Escolar Documentos
Profissional Documentos
Cultura Documentos
1. Table of content
2. General introduction...................................................................................... 21
2.1 How to use this manual ............................................................................... 21
2.2 Abbreviations ............................................................................................... 22
2.3 Warning symbols ......................................................................................... 23
2.4 Pictograms................................................................................................... 24
2.4.1 Screws/Nuts ................................................................................... 24
2.4.2 Repairable ...................................................................................... 25
2.4.3 Other pictograms ............................................................................ 26
3. General safety rules....................................................................................... 31
3.1 Work safety.................................................................................................. 31
3.2 Electrical system.......................................................................................... 33
3.3 Safe lifting.................................................................................................... 34
3.4 Truck modifications...................................................................................... 35
4. Operation and connection sequences ......................................................... 41
4.1 Description................................................................................................... 41
5. Parameters...................................................................................................... 51
5.1 General........................................................................................................ 51
5.2 Parameter settings ...................................................................................... 52
5.3 Operator parameters ................................................................................... 54
5.3.1 Overview ........................................................................................ 55
5.3.2 Description ..................................................................................... 58
5.4 Service parameters ..................................................................................... 59
5.4.1 Overview ........................................................................................ 59
5.4.2 Description ..................................................................................... 59
5.4.3 Description ................................................................................... 521
5.5 Factory parameters ................................................................................... 531
5.5.1 General factory parameters.......................................................... 531
5.5.2 Factory parameters, activation of options .................................... 534
5.5.3 Factory parameters, calibration.................................................... 536
6. Installation ...................................................................................................... 61
6.1 Transporting the truck.................................................................................. 61
6.2 Transporting the mast.................................................................................. 61
6.3 Transporting the truck.................................................................................. 61
6.4 Taking into operation ................................................................................... 62
6.4.1 Battery ............................................................................................ 62
6.5 Dismantling the mast ................................................................................... 64
6.5.1 Dismantling the working light.......................................................... 68
6.6 Putting into operation................................................................................... 69
6.6.1 Installing the mast in the truck........................................................ 69
6.6.2 Fitting the working light................................................................. 615
7. Maintenance ................................................................................................... 71
7.1 Introduction.................................................................................................. 71
7.2 Safety precautions for maintenance work ................................................... 72
7.3 Maintenance instructions............................................................................. 73
7.3.1 Cleaning and washing .................................................................... 73
7.3.2 High-pressure washers .................................................................. 73
7.3.3 Degreasing agents ......................................................................... 73
7.3.4 Cleaning the exterior ...................................................................... 74
7.3.5 Cleaning the chain.......................................................................... 74
7.3.6 Cleaning the motor compartment ................................................... 74
7.3.7 Electric components ....................................................................... 74
7.4 Symbols....................................................................................................... 75
7.5 CCrack detection ......................................................................................... 76
7.5.1 Visual inspection ............................................................................ 76
7.5.2 Crack detection .............................................................................. 77
7.6 Safety checks .............................................................................................. 78
7.7 Periodic maintenance .................................................................................. 79
7.7.1 Every 500 operating hours/180 days.............................................. 79
7.7.2 Every 1000 operating hours/360 days.......................................... 711
7.7.3 Every 2000 operating hours/720 days.......................................... 717
7.7.4 Every 3000 operating hours/1080 days........................................ 719
7.7.5 Every 4000 operating hours/1440 days........................................ 721
7.7.6 ..................................................................................................... 721
7.7.7 Every 5000 operating hours/1800 days........................................ 721
7.7.8 Annual status inspection .............................................................. 721
8. Troubleshooting............................................................................................. 81
8.1 Auxiliary functions........................................................................................ 81
8.1.1 Error log menu................................................................................ 81
8.1.2 Error information menu................................................................... 82
8.1.3 Diagnostic screens ......................................................................... 82
8.2 Initial troubleshooting................................................................................. 815
8.3 Troubleshooting using blocking symbol..................................................... 816
8.4 Troubleshooting using error codes ............................................................ 820
8.4.2 MCU and other warnings and errors ............................................ 825
8.5 Troubleshooting without indications .......................................................... 862
8.5.1 Mechanical brake (3000).............................................................. 862
8.5.2 Steering (4000)............................................................................. 863
9. Chassis C0000................................................................................................ 91
9.1 Overview...................................................................................................... 91
9.2 Description................................................................................................... 92
9.3 Floor C0330................................................................................................. 92
9.3.1 Overview ........................................................................................ 92
9.3.2 Description ..................................................................................... 93
9.3.3 Replacing the floor ......................................................................... 93
9.3.4 Protective covers ............................................................................ 96
9.4 Support arm C0350 ................................................................................... 916
9.5 Battery compartment parts C0390............................................................. 916
9.5.1 Overview, battery support ............................................................ 916
2. General introduction
2.1 How to use this manual
The repair manual is divided into chapters containing the following
information:
General safety rules
Operation and connection sequences This chapter provides a basic
description of the main functions of the truck and their interdependencies.
Parameters This chapter provides a basic description of the truck
parameters.
Installation This chapter describes the preparatory work that is to be
done before the truck is used for the first time.
Maintenance This chapter provides an overview of periodic
maintenance.
Troubleshooting This chapter describes the action you should take when
the truck is completely or partially malfunctioning. It also describes the
cause of the problem together with suggested remedies.
C Codes This chapter describes the various truck systems, e.g. the
hydraulic system and includes descriptions of system parts and the
necessary service procedures. These descriptions are divided according
to Cesab's C code system.
Instructions for disposal instructions This chapter specifies the proper
sorting category for the materials used in the various truck components.
Wiring diagram This chapter provides information on electrical
components and wiring diagrams.
Hydraulic diagram This chapter provides information on electrical
components and hydraulic diagrams.
Tools This chapter provides a list of the special tools required.
Service data and grease specifications This chapter contains
information on general tightening torques and an oil and grease
specification.
Technical data
2.2 Abbreviations
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.
2.4 Pictograms
2.4.1 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.
Slotted screw
Phillips PH
Pozidrive PZ
Torx
Allen key
Hexagonal head
Hexagonal nut
2.4.2 Repairable
The unit's ability to be repaired is stated with the pictogram below in the
margin for each unit's service actions chapter.
Symbol Meaning
Visual inspection of
condition, wear and loose Component replacement.
connections.
Cleaning Measurement
Adjustment Welding
Disassembly/removal Assembly/installation
Additional information under the pictogram can, for example, indicate the
number of cable ties to be cut.
Slut p avsnittet
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.
Slut p avsnittet
Parameter 503 = 5 or 6
CID displays:
Influencing elements
Resulting conditions CID shows a status image for approx. 2 seconds:
5. Parameters
5.1 General
The truck's control system can store a number of different parameters. These
are used to configure the truck according to the task to be performed. The
parameters are divided into groups:
Operator parameters The driver parameters (1-100) are used to
adapt the trucks characteristics to a specific driver or task. Up to 10
operator parameter profiles can be stored.
Service parameters The service parameters (101999) are used to
adapt the truck's performance/actions.
Factory parameters (1001-1250). Truck-specific parameters.
Calibration parameters (12511500) save the value that is created
when calibrating. These must not be changed manually.
Operator parameters are displayed and changed only for a selected operator,
but if a CAN service key is connected, the parameters for all operators can
be displayed and changed. Operator parameters can be changed by the
operator if the truck's program is set up for this.
The service parameters can be changed once a suitable CAN service key or
PDA/PC has been connected to the truck.
Factory parameters can ONLY be changed after a specially configured PDA/
PC has been connected to the truck.
Access
To be able to change the parameters, a service key must be connected. If the
key is not connected, the parameters can only be read. It is not possible to
change the factory parameters without TruckCom.
Parameter screens
Each parameter can be reached by entering the parameter number in the box
marked "Par". The parameter value can be entered using the numerical
keypad, or the plus/minus buttons.
The plus button increases the number by one step and the minus button
reduces it by one step.
The value of the parameter is displayed in the box under "Par". The value is
changed by using the arrow key to select this box and then entering the value
with the keypad or the plus/minus buttons. The value is saved by pressing the
green button (I).
The parameter's factory setting (default value) can be selected by selecting
the factory icon and pressing the green button (I).
d
a Operator icon and number of the logged-in operator profile.
b Icons for selected parameter and number of the parameter.
c Icon for resetting to default value.
d Parameter value.
The arrow keys are used for moving between:
Parameters, where the +/- keys are used to select a parameter
Reset icon, where the parameter value is reset to the default value when
the green button is pressed
The parameter values
The screen changes appearance depending on which driver parameter has
been chosen.
For parameter 1, the steering progressiveness, a screen is shown with two
adjustable fields representing high speed Hare and low speed Snail.
5.3.1 Overview
Par. Description
1 The steering's progressivity
2 Maximum speed, drive wheel direction
3 Maximum speed, fork direction
4 Acceleration
5 Automatic braking when speed is reducing
s
10
9
8
7
6
5
4
3
2
1
v
1 2 3 4 5 6 7 8 9 10
1 257 513 769 1025 1281 1537 1793 2049 2305 2561
2 258 514 770 1026 1282 1538 1794 2050 2306 2562
3 259 515 771 1027 1283 1539 1795 2051 2307 2563
4 260 516 772 1028 1284 1540 1796 2052 2308 2564
5 261 517 773 1029 1285 1541 1797 2053 2309 2565
6 262 518 774 1030 1286 1542 1798 2054 2310 2566
7 263 519 775 1031 1287 1543 1799 2055 2311 2567
8 264 520 776 1032 1288 1544 1800 2056 2312 2568
9 265 521 777 1033 1289 1545 1801 2057 2313 2569
10 266 522 778 1034 1290 1546 1802 2058 2314 2570
5.3.2 Description
Examples:
If operator profile 1 has parameter 2 set to 80 %, operator profile2 has their
corresponding parameter 12 set to 70 %, the maximum travel speed is
limited to:
8 km/h for operator profile '1'
7 km/h for operator profile '2'
Note:
The maximum travel speed can also be limited by the service parameters and
it is always the lowest speed for a parameter that is the limiting one.
