.3 Molex connectors 16 9 8 1 Figure

23 –

Number

Use

156937

Crimping tool for pins

156936

Crimping tool for fitting sleeves/pins

Tools Grease guns Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

23.4 Grease guns Figure

Number

Use

24981

A tool with a pointed nozzle used to apply grease. Length 170 mm.

755132

Single-hand grease gun with straight discharge pipe and nozzle.

755142

Two-handed grease gun with angled discharge pipe and nozzle.

755152

Two-handed grease gun with hose and nozzle.

755145 755146 755147

Lubricating hose 450 mm Lubricating hose 750 mm Lubricating hose 1500 mm

202154PM

Pointed nozzle for grease guns used to apply grease in recessed nipples.

Fits grease guns with hose and discharge pipe. Length 125 mm.

755140

Nozzle for necked nipples. Fits grease guns with hose and discharge pipe.

Tools Other tools T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

23.5 Other tools Figure

1

Number

Use

7513225

Service key (CAN)

1=7521083 2=163793

Service instrument (CASTOR USB) for programming

08-13022

Drive gear puller

2

Threaded bar M16x500mm 3x M16 nuts and one washer V11-1666

23 –

Lifting equipment Mast

Oil and grease specification Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

24 – Oil and grease specification Table 1: Oil and grease specification Lubricant type

Specification

Usage

Grease

S213366 Q8 Rubens WB

Bearings and bushings

Hydraulic oil

See table below.

Hydraulic system

Transmission oil

Synthetic API GL-5 SAE 75W-90

Gearbox

Grease

See table below.

Chains

Grease

Grafloscon A-G1 (Klüber)

Gear ring

Grease

755701-040

Castor wheel

Grease

S213366 Q8 Rubens WB

Mast

Hydraulic oil Ambient temperature

Viscosity class

Specification

< 0°C

VG 27.5

ISO 6743-4 category HV DIN 51524 part 3 = HVLP

> 0°C

VG 32

ISO 6743-4 category HM DIN 51524 part 2 = HLP

Ambient temperature

Viscosity class

Recommended products*

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

> - 30°C < + 5°C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

> + 5°C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

Chain grease

* Similar products from other manufacturers may be used.

Oil and grease specification T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

24 –

Order number 7519083-040

Electrical components and wiring diagram Electric components Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

25 – Electrical components and wiring diagram 25.1 Electric components The table below shows a summary of the major electric components of this truck.

Symbol

Description

Function

A5

Logic card

Tiller arm logic card

A5:S1-18

Hall sensor

Speed control forward/backward

A5:S17

Hall sensor

Safety reversing

A5:S19

Hall sensor

Fork lift control

A5:S20

Hall sensor

Fork lowering control

A5:S21

Hall sensor

Support arm lifting control

A5:S22

Hall sensor

Support arm lowering control

A30

Battery charger

On-board battery charger

B1

Temperature sensor

Drive motor temperature sensor

B11

Pulse transformer

Speed sensor

B60

Inductive switch

Mechanical activation of the brake

B62

Inductive switch

Support arms, lowered position.

B63

Inductive switch

Mast switch 1

B64

Inductive switch

Mast switch 2

B90

Collision sensor

F1

Fuse

Main fuse

150 A

F50

Fuse

Operating circuit A5

7.5 A

F51

Fuse

Operating circuit T1

7.5 A

F52

Fuse

Optional equipment

Option

G1

Battery

K110

Data Handling Unit (DHU)

Remarks

Option

Option

24 V Data handling unit

Option

Electrical components and wiring diagram Electric components T-code 841, 842, 843

Valid from serial number 6109948-

Order number 7519083-040

M1

Motor

Truck traction

M3

Motor

Pump motor

Symbol

Description

Function

P4

Horn

P5

Warning lamp

P6

Display

Truck function display

Q1

Electromechanical brake

Mechanical brake

Q4

Proportional valve

Lowering

Q10

Contactor

Main contactor

Q22a

Solenoid valve

Fork selector

Q23a

Solenoid valve

Support arm selector

Q25b

Contactor

Contactor, pump motor

S18

Switch

Horn button

S21

Switch

Emergency switch off

S97

Switch

Warning lamp P5

Option

S206

Switch

Turtle function

Option

S111

Switch

Option button

Option

S113

Switch

Option button

Option

S114

Switch

Option button

Option

S115

Switch

Option button

Option

S116

Switch

Option button

Option

S223

Keypad/Smart card

Login with PIN code

S224

Controls

Sensilift

Option

T1

Transistor regulator

T7/T8

DC/DC converter

T7=24V/12V T8=24V/24V

Option

X1

Connection

Battery

X21

Connection point

DC/DC converter

X40

Connection point

CAN communication (Extra I/O)

X41

Connection point

CAN communication (External)

Remarks Option

a.Applies only to S212L, 214L and 220D. b.Only applies to S210.

25 –

Date 2015-10-01

Option

Electrical components and wiring diagram Electric components Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

A5:S22 A5:S21 A5:S1-9

A5:S10-18

T-code 841, 842, 843

A5

9

1 10

18

A5:S17 A5:S20 A5:S19 P6

S113 S206 S111

S116 S115 S114

S18:1

S18:2

A5:S20 A5:S22 A5:S19

A5:S21 A5:S17

S223

X41

Electrical components and wiring diagram Electric components T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

S21 X1 G1

T7/T8

F50, F51, F52 F1

Q25

Q10

X21 X40

B90

T1 A30

25 –

Electrical components and wiring diagram Wiring diagram Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

25.2 Wiring diagram 25.2.1 List of symbols Table 2: List of symbols Symbol

Description

Symbol

Description

Truck battery

Emergency switch off NC

Fuse

Switch, pressure (weight) operated

Horn

Sensor, inductive NO

Motor, ACa

Sensor, inductive NC

Contactor

Variable resistance (potentiometer)

Brake coil (normally applied)

Push switch NO

Coil for hydraulic solenoid valve

Multi-pin connect

Pressure sensor, analogue P

a.AC = Alternating Current

NO = Normally open NC = Normally closed

Electrical components and wiring diagram Wiring diagram T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

25.2.2 General wiring diagram F51

B60

S21

F1

6 (+) B+ 24 (83) +24V 40 (-) B-

DRIVE MOTOR

U V W

M1 Q10

-

MAIN CONTACTOR (106) 31

+

T1

72 (95) TILLER ARM IN DRIVE POS.

BRAKE RELEASE (90) 32

B62

74 (94) SUPPORT ARM IN LOW POS

G1

Q1 40

Q4

1

PROP. LOWER VALVE (108) 33 +24V (82) 30

B63

70 (86) MAST SWITCH 1

71 (101) MAST SWITCH 2

PUMP MOTOR 5

EXT. EQUIP.

Q25

OUT PUMP CONTACTOR (107) 34

B64

F

M3

SWE100

M3 Q22

B65

FORK VALVE (98) 80

74 (87) INP. SUPPORT ARM, AT TOP POS.

Q23 SUPPORT ARM VALVE (110)

OPTION 20 B11

81

(84) ENABLE/PRE-CHARGE

P4 1

61 (104) CH A, SPEED SENSOR 62 (103) CH B, SPEED SENSOR

2

SIGNAL HORN (112) 50

B1 63 (92) THERMAL SENSOR (DRIVE MOTOR)

F52

+5V SPEED SENSOR (85) 60 NEGATIVE SPEED/ (105) THERMAL SENSOR

CAN HIGH/LOW (99/100) 119/120

25 +24VDC 40 0VDC T7/T8 X23 12VDC/24VDC 26 0VDC 41

64

OPTION 20 F50 1

20

1

24

24 119/120 (3/4) CAN HIGH/LOW

119/120 (X3/X3) A2:S17 CAN HIGH/LOW Hall SAFETY REVERSE

B90

20 (1) +24V DC 40 (2) 0V DC OPTION

20 (X3) +24V DC 40 (X3) 0V DC

119/120 (3/4) CAN HIGH/LOW

P5 20

RED (+) POS. VOLT. BLACK (-) NEG. VOLT.