5.4.1 Overview
Par. Description
101 Service intervals
104 Time to automatic log-out
105 Travel alarm
106 Warning lamp
107 Battery size
108 Battery limits
109 Resetting procedure for logged data
110 Collision sensor sensitivity in X-axis
111 Collision sensor sensitivity in Y-axis
112 Resetting procedure after collision
114 Travel alarm
115 Warning lamp
117 Collision sensor's alarm
5.4.2 Description
If the acid weight is less than 1.14 g/cm3, the parameter value must be
reduced. If the value is considerably higher than 1.14 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.
Parameter settings for valve-controlled batteries (VRLA).
Cesab recommends that when setting parameter 107 in a Reflex truck with
Hawker Evolution batteries, the recommended value for wet batteries should
be reduced by six (6) units.
DANGER!
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.
When checking the charging state on a discharged 48 V battery, its no-load
voltage should be measured after a rest period. The zero indication should
appear at an open circuit voltage that must not fall below 2.02 V/cell or 48.48
V.
See the instructions below.
Instructions for verifying the parameter setting
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator shows a
discharged battery (0 % on the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
hours.
Note:
Do not allow any charging or discharging during this time.
4. Measure the voltage on the battery at +20 C. 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, the operating time of the truck is reduced. If a
longer operating time is required, the parameter value can be slightly
increased.
5. Each change should be followed up by a new verification of the
parameter setting.
Parameter 108 is used to state the level of the battery's remaining capacity
according to the CID battery charge symbol when the acceleration and lift
speed are limited to 70% of their maximum.
A further, not parameter-controlled, limitation occurs when the CID battery
charge symbol shows 0 %. In this case, the following are limited:
Acceleration 50 % of maximum performance
Lift 30% of maximum performance
Parameter 105 states how travel alarm 1 (buzzer), output X131:23, will
sound when it is active:
Value Type
0 Continual
1 1 tone pulse/sec
2 2 tone pulses/sec
Parameter 106 states how travel alarm 2 (warning lamp), output X131:36,
will flash when it is active:
Value Type
0 Continual
1 1 flash/sec
2 2 flashes/sec
Parameter 114 states the activation pattern for travel alarm 1 X131:23
Parameter 115 states the activation pattern for travel alarm 2 X131:36
The function that activates travel alarms 1
Value
or 2
Driving in the drive wheel direction 1
Driving in fork direction 2
Fork lifting 4
Fork lowering 8
Reach carriage in motion 32
Option in motion 64
Truck started up 128
Examples:
If you want travel alarm 1 to be active when driving in the drive wheel direction
and in the fork direction and travel alarm 2 active when you lift and lower the
forks.
Parameter 114 is then set to 1 + 2 = 3 and parameter 115 is set to 4 + 8 = 12.
Travel
Parameter
alarm
105 106 114 115 1104 1102
1 0/1/2 1-255 0/1
2 0/1/2 1-255 0/1
Parameter 109 indicates whether or not the information from the collision
sensor is to be deleted when logging-in or not:
Value Function
0 Save data on login
2 Delete data on login
4 Zeroing BDI
Parameter 117 specifies how the alarm is given when the collision sensor is
activated:
Value Type
Repeated tone
0
pulses
1 One tone pulse
Note:
for setting the collision sensors sensitivity, see parameters 110 and 111.
Parameter 110/111 states the level, in the X-/Y-direction, at which the truck's
functions are to be blocked in the event of a collision:
Par. Function Value Meaning
0 Inactivated
X:110/ Collision sensor sensitivity in 1 Lowest sensitivity
Y:111 each direction | |
100 Highest sensitivity
The PIN code required to reset the collision sensor is entered in the login
profile Block: 10, Profile: 1.
Par. Description
201 Retardation reversing of travel direction
202 Adjusting the crawl speed max. 2.5 km/h
203 Adjusting the half-speed max. 4 km/h
204 Adjusting the safety speed, max. 1.3 km/h
208 Creep speed in travel direction
213 Permanent speed reduction
214 Adjusting the travel speed in the main lift range
215 Adjustment of travel speed when turning, initial angle
216 Adjustment of travel speed when turning, final angle
Parameter 201 Retardation when reversing
Parameter 201 may be used to produce a smoother retardation when the
application requires this for all operator profiles.
Shock lookout
The speed can be reduced from 2.5 km/h.
Steering angle reference error
The speed can be reduced from 4km/h.
The safety speed is set when the truck is started in emergency drive mode
and in case of lift height limitation.
The speed can be reduced from 1.3 km/h.
The parking brake must first be released before the truck can begin to travel.
If '0' is indicated, then the feature will be inactive.
Value Function
0 Inactivated
1 Activated
Parameter 214 Adjusting the maximum travel speed in main lift range
Parameter 214 can be used to decrease the travel speed to 3 km/h when the
forks are in the main lift range.
This parameter is only used when a mast split sensor is used.
Defa Maxi Incre
Par. Description Min. Unit
ult mum ment
Adjusting the travel speed in 0.1
214 0 0 1 1
the main lift range km/h
Value Function
0 Travel speed: 10 / 9 km/h
1 Travel speed = 3 km/h
Parameters 215/216
Par. Description
301 Extra valve function 1
302 Extra valve function 2
Extra valve function 1, output A. Maximum oil pressure through valve
305
Q18
Extra valve function 2, output A. Maximum oil pressure through valve
306
Q18
Extra valve function 1, output B. Maximum oil pressure through valve
309
Q19
Extra valve function 2, output B. Maximum oil pressure through valve
310
Q19
313 Extra valve function 1, time for closing valve selected in P301.
314 Extra valve function 2, time for closing valve selected in P302.
317 Extra valve function 1, output A. Maximum oil flow through valve Q18
318 Extra valve function 2, output A. Maximum oil flow through valve Q18
321 Extra valve function 1, output B. Maximum oil flow through valve Q19
322 Extra valve function 2, output B. Maximum oil flow through valve Q19
325 Extra valve function 1, output A. Opening/closing time valve Q18
326 Extra valve function 2, output A. Opening/closing time valve Q18
329 Extra valve function 1, output B. Opening/closing time valve Q19
330 Extra valve function 2, output B. Opening/closing time valve Q19
341 Reduction of lifting speed
342 Reduction of lowering speed
343 Reduction of reach speed
345 Sensitivity for lifting and lowering
346 Ramping speed reach movement
347 Ramping speed, lowering
371 Lift height limitation: Creep speed, lifting
373 Lift height limitation: Creep distance, lifting
375 Lift height limitation: Braking distance, lifting
377 Lift height limitation: Maximum stop tolerance
380 Lift height limitation 1
387 Configuration of lift height limitation 1
5.4.3 Description
Examples:
The value 0 means that only Q18/Q19 are activated by the extra valve
function.
The value 1 means that Q9 and Q18/Q19 are activated simultaneously by the
extra valve function. Q18/Q19 are used to provide the direction and Q9 is
used for the selection of a function.
The value 3 = 1+2 means that Q9 and Q18/Q19 are activated
simultaneously,but with Q18/Q19 in reverse order. This produces a hydraulic
movement in the opposite direction.
Note: To start the functions, see parameter 1007.
Parameter 347 Ramping speed lowering function is used when the operator
wants rapid reaction to full movement on the lever that generates a small
lowering.
P377
P371
P373
P375
Value
Function
P387
0 Not active
1 Possible to bypass
2 Stop
Overview
Par. Description
503 Login method
508 Display of height information
509 Buzzer activation
512 Truck family
513 Date format
Description
Value
Function Access
P503
The operator is permitted
3 Keypad with 100 PIN codes to change operator
parameters
The operator is not
4 Keypad with 100 PIN codes permitted to change
operator parameters
The operator is permitted
5 Keypad with T.W.I.S. to change operator
parameters
The operator is not
6 Keypad with T.W.I.S. permitted to change
operator parameters
Parameter 508 specifies whether the CID is to display the fork height:
Value P508 Function
Fork height is not
0
displayed
1 Fork height is displayed
Parameter 509 states which operations will cause the CID's buzzer to sound:
Operations that
The value which is
activate the CID's
added to P509
buzzer
Blocking symbol active 1
Parameter value is
2
entered
Safety pedal and option
4
buttons are used
The CID's buttons are
8
used
Example 1:
The buzzer is to be switched off Normally P509 is programmed with the
value 0.
Example 2:
The buzzer shall sound when the option buttons or the CIDs buttons are
pressed 4 + 8 = 12.
Parameter 512 must always have the value 4 for this truck. This parameter
automatically specifies the type of truck for which the program has been
created.
Parameter 513 specifies whether the CID is to display the date:
Value P513 Display
0 yyyy-mm-dd
1 dd-mm-yyyy
Overview
General factory parameters are used to specify the truck type and how the
truck is configured.