40

A2:S21

Hall SUPPORT ARM

LIFT

S97

A30

OPTION

MAINS, VAC MAINS, VAC MAINS, EARTH OPTION

A2:S22

(X1 1) HORN 2 (X4 1) HORN 1

Hall SUPPORT ARM

LOWER

A2:S1-S9 A2:S10-S18

S18:2

Hall

S18:1

(X4 2) (X1 2)

Hall

A5

(X11)

(X2:1/2) TURTLE S206

S224 A

+ -

25 –

(X2:1/3) TURTLE

SPEED REF. VALUE

+24V DC (X3) 20 0V DC (X3) 40 CAN HIGH (X3) 119 CAN LOW (X3) 120

(X8:1) +5V DC (X8:2) FORK LIFT/LOWER (X8:3) OUT 0V DC

(X12)

KEYBOARD / SMART CARD S223

119/120 (2/3) CAN HIGH/LOW 20 (1) +24V DC 40 (8) 0V DC

X41 T20

K110

ANTENNA

OPTION

DISPLAY P6 Based on 236986 rev. F

Sh. 3

Sh. 3

40

1

24

MOTOR CONTROLLER T1 X21

24/BN

S21 1

2

21/WH

X21

21

7,5A F51

6

150A F1

G1 1

1

2

+

-

7,5A F50

Sh. 4

40

20

INP. B-

84

INP. ENABLE / PRE-CHARGE

20

INP. B+

2D2

M3

1D1

5

OUT. P-

1

31

2

106

2

OUT. MAIN CONTACTOR

OUT. U

DRIVE MOTOR

OUT. V

4

B11 1

60 B11

RD

BU

B11 2

61

BK

WH

B11 3

62

TEMP. DRIVE MOTOR B11 4

B1 1

GN RD

63

85

OUT. +5V SPEED SENSOR

104

INP. CH A, SPEED SENSOR

103

INP. CH B, SPEED SENSOR

92

INP. THERMAL SENSOR

105

OUT. NEGATIVE SPEED / THERMAL SENSOR

2

B1

OUT. W

Valid from serial number 6109948-

3

M1

B1

64

Wiring diagram

T-code 841, 842, 843

1/11 PROD F 236986

Electrical components and wiring diagram

Q10 30

25.2.3 Wiring diagram

PUMP MOTOR

Date 2015-10-01

6

Sh. 2

Order number 7519083-040

Sh. 2

7

24

MOTOR CONTROLLER T1 X21

24/BN

S21 1

21/WH

2

X21

7,5A F51

21

G1 1

2

1

+

-

7,5A F50 F1 150A

40

20

INP. B-

84

INP. ENABLE / PRE-CHARGE

PUMP MOTOR A1/1D1

Sh. 4

M3

10

A2/2D2

1

2

6

6

INP. B+

20

30

1

31

2

106

OUT. MAIN CONTACTOR

107

OUT. PUMP CONTACTOR

Q25 1

34

2

2

OUT. U

DRIVE MOTOR 3

M1

OUT. V

4

B11 1

60 B11

BU

B11 2

61

BK

WH

B11 3

62 B1

TEMP. DRIVE MOTOR B11 4

GN RD

B1 1

63

64

85

OUT. +5V SPEED SENSOR

104

INP. CH A, SPEED SENSOR

103

INP. CH B, SPEED SENSOR

92

INP. THERMAL SENSOR

105

OUT. NEGATIVE SPEED / THERMAL SENSOR

Order number 7519083-040

1/12 PROD F 243986 (SWE100)