Par. Description
1001 Truck type
1002 Mast type
1003 Pump type
1007 Lever activation
1009 Type of height indication
Description
Overview
Par. Description
1101 180 degree steering
1102 Warning lamp
1103 Lift height limitation
1104 Travel alarm
1105 Working lights
OTP speed reduction when
1106
cornering
1107 ANSI braking norm
Description
Maxi
Defa Increme
Par. Description Min. mu Unit
ult nt
m
1101 180 degree steering 0 0 1 1
1102 Warning lamp 0 0 1 1
1103 Lift height limitation 0 0 1 1
1104 Travel alarm 0 0 1 1
1105 Working lights 0 0 1 1
OTP speed reduction
1106 0 0 1 1
when cornering
1107 ANSI braking norm 0 0 1 1
Description
Note:
All calibration parameters are set via the CID's calibration functions and must
not be changed via the parameter menus.
6. Installation
6.1 Transporting the truck
When transporting the truck on a lorry or the like, the truck must be properly
anchored with stropping. Use inserts and sheets of shock-absorbing material
to prevent damage to the truck during lashing and transport.
Method 1
When the truck is to be transported over long distances you should use a fork
lift truck with the following lift capacity:
Load R112,R114,R116
Load centre distance (Tp) 800
Weight without battery and 1600
mast
Tp
Insert the forks under the support arms and lift as illustrated in the diagram.
Method 2
To move the truck over short distances, you can use an extension cable from
an adjacent battery.
6.4.1 Battery
DANGER!
Risk of moving the centre of gravity.
A battery weight that is too low gives impaired stability and braking capacity.
The battery weight must be in accordance with the information on the trucks
identification plate.
1. Supply the truck with power from an external source.
2. Apply the parking brake.
3. Make sure the battery-coupler is up
DANGER!
Falling battery.
If the truck tips the battery may fall out if the battery catch is not locked.
Check that the battery catch is locked.
DANGER!
Falling battery.
When replacing a battery, there is a danger of it slipping and falling.
Always use an approved lifting device to lift the battery and use a battery
yoke that fits the battery.
Step 1 Step 3
Step 2
Step 14 Step 15
Step 16 Step 17
Step 18 Step 19
Required tools
Lifting tool 11-1091BT for 1.6-20 ton masts
Lifting tool 11-1133/4BT for 2,5 ton masts
Allen key 8mm for reach carriage cover
Plugs for hydraulic hoses and valve units.
Allen key 17mm for mast bolt
Allen key 14mm for eccentric insert
Allen key 10mm for locking ring
Absorbent sheet
Method
Park the truck in an area that has accessibility and plenty of space to
dismantle the mast and place it on a pallet.
1: Lift the mast so that the hose clamps may be taken off.
2: Lift away the forks from the fork yoke, use suitable lifting tools.
3: Secure with a one-inch wood beam that fits between the fork yoke and
the inner guide, and strap it with plastic straps. (Figure step 3). Use two
straps to secure if the mast is 9000mm or taller.
4: Fit the lifting yoke to the upper part of the mast.
5: Remove the undercarriage cover using a 8mm Allen key to reach the
hoses.
6: Remove electrical connections and place an absorbent sheet in the
undercarriage
7: Prepare the removal of hoses, place plugs near the valve unit in order to
minimise oil spillage.
8: Mark the hoses before you remove them.
9: Plug the hoses and the connections in the valve unit. Note: Do not
forget to fit the red lock details. Remove the absorbent sheet and wipe
off any oil spillage.
10: Check if there are any markings on the mast cylinder.
11: Remove the front M20 socket head bolts (2ea), use a 17mm Allen key.
(Figure step 11a) Undo slightly the socket head bolt on the mast cylinder.
(Figure step 11b) Then remove the lock ring by undoing the socket head
bolts. (Figure step 11c)
12: Turn the cylinder 1/4 turn upwards using a 60mm key in order to remove
the mast from the undercarriage.
13: Remove the shims from behind the M20-bolts.NOTE! Mark each
mounting so that you know how many shims should be on each
side respectively. This important in order to ensure the correct
mast angle for the client.
14: Lift out the mast, make sure that hoses and cables do not snag, tighten
the lock ring and adjusting screw back in place. Check that the mast sign
is not damaged.
15: Manufacture a wooden bed to transport the mast on.
16: Place the mast on the wooden bed. Use extra lifting equipment. (Figure
step 16)
17: Strap the mast with plastic straps to secure the mast for transport.
18: Fit the undercarriage cover, the battery support and place the forks on
supports and strap them to the undercarriage
19: If several masts are removed for transport, place a pallet on the lower
mast before placing the next one on top of it.
Step 1
Step 2 Step 3
Step 4a Step 4b
Step 5 Step 7
Step 6
Step 10b
Step 11 Step 12
C
Step 13 Step 14
189 Nm
124 Nm
Step 15
Step 16 Step 17
Method
1. The precondition of installing the mast in the truck is that the correct mast
is mounted on the correct truck. The matching is done by using the label
and the identification plate behind the operators seat.
2. Park the truck in an area that permits good access and room to mount
the mast on the truck. Place the mast a bit from the truck so that there is
no interference when the mast is lifted from the pallet. Remove the
strapping.
3: Fix the lifting yoke to the top part of the mast when it is still lying on the
pallet.
4: When installing the mast in the reach carriage, it is important to ensure
that the hoses are correctly installed, see figures 4a and 4b
5: For reach carriage with additional sheet metal (applies to 2.0 and 2.5 ton
mast), the hoses must be traced as per the figure 5.
6: Check that the hoses are not pinched by rear of the reach carriage when
placing the mast.
7: Lubricate the eccentric insert of the mast with MoS2 grease. Place the
mast in the reach carriage.
8: Turn the eccentric inserts so that the flat part is facing forward (towards
the forks) according to figure 8.
Note: The eccentric inserts must not be turned so that the large flat surfaces
face inwards in the cups on the mast attachment in the reach carriage.
. Tighten the bolts at the bottom of the mast to 519Nm for 1.6-2.0 ton masts
and
266Nm per bolt (2ea per side) for 2.5 ton masts.
15: Apply Loctite 29320 (Loctite 242 blue) to the threads of the adjusting
screws and tighten to 189Nm. Then tighten the lock ring screws to
124Nm.
16: Refit the hoses at the correct places. Observe the markings on the hoses
that must have been made when the mast was removed from the truck.
17: Connect the electrics connectors needed to start the truck.
7. Maintenance
7.1 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.
7.4 Symbols
Check the support lugs for wear and that they have the
0840.1 closing stamp. The distance to the floor must be no more
than 12 mm.
Check the parking brake air gap with the brake applied by
checking that
3370.2
0.2 mm but not a 0.5 mm feeler gauge between the brake
unit magnet housing and the movable pressure disc.
7120.1
7120.2
7120.3
3370.1
5110.1
5110.2
5110.3
0620.1
2550.1
0840.1
0390.2
0390.1
0390.1
Inspect the battery lock for correct installation and
possible wear.
3370.1
Check the air gap of the parking brake.
3370.2
Check the parking brake torque, 41 Nm (nominal). -
4310.1
7130
7110.1
7130.1
5590.2
5590.3
5110.8
6600.2
7400.1
3550.2 5000.4
5430.1
5430.2
7190.2 7190.1
3530.1
3530.2
6120.2 3530.3
7190.4 7190.7
7190.5 7190.8
7190.3
0000.2
5000.3
3370.2
5110.7
5110.9
0390.3
3550.1
1700.1
2550.2
5000.2
5200.1
5110.4
5110.5
5110.6
0640.1
6140.1
1700.1
5000.1
5390.1
5590.1
7.7.6
8. Troubleshooting
8.1 Auxiliary functions
Description
The error log displays a list of the last 20 errors logged.
Five errors are listed directly on the menu. The log number, date and error
code are displayed for each error. The selected error is highlighted by means
of a box that can be moved up or down the list using the arrow keys. When
the selection approaches the top or bottom of the list, the menu rolls the list
on, to display more errors if there are any.
Access
i
The login screen may vary depending on the setting of parameter 503.
Description
NOTE:
The error information menu is mainly intended for software development and
shows detailed information about the logged error.
The error code (3:143) is shown on the left of the window. Beneath it are the
log date (101109) and time (12:57) when the error occurred.
The window also shows logged information relating to the error.
Only five values are displayed at a time; to obtain more values, the arrow
keys must be used.
Access
Description
The CID diagnostic screens are used to check the values of subsystems.
Some screens also show other information that may be of use to a service
technician.
NOTE:
Update of diagnostic screen data has lower priority than regular truck
functions. Thus, the screens are only updated once per second.
Access
119/
Function Conn.
1 Steering pulse transducer 1 A X504:13
2 Steering pulse transducer 1 B X504:11
3 Steering pulse transducer 2 A X504:14
4 Steering pulse transducer 2 B X504:12
6 Horn X503:6
8 Height limitation bypass X503:4
9 Working lights X503:3
10 X503:9
11 X503:4
12
13
14
15
16
17
18
19 Emergency switch off X504:17
21-32 Not used
Function Conn.
1 X130:10
2 X130:24
3 X130:38
4 X130:11
5 X130:25
6 X130:39
Height sensor in main lift
7 X130:12
zone, pulse A
Height sensor in main lift
8 X130:26
zone, pulse B
9 X130:40
10 X130:13
11 X130:27
12 Seat switch X130:41
13 Mast lowering mode A X131:2
14 X131:16
15 X131:30
16 X131:3
17 X131:17
18 X131:31
19 X131:4
20 X131:18
21 X131:32
22 Emergency switch off X131:5
23 X131:19
24 X131:33
25 Key relay X131:6
Function Conn.
2 Chassis fan X131:34
3 Main contactor X131:7
4 Lifting valve X131:21
5 X131:35
6 Working lights X131:8
7 X131:22
8 Travel alarm 2 (Warning lamp) X131:36
9 Fan for frequency converter X131:9
10 Travel alarm 1 (Buzzer) X131:23
11 Extra hydraulic valve 1A X131:37
12 Reach carriage valve in X131:10
13 Reach carriage valve out X131:24
14 Routing valve. X131:38
15 Extra hydraulic valve 1B X131:11
16 Horn X131:25
17 X131:39
18 X131:12
Screen 11 Temperatures
Unit C
Screen 12 Voltages
Function Unit
Left Travel speed, actual value m/s
Right Travel speed, target value m/s
~0.5 V: not depressed
A Accelerator
~4.5 V: Depressed all the way
~0.5 V: not depressed
B1 Brake pedal
~4.5 V: depressed all the way
~4.5 V: not depressed
B2 Brake pedal
~0.5 V: depressed all the way
1 Main contactor
2 Power stage in ACT activated
3 Safety switch
4 Seat switch
5 Parking brake
Travel direction selector, drive
6
wheel direction
Travel direction selector, fork
7
direction
Function Unit
Steering response, actual
Left
value
Steering response, target
Right
value
0 RPM with stationary
steering wheel
Steering motor speed, actual
Left 2300 3000 RPM with
value
considerable steering wheel
movements
Steering motor speed, target Should be close to
Right
value corresponding actual value
S1 Steering command 0% with stationary steering
wheel
S2 Steering command 100% with considerable
steering wheel movements
1
2 Steering reference sensor
Drive wheel direction
3
requested
4 Fork direction requested
5 Reverse steering
6
7
8
Function Unit
H Height, total (displayed) mm
S Lifting/lowering speed mm/s
100%
0 when the
L Lift/lowering lever
lever is not
activated
Requested hydraulic pump
P Rpm
speed
1 Pulse A
2 Pulse B
3 Reference sensor
4 ACH Active
Function Unit
0% at maximum in
Actual reach movement
R 100% at maximum
length
out
*/- 100%
L Reach movement lever 0 when the lever is
not activated
Requested hydraulic pump
P Rpm
speed
Function Unit
100%
0 when the
L1 Tilt lever
lever is not
activated
100%
0 when the
L2 Sideshift lever
lever is not
activated
Requested hydraulic pump
P Rpm
speed
Begin troubleshooting
Yes
No
No
Troubleshooting
without indications
The MCU does not know if the If the indication is shown constantly, check that the signal from
safety pedal [B31] is affected. the safety pedal switches status when the chair is loaded, CID
diagnosis screen 3/pos 6.
Main lift not in bottom position Speed reduction is due to the truck being driven with the
main lift above the bottom position.
Check that the sensor [B58] is correctly connected. The
CID's diagnostic screen 4, pos 13 [B58]
Troubleshooting using
error codes
Error Yes
CID, warnings and
code
No
No
Error Yes
Drive system error
code
No
Error Yes
Hydraulic system error
code
No
No
Troubleshooting
without
The first digit of the three-digit error code indicates the severity of the error
and how the truck is affected/responds when the error occurs.
.
The error codes are subdivided into smaller categories based on the last two
digits of the code (see below).
2:180 No contact with the shock sensor. 1. If the truck is not equipped with a
collision sensor, set parameter 110 = 0
and 111 = 0.
2. Check that cables and contacts are
undamaged.
3. Replace [B90]
3:385 The voltage from the accelerator Check that accelerator output voltage is
pedal [B32] is outside the specified within the interval 0.25 V to 4.75 V. The
limits. CID's diagnostic screen 3, pos 5:
Driving is blocked and the truck is
brought to a stop with the plug brake.
3:462 Unexpected movement in a stationary 1: Check the sensor B11 and its wiring.
truck There may be a short-circuit.
Examples: If the truck gets hit. 2: This error code may be generated if
pushing a load with the truck
5:135 Risk of thermal overload in the 1. Check that there are no objects
steering servo. blocking the steering movement.
The indication is shown from 80 % up to
2. Check that the steering gear is not
100 %. At 100 % the indication switches
jammed or blocked by dust, thread or
over to error code 5:325.
contaminants.
Travel speed limited to
maximum 4 km/h. 3. Replace the steering servo.
Slut p avsnittet
9. Chassis C0000
9.1 Overview
b
a
f
c
e d
Pos. Description
a Protective overhead guard
b Roof pillar
c Battery
d Support arm wheels
e Support arm
f Carrier
g Floor
h Drivers seat
i Protective cover
9.2 Description
The truck chassis consists of a base plate with support arms. The battery
compartment and motor and cab fixing points are then fitted to the chassis.
The lifting mast and fork unit are not part of the chassis.
9.3.1 Overview
b
a
f
c
e d
Pos. Description
a Floor
b Safety pedal
c Accelerator and brake pedal
d Wall mount
e Floor pipe
f Step-in plastic
9.3.2 Description
The truck has a floor that can be raised and lowered mechanically to three
different levels.
Step 1 Step 2
Method
1: Remove the screws.
2: Remove the connector [X10].
Step 1 Step 2
Overview
b
a c
k
j d
g
e
Pos. Description
a Top cover
b Finger guard
c Cover, wiring harness
d Elbow panel
e Rear cover
f Inner motor cover
g Lower interior cover
h Front knee cover
i Lower steering arm cover
j Upper steering arm cover
k Side cover
Description
The truck has protective covers made of plastic.
Method
1: Undo the screw at the place of the front roof beam.
2: Undo the screw on the right side.
3: Lift away the top cover.
Method
1: Put the top cover in place.
2: Fit the screws on the right side.
3: Fit the screw at the place of the front roof beam.
Fitting the steering arm covers
See section " Fitting the steering arm covers".
Step 1 Step 2
Method
1: Take out the screws.
2: Lift away the steering arm covers.
Step 1 Step 2
Method
1: Put back the steering arm covers.
2: Fit the screws.
Step 1
Method
1: Remove the cover
Step 1
Method
1: Fit the cover.
Method
1:
Method
1:
Method
1: Undo the two screws on top.
2: Undo the screw on the side.
3: Lift away the motor covers.
Method
1: Put back the motor cover
2: Screw in the side screw.
3: Fit the screws on the top.
Step 1 Step 2
Method
1: Take out the screws.
2: Lift away the inner motor cover.
Step 1 Step 2
Method
1: Put back the inner motor cover
2: Fit the screw.
Step 1 Step 2
Method
1: Remove the screws.
2: Take off the front knee cover.
Step 1 Step 2
Method
1: Put back the front knee cover
2: Fit the screws.
Fitting the steering arm covers
Pos. Description
a Battery roller
b Battery stop
c Battery locking device
9.6.1 Overview
a b
Pos. Description
a Operators seat, Basic
b Operators seat. Comfort High
c Operators seat, Comfort Low
9.6.2 Description
The operator's seat is available in three different models:
Basic
Comfort Low
Comfort High
An armrest (d) is an option and the seat can also be fitted with a safety belt
to increase the operator's safety.
In the seat there is a switch [B49] which must be activated; the operator must
sit in the seat in order for the truck to be driven.
Step 4 Step 5
Method
1: Push the seat forward.
2: Undo the two rear screws.
3: Undo the front screws from underneath.
4: Remove the connector [X47].
5: Lift away the seat.
Step 4 Step 5
Method
1: Put back the operators seat.
2: Push the seat forward.
3: Fit the rear screws.
4: Fit the rear screws.
5: Connect the connector [X47].
Method
Step 1 Step 2 S
Method
1: Push the seat forward.
2: Undo the rear screws.
3: Push back the seat.
4: Undo the front screws.
5: Disconnect the connector [X47].
6: Lift away the seat.
Method
1: Put back the operators seat.
2: Connect the connector [X47].
3: Push back the seat.
4: Fit the front screws.
5: Push the seat forward.
6: Fit the rear screws.
c
b
Press the button (a) to adjust the inclination of the back rest.
Lift the clamp (b) and release the lock to adjust the forward/backward
position of the seat.
Set the seat's spring pressure using the knob (c). To adjust suspension to
match your weight, sit on the seat and turn the knob until the green mark
points straight up.
Step 4
Method
1: Loosen the two screws securing the cover over the seat back rest.
2: Turn up the cover.
3: Split the connector [B49] at the switch.
4: Remove the switch from the connector.
Step 4
Method
1: Fit a new switch.
2: Connect the connector [B49].
3: Turn back the cover.
4: Fit the back rest cover.
Method
1: Push the seat as far forward as it will go.
2: Loosen the locking pin.
3: Use a finger to push the back rest locking spring back, while using the
other hand to take grasp the lower edge of the back rest and lift it up.
4: If the seat has a heater, disconnect the switch [X63], and then connect
the new back rest [X63] before assembling the back rest. (PICTURE?)
5: Lift away the seat.
Step 2 Step 3
Method
1: If the seat has a heater, split the connector [X63], and then connect the
new back rest switch [X63] before assembling the back rest.
2: Align the three hooks of the back rest in the seat frame, and push the
back rest down until the locking spring interlocks with the hook.
3: Fit the locking pin.
Step 1 Step 2
Method
1: Undo the four screws to the seat plate.
2: Lift away the seat plate.
Step 1 Step 2
Method
1: Put back the seat plate.
2: Fit the screws of the seat plate.
9.7.1 Overview
Pos. Description
a Accelerator
b Brake pedal
c Safety pedal
9.7.2 Description
9.7.3 Preconditions
Before driving is permitted, the operator must have first:
Activated switch [B49] by sitting in the operator's seat
Activated the safety pedal [B31] by putting his left foot on it. If the truck has
a cab with a door, the door functions as a safety pedal and must be closed.