Date 2015-10-01

RD

OUT. W

Valid from serial number 6109948-

Q10 Sh. 2

Electrical components and wiring diagram

Sh. 2

1

Wiring diagram

Sh. 3

40

T-code 841, 842, 843

Sh. 3

Order number 7519083-040

MOTOR CONTROLLER T1 24

24 Q22

X20

1

X20

Q23

X20

2

80

81

INP. +24V, "HIGH SIDE DRIVER"

98

OUT. FORK VALVE

110

OUT. SUPPORT ARM VALVE

112

OUT. SIGNAL HORN

82

OUT. +24V, "HIGH SIDE DRIVER"

90

OUT. BRAKE RELEASE

108

OUT. PROP. VALVE

99

INP. CAN HIGH

100

INP. CAN LOW

P4 IN 2

Sh. 1

50

1

30

30 Q1 1

2

32

Valid from serial number 6109948-

1

X20

2

83

Q4 1

Sh. 4

33

119/RD

120/WH

120/WH

2/11 PROD F 236986

Wiring diagram

119/RD

T-code 841, 842, 843

Sh. 4

2

Electrical components and wiring diagram

Sh. 1 3

Date 2015-10-01

ONLY STACKER WITH "SUPPORT ARM LIFT"

9

40

X63

X20

X63

X20

X63

X20

X63

X63

X20

X63

70

X20

71

INP. MAST SWITCH, 1

101

INP. MAST SWITCH, 2

95

INP. TILLER ARM IN DRIVE POS.

94

INP. SUPPORT ARM, IN LOWEST POS.

87

INP. SUPPORT ARM, AT TOP POS.

EXTERNAL EQUIPMENT

IF B64 NOT FITTED X65

B60 YE 1

2

GN

X65

72

3

NOTE! EXTERNAL EQUIPMENT SHALL NOT BE ELECTRICAL CONNECTED TO THE TRUCK FRAME.

X65

IF B62 NOT FITTED

B62

X20 1

X20 2

74

X20

B65

X20 1

X20 2

73

Date 2015-10-01

86

Valid from serial number 6109948-

X20

3

Sh. 1 4

24

3

Sh. 2

X20

Order number 7519083-040

3/11 PROD F 236986

Electrical components and wiring diagram

MOTRO CONTROLLER T1

Wiring diagram

T-code 841, 842, 843

IF B63 NOT FITTED

Sh. 2 7

Sh. 3 7

40

20

X5

X5

X5

OG

A5 3

120

RD

A5 7

119

BN

A5 2

40

BK

A5 6

20

A5 5

20

X41 20

VT

2

40

GY

A5 1

40

3

119

WH

A5 8

119

4

120

PK

A5 4

120

CAN, SERVICE CONNECTOR

CAN LOW

X3

CAN HIGH

X3

INP. 0V DC

X3

INP. +24V DC

X3

OUT.+24V DC

X3

OUT. 0V DC

X3

CAN HIGH

X3

CAN LOW

X8:1

OUT. +5V DC

X8:2

INP. A_IN

X8:4

OUT. 0V DC

Valid from serial number 6109948-

1

X3

FORK LIFT/LOWER

11

Wiring diagram

T-code 841, 842, 843

4/11 PROD F 236986

Electrical components and wiring diagram

Sh. 1 9

119/RD

X5

Date 2015-10-01

Sh. 2 7

120/WH

Order number 7519083-040

ELECTRONIC CARD TILLER ARM A5

X12 1

+5V DC

X1 2

X12 2

SI

X1 3

X12 3

SCK

X1 4

X12 4

ENABLE

X1 5

X12 5

LCLK

X1 6

X12 6

0V DC

X4 1

INP. HORN 1

X4 2

OUT. OV DC HORN 1

X1 1

INP. HORN 2

X1 2

OUT. 0V DC HORN 2

DISPLAY P6

8 8 8 8

2

Valid from serial number 6109948-

S18:1 1

S18:2 1

S113

2

X2:1/2 TURTLE

OPTION

Date 2015-10-01

1

2

X2:1/3 TURTLE

Order number 7519083-040

5/11 PROD F 236986

Electrical components and wiring diagram

X1 1

Wiring diagram

ELECTRONIC CARD TILLER ARM A5

T-code 841, 842, 843

DISPLAY P6

Order number 7519083-040

KEY BOARD / SMART CARD S223

3

5

6

8

9

0

I

7

X11 2

2580

X11 3

369#

X11 4

123

X11 5

456

X11 6

789

X11 7

-0#

X11 8

LED_GREEN

X11 9

LED_RED

Valid from serial number 6109948-

147-

SMART CARD

X11 10 0V DC

6/11 PROD F 236986

Wiring diagram

T-code 841, 842, 843

13

Electrical components and wiring diagram

2

4

X11 1

Date 2015-10-01

1

ELECTRONIC CARD TILLER ARM A5

Sh. 3 8

Sh. 4 9

Sh. 4 9

(RED)

RED

40 (BLACK)

BLACK

120/WH

119/RD

X40

X40

120/WH

119/RD

+

OUT. POSITIVE CHARGER VOLTAGE

-

OUT. NEGATIVE CHARGER VOLTAGE

4

INP. CAN LOW

3

INP. CAN HIGH

Valid from serial number 6109948-

Sh. 4 8

1

MAINS CONNECTOR

MAINS, VAC

MAINS, EARTH

Order number 7519083-040

7/11 PROD F 236986

Date 2015-10-01

MAINS, VAC

Electrical components and wiring diagram

BCU A30

Wiring diagram

T-code 841, 842, 843

OPTION ONBOARD CHARGER

X21

X23

26

41

26

41

40

25

OUT. 0VDC

8/11 PROD F 236986

OUT. 12VDC / 24VDC

INP. 0VDC

INP. +24VDC

DC/DC CONVERTER T7 / T8

Date 2015-10-01

X21

OPTION

Order number 7519083-040

DC/DC CONVERTER (T7=24V/12V, T8=24V/24V)

Electrical components and wiring diagram Valid from serial number 6109948-

Wiring diagram T-code 841, 842, 843

Electrical components and wiring diagram Wiring diagram Date 2015-10-01

CAN LOW 4

120/WH

3

119/RD

40

2

CAN HIGH

INP. 0V DC

INP. +24V DC 1

20

X40

X40

X40

X40

SHOCK SENSOR

OPTION 25 –

Order number 7519083-040

9/11 PROD F 236986

Valid from serial number 6109948-

SHOCK SENSOR B90

T-code 841, 842, 843

Electrical components and wiring diagram Wiring diagram

INP. 0V DC 8

40

3

CAN LOW

CAN HIGH 2

119/RD

20

1

DHU K110

X40

X40

X40

X40

T20

DATA HANDLING UNIT (DHU)

OPTION

10/11 PROD F 236986

T-code 841, 842, 843

INP. ANTENNA

Valid from serial number 6109948-

120/WH

Date 2015-10-01

INP. +24V DC

Order number 7519083-040

Electrical components and wiring diagram Wiring diagram Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

220 2 S97

— End of section —

25 –

X40

X40

1

WARNING LIGHT

OPTION

3

P5

1

11/11 PROD F 236986

T-code 841, 842, 843

Hydraulics chart Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

26 – Hydraulics chart Simplex/ Duplex tele

Duplex tele panoramic

Duplex Hilo

Triplex Hilo

Support arms

1

14

2

SA

F

3

13 Q23

Q22

Q4

12

4 Max 230 Bar

5

6

7

11

8

10

9

Pos.