Selected travel direction
If the operator seat is not loaded and the safety pedal depressed, a blocking
symbol will be displayed in the CID.
If no direction has been selected, the green arrows that indicate direction
flash alternately.
Step 4
Method
1: Disconnect the connector [B32] and the cable bracket.
2: Remove the screws of the accelerator.
3: Remove the screws of the brake pedal.
4: Lift out the pedal insert.
Step 4
Method
1: Fit the pedal insert in the floor plate.
2: Connect the connector [B32] and the cable bracket.
3: Fit the screws of the accelerator.
4: Fit the screws of the brake pedal.
Fitting the floor
See section " Fitting the floor".
Step 1 Step 2
Step 3
Method
1: Disconnect the connector [B31].
2: Remove the screws.
3: Lift out the safety pedal from the floor plate.
Method
1: Fit the safety pedal in the floor plate.
2: Fit the screws of the safety pedal.
3: Connect the connector [B31] to the safety pedal.
Fitting the floor
9.10.1 Overview
Pos. Description
a Protective overhead guard
9.10.2 Description
The truck has a corrugated roof mounted on two supports.
Method
1: Undo the three bolts on the right side of the roof.
2: Undo the three bolts on the left side of the roof.
3: Lift away the roof.
Method
1: Put back the roof.
2: Fit the bolts on the right side.
3: Fit the bolts on the left side.
Method
1: Undo the screws in the lower bracket. Undo the middle screw that goes
through the support.
2: Undo the screws to the rubber bushing.
3: Lift out the support.
Method
1: Put back the support.
2: Fit the screws around the rubber bushing.
3: Fit the screws in the lower bracket.
Step 1 Step 2
Method
1: Remove the screws.
2: Lift out the support.
Step 1 Step 2
Method
1: Put back the support
2: Fit the screws.
Step 1 Step 2
Method
1: Take out the screws.
2: Lift away the finger guard.
Step 1 Step 2
Method
1: Put back the finger guard.
2: Fit the screws.
d e
c
b
Pos. Description
a Fan motor for frequency converter
b Truck traction
c Steering servo motor
d Pump motor
e Fan motor for motor compartment
10.2 Description
The truck motors are the drive motor, the pump motor for the hydraulics, the
steering motor for rotating the drive unit (steering) and two cooling fans.
10.3.1 Overview
a
Pos. Description
a Toothed wheel
b Speed sensor
c N-shield
d Bearing
e Temperature sensor
f Stator
g Rotor
h Bearing
i D-shield
j Terminal
k Stud
10.3.2 Description
The pump motor is a brushless, short-circuited, three-phase asynchronous
motor.
The motor has the following for monitoring and feedback to the motor control
system:
A sensor that detects the engine temperature.
A sensor with associated toothed wheel that measures direction of rotation
and speed
Step 4 Step 6
Step 5
Step 7
Method
1: Undo the hose clamp to the suction hose of the tank.
2: Undo the supply hose to the pump.
3: Disconnect the power cables.
4: Disconnect the connectors [B12 and B2].
5: Fit the motor lifting eye.
6: Remove the four screws that hold the motor to the chassis.
7: Lift out the pump motor.
Method
1: Place the motor in the truck
2: Remove the lifting eye.
3: Fit the screws holding the motor in position.
4: Fit the supply hose.
5: Tighten the hose clamp to the suction hose of the tank.
6: Connect the connectors [B12 and B2].
7: Connect the power cables (Tightening torque 20 Nm +/- 2).
Fitting the seat plate
See section " Fitting the seat pad".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
Step 1 Step 2
Step 3 Step 4
Method
1: Disconnect the temperature sensor connector.
2: Undo the wire clip and remove the wire.
3: Remove the connector fitting.
4: Cut the wire as far in as possible.
W
V
Step 1 Step 2
Method
1: Wipe the surface where the new temperature sensor will be mounted.
2: Place the temperature sensor in a suitable location.
3: Apply steel plastic on top of the sensor. Cover the whole sensor.
4: Affix the steel plastic and the sensor with masking tape and allow to set.
5: Remove the masking tape.
6: Connect the connector to the sensor.
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
10.4.1 Overview
b e
Pos. Description
a Contact [X901]
2 threaded holes, 1 is concealed in the
b
illustration
c 3 screws, 1 is concealed in the illustration
d Steering servo motor
e Guide pin
f Gear wheel
10.4.2 Description
F72
MC On
B Neg
The steering motor (a) is located on the drive unit cowling (b). It receives
signals from the pulse generator located in the steering column. The steering
motor is equipped with a gear wheel (c) working directly on the gear ring of
the drive gear.
a
NOTE:
For reasons of safety, the gear wheel is glued to the shaft spline and is
secured with a circlip.
The motor must be discarded immediately if the gear wheel sits loose on the
splines.
Repair of the mechanics is not permitted for reasons of safety.
b
a
View from the underside of the steering motor: a: Attachment, b: Guide, c:
Threaded hole for removing steering motor.
Method
1: Disconnect contact [X901] from the steering servo motor.
2: Remove the steering servo motor.
3: Move two screws to the threaded holes of the motor flange.
4: Screw them in alternately so that the motor is lifted straight up.
Step 4
Method
1: Fit the steering servo motor by lowering it straight down so that the gears
are not damaged.
2: Carefully tap on the motor flange with a plastic mallet so that it gets good
guidance by the guide pin.
3: Fix the steering motor in place by tightening alternately (Tightening
torque 46Nm).
4: Connect the connector [X901] to the steering servo motor.
Overview
Pos. Description
a Fan
b Air duct
Description
The fan is an axial fan that ventilates the frequency converters. The fan can
be tested using the CID service function for forced fan operation.
Method
1: Disconnect the connector [G3]
2: Disconnect the main harness that is fixed in place with cable ties above
the fan unit.
3: Undo the screws that hold the fan unit.
4: Lift away the fan unit.
5: Remove the fan screws.
6: Separate the fan and the air duct.
Method
1: Fit the fan to the air pipe.
2: Fit the fan screws to the air duct.
3: Fit the fan unit to the chassis.
4: Fit the screws to the fan unit.
5: Connect the connector [G3]
6: Fit the cable ties.
Fitting the floor
See section " Fitting the floor".
Overview
a
Pos. Description
a Fan
b Air duct
c Wiring harness
Description
The fan is an axial fan that ventilates the motor compartment. The fan can be
tested using the CID service function for forced fan operation.
Step 4
Method
1: Disconnect the connector.
2: Loosen the screws securing the fan and the air duct.
3: Remove the cooling fan and air duct.
4: Separate the cooling fan and the air duct.
Step 4
Method
1: Assemble the fan and the air duct.
2: Position the fan and air duct.
3: Fit the fan and the air duct. Tightening torque 4Nm.
4: Connect the connector [G4].
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
10.6.1 Overview
a
Pos. Description
a Nut
b Toothed wheel
c N-shield
d Bearing
e Circlip
f Rotor
g Stator
h D-shield
i Speed sensor
j Temperature sensor
10.6.2 Description
The drive motor is a brushless, short-circuited, three-phase asynchronous
motor.
The motor has the following for monitoring and feedback to the motor control
system:
A sensor that detects the engine temperature.
A sensor with associated toothed wheel that measures direction of rotation
and the RPM.
Step 4
Method
1: Disconnect the power cables from the drive motor.
2: Disconnect the connectors to the drive motor.
3: Remove the drive motor.
4: Lift out the drive motor using suitable lifting equipment
Risk of damage to the splines.
The splines on the end of the motor are easily damaged.
Lift out the motor carefully.
Method
1: Install the drive motor. Tightening torque 24 Nm
2: Connect the connectors to the drive motor.
3: Connect the power cables. Tightening torque 20 Nm +/- 2
Fitting the brakes
See section " Fitting the parking brake".
Fitting the floor
See section " Fitting the floor".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
Fitting the seat plate
See section " Fitting the seat plate".
Step 4
Method
1: Disconnect the temperature sensor connector.
2: Undo the wire clip and remove the wire.
3: Remove the connector fitting.
4: Cut the wire as far in as possible.
W
V
Step 1 Step 2
Method
1: Wipe the surface where the new temperature sensor will be mounted.
2: Place the temperature sensor in a suitable location.
3: Apply steel plastic on top of the sensor. Cover the whole sensor.
4: Affix the steel plastic and the sensor with masking tape and allow to set.
5: Remove the masking tape.
6: Connect the connector to the sensor.
Fitting the floor
See section " Fitting the floor".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the motor cover
See section " Fitting the motor cover".
Step 4
Method
1: Fit the sensor.
2: Fasten the cable in the cable bracket.
3: Connect the connector [B11].
4: Fit the sensor screw. Tightening torque 5 Nm +/-1
Fitting the floor
See section " Fitting the floor".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
d e c
Pos. Description
a Level plugs
b O-ring
c Lower cover
d Drain plug
e Screws for lower cover
11.2 Description
The drive gear is a two-stage angle gear which is integrated with the motor
and brake to form a complete drive unit that can be steered through 360.
The drive unit is anchored to the chassis with 6 bolts. The steering bearings
and a gear ring for the steering motor are fitted in the top edge of the gear.
The drive gear is equipped with conical roller bearings for the drive shaft and
pinion. The bearings are pre-tensioned to reduce the risk of play.
The input shaft has splines with which the drive motor's output shaft meshes.
The steering bearing and the steering gear ring are bolted to the drive gear
and can be replaced once the drive unit has been removed from the truck and
the motor unbolted from the drive gear.
The output shaft has a hub for the wheel, with replaceable studs for the drive
wheel.
The gear oil must normally be changed after 1000 operating hours. The gear
has two oil level plugs for checking/topping up the oil level. The oil volume of
the gear is 3.3 litres.
Method:
1: Remove the back piece so that the drive gear is made free, 4 pcs Allen,
5 mm.
2: Thoroughly clean the area around the level plug.
3: Remove the level plug together with the sealing washer. Discard the
washer.
4: Use a pump intended for changing oil and fill with new, clean oil
according to specification until the oil reaches the lower edge of the filler
hole.
5: Replace the sealing washer for the level plug and screw the plug back in.
6: Screw the back piece into place.
Note:
Collect any spilled oil using a suitable decontamination agent.
WARNING!
Risk of burn injuries!
If the truck has just been used, the oil can be very hot!
When draining the oil, it must be done so that no hot oil can come into
contact with the skin or be absorbed by clothing.
Step 7
Step 5
Method:
1: Undo the back piece to expose the drive gear.
2: Carefully clean the areas around the level and drain plugs.
3: Place a container, approx. 6 l, under the drain hole to collect the oil.
4: Remove the drain plug together with the sealing washer. Discard the
washer.
5: Remove the level plug together with the sealing washer. Discard the
washer.
6: Allow all the oil to drain into the collection vessel.
7: Clean the magnet on the drain plug, replace the sealing washer and
screw back the plug.
8: Use a pump intended for changing oil and fill with new, clean oil
according to specification until the oil reaches the lower edge of the filler
hole.
9: Replace the sealing washer for the level plug and screw it back in.
10: Screw the back piece into place.
Note:
Remove spilt oil using a suitable adhesive.
Oil refill table
The amount of oil is also written on the drive gear identification plate.
Method
1: Drain the oil from the drive gear as described.
2: Remove the screws from the lover cover and remove it from the gear.
3: Replace the O-ring in the cover.
4: Lubricate the screws for the cover, place the cover on the gear and
mount it in place.
NOTE:
Care must be taken to prevent damage to the cover O-ring.
5: Refit the plugs, fill with oil and finish as described in.
Method
1: Use a jack to raise the truck by approximately 16 cm.
2: Support the truck:
3: Loosen the six screws of the gear, but do not remove them.
4: Place a block of wood, approximately 7070 mm, under the gear.
5: Lower the truck so that the gear is resting on the block of wood.
6: Remove the screws holding the gear.
7: Raise the truck by 21 cm and chock up the truck.
Method
1. Place the gear in a standing position on the floor under the truck.
2. Lower the truck over the gear.
3. Place three screws, M12x110 mm, in the fixing holes to hold the gear in
place.
4. Raise the truck and place spacers under the gear.
5. Lower the truck over the gear.
6. Screw the gear in tight. Tightening torque 80 Nm.
7. Raise the truck and place the drive wheel. Fit the washers and nuts and
tighten the nuts by hand as hard as possible.
8. Lower the truck onto the wheel.
9. Torque tighten the drive wheel nuts crosswise. Tightening torque 140
Nm.
10: Screw the floor and pedals back into place. Join the connector unit for
the pedal harness.
11: Screw the carrier back into place behind the drive wheel and foot step.
12: Function test the truck.
Step 1 Step 2.
Method
NOTE:
When installing the new bearing, always use new screws.
1: Undo the screws securing the steering bearing to the gear. Discard the
screws.
2: Lift up the bearing by hand.
3: Clean away all remaining thread-locking from the drive gear threads.
4: Wipe the bearing contact surfaces clean.
Slut p avsnittet
12.1.1 Overview
Pos. Component
a Dust plug
b Hub
c Steering key
d Rubber gaiters
e Brake unit
12.1.2 Description
The truck has three different types of brake:
Travel brake
Parking brake
Emergency brake
Travel brake
The travel brake is designed as a system:
Regenerative plug braking using the drive motor. Parking brake
The parking brake is made up of a single stage electromechanical disc brake
fitted on the drive motor which is engaged by means of spring force. The
parking brake is released electrically (DC voltage).
The parking brake is activated/is active as follows:
The parking brake is activated automatically when the truck has been
stopped while being driven and the brake pedal is depressed with the truck
stationary. The brake is released when the accelerator is depressed.
The parking brake is activated automatically with a few seconds delay
when the operator leaves the truck.
The parking brake remains active after the main power has been switched
on.
Emergency brake
Emergency braking of the truck takes place in the event of a fault with the
steering system or a serious fault in the electrical system.
The parking brake on the drive motor is the main emergency brake.
Plug braking can operate during emergency braking provided there is a
supply voltage.
Accelerator released
The regenerative plug brake is automatically engaged when the accelerator
is released. The braking force can be adjusted using an operator parameter.
The plug brake force is regulated to allow for the current speed and the extent
to which the accelerator is released. This works as follows:
Braking at a high speed, with the accelerator fully released, results in high
brake force.
Braking at a low speed, with the accelerator fully released, results in lower
brake force.
Braking at a high speed, with the accelerator half released, results in
medium brake force.
12.2.1 Overview
a
Pos. Component
a Dust plug
b Hub
c Steering key
d Rubber gaiters
e Brake unit
12.2.2 Description
The brake is a single stage electromechanical spring-loaded brake that is
released when the magnetic coil is energised. Polarity does not affect its
operation. This brake serves as a parking brake and emergency brake.
Technical data
S S Step 3
Step 4 Step 5
Method
1: Remove the dust plug
2: Remove the connector [Q1].
3: Undo the three screws of the brake unit.
4: Lift out the brake unit.
5: Remove the hub and the key.
Method
1: Adjust the hub with groove key to the motor shaft.
2: Fit the brake unit.
3: Fit the connector [Q1].
4: Fit the screws. Tightening torque 10.1 Nm +/- 1.1 Nm.
5: Fit the dust plug.
Step 1
Method
1: Remove the dust plug
Step 1
Method
1: Fit the dust plug.
Fitting the motor cover
See section " Fitting the motor cover".
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
Step 1 S Step 3
Step 4 Step 5
Method
1: Remove the dust plug.
2: Remove the connector [Q1].
3: Undo the screws of the brake unit.
4: Remove the brake unit.
5: Remove the hub and the guide key.
Step 4
Step 5
Method
1: Fit the hub.
2: Place the brake unit in position.
3: Fit the brake unit. Tightening torque 10.1 Nm +/- 1.1 Nm.
4: Fit the connector [Q1].
5: Fit the dust plug.
Step 1 Step 2
Method
1: Remove the connector [Q1].
2: Remove the rubber gaiter.
Step 1 Step 2
Method
1: Fitting the rubber gaiter.
2: Connect the connector. Fit the motor cover.
See section " Fitting the motor cover".
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
Step 1 Step 2
Step 3
Method
1: Remove the dust plug.
2: Turn the motor shaft with the torque wrench so the brakes release. The
braking force is too low if the brake lets go before the torque wrench
slips.
3: Fit the dust plug.
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
Method
1: Check that the parking brake is applied.
2: Remove the connector.
3: Remove the rubber gaiter.
4: Use a feeler gauge to check that the gap is not larger than 0.65 mm.
5: Check that the brake releases.
Fitting the seat plate
See section " Fitting the seat plate".
Fitting the operators seat
See section " Fitting the operators seat (Basic)".
See section " Fitting the operators seat (Comfort Low, Comfort High)".
12.3.1 Description
The truck has two types of wheels; one is a drive wheel with rim that is
mounted to the drive gear. Further it has two support arm wheels that are
mounted with a split shaft from both sides of the support arm. They are
tightened with a bolt from the outside.
Dimensions, mm Material
330 x 140 Vulkollan
Dimensions,
Type Material
mm
280 x 106 Unbraked Vulkollan
12.4.1 Overview
b
c
Pos. Description
a Wheels
b Conical washer
c Wheel nut
Method
To avoid heavy and uncomfortable lifting when changing the drive wheel, you
can use a board or a panel (or two, if the board or panel does not easily slide
over the floor surface).
1: Remove the fender at the drive wheel, 4 x Allen 5 mm.
2: Raise the truck by approximately 1 cm. Remember to secure the truck
with spacers to prevent it dropping down onto its chassis if the jack
should fail.
3: Turn the drive wheel so that the nuts are facing you. Apply a flat point bar
against the gear ring, taking care that the teeth do not become damaged.
4: Raise the truck so that a plank/panel can be pushed under the drive
wheel. This is then used to withdraw and insert the wheel under the
truck.
5: Remove the seven nuts and washers.
6: Remove the wheel from the gears. The truck may need to be raised
slightly as you do this.
Step 1. Step 2.
1: Push in the plank with the wheel so that the wheel is in the proper
position.
2: Fit the conical washers and screw on the wheel nuts by hand.
Make sure the rim slides in over the hub flange.
3: Torque tighten the wheel nuts in a crosswise pattern to 140 Nm.
4: Refit the fender by the drive wheel.
12.5.1 Overview
e
d
a
b c
Pos. Description
a Shaft
b Circlip
c Bearing
d Circlip
e Spacers
f Spacers
a
b
d
e
c
Method
1: Lift the truck so that the wheel goes free from the floor, and secure it with
something suitable (e.g. wooden blocks).
2: Remove the wheel cover (a) and the 3 screws (b)
3: Undo the screw (c) 1cm, and knock it inwards so it is possible to remove
the shaft (d) from the support arm.
4: Pull out the screw (c) and screw in a M16 screw to pull out the shaft (e) at
the same time that you pull the wheel up or down from the support arm.
Method
1: Fit the wheel in the support arm with the shaft (d) and (e)
2: Screw in the screw (c) and torque tighten to 83Nm.