Description

Pos. Description

1

Lift cylinder, support arm1

8

Tank

2

Solenoid valve, fork selection [Q22]1 Solenoid valve, support arm selection [Q23]1 Proportional valve, lowering [Q4] Non-return valve Pressure limiting valve, max. 230 Bar Pump

9

Filter

10

Filter

11 12 13 14

Air filter Flow regulator valve Lift cylinder, mast Hose rupture valve

3 4 5 6 7

1.Only applies to S212L, S214L and S220D

Hydraulics chart T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

26 –

Order number 7519083-040

Instructions for disposal General Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

27 – Instructions for disposal 27.1 General The disposal instructions were developed to support our company's objective of protecting the environment. By recycling materials, resources can be utilised more efficiently, while reducing emissions.

The following instructions specify the sorting category of the materials used in the various truck components. To achieve optimum sorting, all components should be disassembled to a level corresponding to the sorting categories.

27.2 Marking of plastics 27.2.1 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. The picture 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 (see picture) • 06: PS – Polystyrene • 07: O – Other

Instructions for disposal Marking of plastics T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

27.2.2 Marking according to standard Standards: 58-02-001, 58-02-003 and 58-02-004.

A few examples of markings are presented below. For more information please refer to the standards above.

The product material and trade name of each item are indicated between arrows, e.g. >PP<.

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

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<

27 –

Instructions for disposal Pressure vessels Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

T-code 841, 842, 843

27.3 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.

27.3.1 Gas struts WARNING! Gas dampers have extremely high internal pressure. To prevent injury, always follow the instructions of the manufacturer.

Wear safety goggles when disassembling 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

ca 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.

Instructions for disposal Sorting categories T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

Order number 7519083-040

27.4 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 noncombustible and not hazardous • Combustible material (including small plastic and rubber parts) • Please return batteries to the manufacturer.

Component

Category

Chassis

• Iron/steel

Inspection covers, sheet metal

• Iron/steel

Inspection covers, plastic

• Plastic

Forks and frames

• Iron/steel

Operator's platforms

• Iron/steel, including any gas dampers

Comments

• Handle: >ABS< Sort according to the material marking Be sure to depressurise dampers

• Mats, cushions: combustible Roofs and overhead guards

• Iron/steel

Gates and operator protective devices

• Iron/steel • Plastic handles: >PA< • Crush protectors: >PMMA<

Hydraulic unit

• Oil • Hydraulic hoses: Oil-polluted material • Oil tank: >PP< • Motor, valves: Electronic components • Pump: Iron/steel • Accumulator: Iron/steel

27 –

Ensure that the system has been depressurised.

Carefully drain all oil.

Any accumulators should be emptied of gas and if possible opened.

Instructions for disposal Sorting categories Order number 7519083-040

Date 2015-10-01

Valid from serial number 6109948-

Component

Category

Travel motors

• Motor: Electronic components

T-code 841, 842, 843

Comments

• Wires • Parking brake: Hazardous waste Drive gears Wheels

• Iron/steel

Carefully drain all oil

• Oil

Hazardous waste

• Tread: Plastic according to marking

If the tread and hub cannot be separated, then sort the wheel as complex material

• Hub: Iron/steel Tiller arms

• Electronic components • Wires

Be sure to depressurise dampers

• Iron/steel, also gas dampers Electrical system

• Logic cards, transistor regulators, Expansion unit SEU, contactors: Electronic components

Hazardous waste

• Wires

Mast

• 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 beams, rollers, cylinders, hydraulic pipes: Iron/steel

Oil-polluted components should be handled as hazardous waste

• Hydraulic hoses: Oil-polluted () • Wires • Sensors/switches: Electronic components • Plastic components: According to marking or as combustible waste Chargers and connectors

• Electronic components • Wires

Instructions for disposal Sorting categories T-code 841, 842, 843

Valid from serial number 6109948-

Date 2015-10-01

This page is intentionally left blank

27 –

Order number 7519083-040