3: Now fit the wheel cover (a) and the 3 screws (b)
4: Lower the truck to the ground.
Method
1: Remove one of the circlips.
2: Tap out the sleeve using a plastic mallet, the last part using a drive
mandrel.
3: Tap away the bearings using a mandrel.
Assembling bearings
Method
1: Install the new bearing using a brass drift.
2: Use a plastic mallet to tap the sleeve into the bearing.
3: Fit the spring ring.
CAN1 CAN2
CID MCU EPS
13.2.1 Overview
13.2.2 Description
The steering wheel in the steering console is directly mounted on a double
pulse transducer [B13], where each transducer has 2 phases (A and B).
Rotation of the steering wheel generates a pulse train/phase to CID. The
pulse transducer can be replaced without removing the steering console from
the truck.
13.2.3 Adjustment
c
d
e
f
g
7: Undo the connector unit for the pulse transducer.
8: Remove the three screws (g) (torx 20) that hold the pulse transducer (h)
in place.
9: Reassemble in reverse order.
Step 4 Step 5
Method
1: Undo the screws to he covers on top and underneath the console.
2: Remove the covers.
3: Undo the screws to the large lower protective cover.
4: Remove the lower protective cover.
5: Remove screws.
d
c
5: Remove the three screws (d) that hold the steering console in place and
remove the steering console from the truck.
e
f
j
k
h m
k
11: Remove the four screws (n) and the cap (o).
12: Remove the screws (p) and sleeve (q) by the steering console bracket
joint.
13: Note how the cable is fixed in the steering console and then remove the
cable.
p
q
c
4: Refit the panels around the steering console.
(a)
(b)
(c)
1: Remove the disc with the logo from the centre of the steering wheel a.
2: Remove the two screws and the washer (b).
3: Remove the steering wheel (c).
13.3.1 Description
The steering unit is integrated with the steering motor to form a single
module. The electronics of the unit are powered directly from the battery,
input "EN", but motor current is obtained via the truck's main contactor [Q10]
via input PS.
Communication with the other systems of the truck is handled via the truck's
CAN2 bus.
The steering reference sensor has its own input directly to the steering unit
and the sensor is also powered by the steering unit.
PS
EN PWM
F/B
HALL
EFFECT
SENSOR
General
These instructions apply to the replacement of the steering reference sensor
[B17] located on the drive gear housing, up against the drive motor.
When the sensor is to be replaced, disassemble the floor first. See section
"9.3.4 Protective covers".
Fig 1. Fig 2.
14.2 OTP
Description
OPT is a collective term for a combination of options. This truck has one of
these.
- Travel speed reduction - steering angle
Par. Description
107 Battery size
Battery status when acceleration and lift speed are
108
limited
109 Resetting (4 = BDI reset)
Overview
X1
Method
Dismantling
1: Run out the battery. This will expose 3 clamps that hold the battery wiring
in place inside the motor compartment.
2: Disconnect the battery by pulling out the battery connector.
3: Remove the 2 screws and the wiring harness where the connector is
fastened to the chassis.
4: Follow the wiring harness down to the contactor (Q10), and remove the 2
nuts holding the harness.
5: Remove the wiring harness from the ACT/ACH
Assembly
1: Start by mounting the battery connector in place in the chassis with 2
screws.
2: Attach the wiring harness to the contactor
3: follow the wiring harness down and attach it to the ACT/ACH
4: Fix the wiring harness in place using 3 clamps, two on the battery wall
and one up by the connector. These are screwed in from underneath and
the from the battery compartment respectively.
X1
-
Method
Dismantling
1: Run out the battery, and disconnect the battery connector
2: Remove the plus and minus cables from the battery
3: Remove the cover holding the battery harness in place
4: Once the battery wiring is removed, remove the 2 clamps to be able to
remove the wiring harness from the cover.
Assembly
1: Fit the plus and minus cables to the battery
2: Check that the length before you fit the wiring harness with 2 clamps to
the cover.
3: Fit the cover with the wiring harness to the battery.
14.4.1 Horn
Overview
+ (2) - (1)
Description
The horn [P4] is supplied battery voltage to connection +.
Control is handled via MCU output X131:25, HORN. When the output is low,
the horn sounds.
Method
Dismantling
1: Remove the connector P4
2: Remove the 2 screws and remove the horn
Assembly
1: Use the 2 screws to fit the horn
2: Connect the connector P4
Overview
Description
The main contactor is supplied +48 V via fuse [F60] and the emergency
switch off [S21].
The other connection of the contactor coil goes to MCU output X131:7,
OUTMAIN CONTACTOR.
When all the conditions for supplying the high current circuits of the steering
servo and motor control units are met, the MCU output goes low and the
contactor closes
If the main contactor is supplied +48 V via [S21], MCU input X131:5 and CID
input X504:17 are also supplied to indicate emergency switch off status
Method
Dismantling
1: Remove the 3 nuts to remove the main wiring harness and the fuse.
2: Remove the 2 screws and remove the contactor Q10.
Assembly
1: Use the 2 screws to fit the new contactor
2: Fit the main wiring harness and fuse using 3 nuts
Description
The instrument panel, a.k.a. operating panel, contains the controls for all
hydraulic functions, travel direction and signal. The information display and
keypad allow access to the truck.
1 2
3 4
Dismantling
1: Remove the two screws to remove the finger guard
2: Unbutton the plastic cover to remove it and access connector X500
3: Disconnect connector X500
4: Push in the button for controlling the operating panel, and pull it to the
rearmost position. Then use a screwdriver in the tiny hole indicated by
one of the yellow arrows to push the catch. Then pull the operating panel
so far back that it comes off.
1 2
3 4
Assembly
1: Put the operating panel in place by fitting it into the grooves. Pull it
forward so that it locks in place. Make sure that it is securely in place.
2: Connect connector X500
3: Fit the plastic cover by snapping it in place.
4: Assemble the finger guard
1 2 3
4 5 6
+ 7 8 9
C 0
Information symbols
Delete height
Automatic brake
ESO (Emergency
Switch Off)
Calibration of sensors.
Menu navigation
1 2 3
4 5 6
+ 7 8 9
C 0
For menu navigation there are buttons with arrows, plus/minus (+/-), i and
C.
To select an icon press on the up/down arrow until the icon for the function
you require is highlighted with a stronger border. Then press the green button
(I) to select your chosen menu.
The C-button is used to move up through the levels, and the i-button is used
as a short cut to the information screen or to the operator information menu,
depending on whether the truck is in logged-in or logged-out mode.
When logging in without the CAN key or Truck Com, only a limited number of
functions are accessible and only icons for accessible functions are
displayed.
Login a
Screen
c
i c
j
Info Startup
Screen Screen
i i
User
Screen
i c
c Driver
| c info
Error
info
i i c
Teach
In
d e
Overview of the functions that are accessible without
the CAN key or TruckCom.
a: Login procedure, d: Only read access
e: Parameter-based access, j: Logged in
Login a
Screen
C
i C
j
Info Startup
Screen Screen
User
Screen
C i C
Driver
i i info
i C
i
Teach
C
In
| C
Error i/C
info
i/C
C C i/C
i/C
| C
Diagn.
h
*
LED symbols
Once the truck is started, the LED symbols of the display come on for a short
time and then go out again.
In emergency travel mode, all the symbols flash simultaneously.
A B C D E F G
STOP
1 2 3
Overview
Method
Dismantling
1: Remove the 6 screws and remove the lower section
2: Remove the 4 screws and remove the plastic cover
3: Remove the electronic card
4: Undo the 4 screws and remove the display
Overview
Overview
B19
B58
X15
Description
B58
B19
X15
Method
Dismantling
1: Disconnect the connector to B19
2: Undo a nut with washer to remove the sensor bearing.
Assembly
1: Fit the new sensor bearing with at nut and washer
2: Connect the connector to B19
Method
Dismantling
1: Disconnect the connector to B58
2: Undo the 2 screws and remove the sensor.
Assembly
1: Use the 2 screws to fit the sensor
2: Connect the connector to B58
1. 2.
80mm10mm
3.
4. 5.
1: Fit the wire to the upper bracket using a spring and wire lock (Fig. 2)
2: Lay the wire 1 turn around a wheel,and then down to the lower bracket.
3: Tighten or relax to get the correct length 80mm10mm (Fig. 3)
4: Fit the wire lock (Fig. 4)
5: Check the routing of the wire; it must go 1 turn around the wheel (Fig. 5)
Method
Dismantling
1: Remove the connector X15
2: Cut off the tie straps and remove the clip on the side of the mast.
3: Disconnect the connectors to B19 and B58
Assembly
1: Start by fitting the wiring harness to the top with the connectors B19 and
B58
2: Fit the wiring harness to the side of the mast using the clip
3: Connect the wiring harness to X15, and use tie straps to collect the left-
over portions of the wiring harness
Method
Dismantling
1: Remove the 6 screws and remove the lower section
2: Remove the 4 screws and remove the plastic cover
3: Remove the 9 screws and remove the plastic cover for the levers
4: Remove the wiring harness from the plastic cover to the levers.
5: Disconnect the connector to the levers
6: Disconnect the connector to A6
Overview
Description
Drive/pump motor output control is done via two regulators, ACT and ACH
respectively. For R112-116 both motor controllers are 250A.
The regulators contain software for drive motor and
pump motor output control. When programming using TruckCom via the truck
CAN
service socket, they are configured for each motor respectively.
The units have the same inputs and outputs. The difference is that the are
programmed in different ways using the software controlling movement and
hydraulics.
The regulators handle
battery measurement that is used internally and rapport it as a CAN
message to MCU that calculates status that is then displayed in the CID
display via a CAN message.
Own temperature and motor temperature.
Any malfunctions are registered through internal monitoring and the
information is sent via CAN to the MCU, which registers the error code and
displays it on the CID display.
The regulators have a green LED to indicate status:
Start-up LED flashes twice
Normal operation LED remains lit
LED Status
Off The regulator has no power, or it has power but does not work
A warning has been generated. This may lead to a reduction in the maximum
Flashing slowly
power available to the motor
Step 4 Step 5
Method
1: Disconnect the power cables.
2: Disconnect the plastic yoke.
3: Undo the screws on the ACH that hold the yokes.
4: Turn the yokes over the ACH.
5: Remove the ACT
Method
1: Fit the ACT. Tightening torque 8Nm +- 1
2: Turn back the yokes.
3: Fit the yokes to the ACH. Tightening torque 8Nm +- 1.
4: Fit the power cables. Tightening torque 8Nm +-1.
5: Connect the plastic yoke.
6: Update the software.
Software update
Add the steps?
Step 4 Step 5
Method
1: Disconnect the power cables.
2: Disconnect the plastic yoke.
3: Disconnect the yokes to the ACT.
Method
1: Fit the ACH
2: Turn the yokes to the ACH
3: Connect the power cables. Tightening torque 8Nm +- 1
4: Connect the plastic yoke.
5: Tighten the yokes to the ACT. Tightening torque 8Nm +- 1.
6: Update the software.
Software update.
Add the steps.
Overview
Description
Fuses
Method
Description
Overview
Description
The mast wiring harness are the wires that provides the functions to the mast.
It goes from X14 in the reach carriage and all the way up to the fork carriage
valve where it joins Q9.
Overview
Q9
H3
Q9
X14
X14
Method
Dismantling
1: Lift the mast to unload the fork carriage. Use a wooden block or similar.
When this is done, removal of the wiring harness is easier since it is
slack.
2: Undo the spring tension of the wiring in the fork carriage
3: Disconnect the connector Q9 and release the wiring if it is fixed with
cable ties in the fork carriage
4: Follow the wiring to the hose/wire reel where you remove the jumping-off
protection. Then remove the wiring harness.
5: Follow the wiring down to the bottom of the mast, and unhook the
harness from the reel.
6: Remove 2 plastic covers at the wire grommet
7: Undo the spring tension of the wiring
8: Pull the wiring from the top hose/wire reel and down through the wiring
grommets so that the wiring lies to the side of the mast
9: Remove the cover
10: Cut away the cable ties holding the cable
11: Disconnect connector X14, and the mast harness is finally removed.
Assembly
1: Connect the wiring harness to connector X14 in the reach carriage
2: Trace the harness through the hole in the reach carriage and follow the
hoses upward.
3: Lay the harness along the hoses on the side of the mast up through the
cable grommet.
4: Lay the harness over the hose/wire reel and fit the jumping-off protection.
5: Fit the spring tensioner to the wiring harness
6: Pull the wiring down to the bottom of the mast and hook it on with the
steel wire.
7: Trace the wiring up to the hose/cable reel that is attached to the free lift
cylinder.
8: Fit the jumping-off protection
9: Trace the wiring to the fork carriage and connect it to connector Q9
10: Fit the spring tensioner to the wiring in the fork carriage.Fit the spring
tensioner to the wiring harness.
11: Fix the wiring in place using cable ties
Description
The mast wiring has a spring at each end that tensions the wiring. They must
be adjusted to 70mm 10
Both Triplex Hilo and Duplex Hilo have the same adjustment.
Overview
Description
The reach carriage wiring connects the mast with the valve and the main
wiring harness of the truck.
Overview
X13
X11
X12
X14
X15
Method
Dismantling
1: Disconnect the connector X13 to the main valve unit
2: Disconnect the connector X14 for the mast functions and if the truck is
equipped with height indicator, also disconnect the connector X15.
3: Remove 2 cable clips to remove the wiring harness.
4: Disconnect the connectors X11 and X12 that join the main wiring
harness of the truck.
Assembly
1: Start by connecting the wiring harness to connectors X11 and X12
2: Trace the wiring along the hydraulic hoses
The MCU [A5] is the main processor in the truck and communicates with the
traction regulator, the lift regulator, the steering servo and the displays via two
CAN networks. The truck parameter and error code settings are also stored
in the MCU. A back-up copy of the parameters is also saved in the CID.
The MCU monitors and regulates the truck functions relating to steering,
driving, braking, hydraulics, communication and various other things.
The TruckCom service program must be used for downloading new software.
See the separate manual for TruckCom.
The MCU is connected to both CAN1 and CAN2 and acts as a hub for CAN
communication between the various processors in the truck.
CAN1 is used for communication between the MCU and the various
displays (CID and LID), the fork control unit (FCU), the expansion unit
(GFU) and the options DHU and Shock Sensor.
CAN2 is used for communication between the MCU, the steering servo
(EPS), and the regulators (ACT and ACH).
A green LED indicates function status. The LED is situated between the two
JPT contacts and is visible from the outside. The LED indicates both
hardware and software status.
LED is lit Normal operation
LED
LED location
IConnections
There are two 42-pin contacts on the same side of the card X130 (Grey) and
X131 (Black).
1 14 1 14
15 28 15 28
29 42 29 42
X130 X131
X130:
X131:
31 Speed limitation 2 48 V In
End of aisle stop 2, drive wheel
32 48 V In
direction
33
34 Chassis fan 0 48 V Out:
35 Right-hand direction indicator 48 V Out:
36 Travel alarm 2, warning lamp 48 V Out:
Extra hydraulic valve 1A, battery
37 48 V Out:
change
38
39 Support arm brakes, inner 0 48 V PWM Out:
40 Valve for main mast lowering [Q4] 0 24 V PWM Out:
41
42 CAN1 low 0.5 2.5 V In/Out
Step 1 Step 2
Method
1: Disconnect the connectors to the MCU.
2: Remove the MCU.
Step 1 Step 2
Method
1: Fit the MCU
2: Disconnect the connectors.
Active area
The sensors have an active area, 25 25 mm, which is marked with the
symbol:
The sensitivity of the sensors is such that metallic objects within the area
0 6.5 mm are detected.
To avoid erroneous detection, there should be a free area around the
sensors active area:
d2
a sa
d1
d2
a sa
t
Pulse ratio = 50%
Phase ratio: One complete pulse is considered 360 and one channel's
pulses are always offset 90 30 in relation to the other's. The design of the
sensor determines how many such pulses are emitted by the sensor during
one revolution of the shaft.
Which of the channels, A or B, that is first, is determined by the shaft's
direction of rotation.
360
A
B
90
Phase ratio with anticlockwise rotation as seen from the steering wheel side.
Channel B goes high 90 before channel A.
Steering sensor
The steering sensor produces 64 pulses per channel when the shaft is
rotated one revolution.
Height measurement
The sensor bearing for height measurement produces 32 pulses per channel
when the shaft is rotated one revolution.
Description
When the emergency switch off [S21] is depressed, the main contactor [Q10]
and the key relay [K20] open. This is indicated on the truck Central
Information Display.
The user must log out before the truck can be activated again. If the truck is
started while the emergency switch off depressed, the emergency switch off
must be pulled up before the truck can be started.
DANGER!
Risk of short-circuiting.
The truck battery circuits are still live even if the emergency switch off is
depressed.
When working on the electrical system, the battery must be mechanically
disconnected.
Overview
Indications in CID
Indication on the Central Information Display when the emergency switch off
is depressed and the truck is in logged-in mode.
Method
It is necessary to remove some covers before it is possible to access the
emergency switch off for removal. (see the chapter Chassis for the removal
o covers)
Dismantling
1: Remove the connector
2: Remove the emergency switch off by undoing the nut holding the switch
Assembly
1: Fit the emergency switch off with a locknut
2: Connect the connector
Description
To prevent the risk of crushing, it is necessary to depress the safety pedal
[B31] in order to operate the truck.
F
Use the left foot to keep the safety pedal depressed while operating the
truck.
If the operator removes his foot from the safety pedal during operation, the
truck is plug braked. If the operator presses down the safety pedal again
within one second, the truck continues. If not, the operator must release the
accelerator and begin again.
If the truck has a cab with door, the safety pedal function is replaced by the
door, which must be closed.
MCU input X130:31 indicates safety pedal status.
X10
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X10
85/WH
6 2 X130:4 INP. BRAKE REFERENCE 1
X10
86/BK
3 X130:18 INP. BRAKE REFERENCE 2
X10
87/GY
1 4 X130:17 INP. ACCELERATOR SIGNAL
X10
55/RD
X130:1 OUT. +5VDC
Location
The safety pedal is positioned to the left of the accelerator and brake pedal,
see figure.
[B31]
Indication in CID
The status of the safety pedal input can be seen on the CID diagnostic screen
3, position 6:
The value should be 1.5 V 1% when the pedal is not actuated and 3.5 V 1%
when the pedal is activated.
5V
Never
Active
3,5V 1%
Always
Active
1,5V 1%
Step 1. Step 2.
n
s
Step 5. Step 7.
Required tools
Torx key T30
Screwdriver or similar
Method
1: Switch off the truck and disconnect the battery connector.
2: Disconnect the connector unit from the pedal unit.
3: Open up the pedal by loosening the locking lug in the front edge of the
pedal using a screwdriver.
4: Remove the pedal fixing screws (Torx T30) if the pedal must be replaced.
5: If the spring is to be changed, open up the pedal using a screwdriver.
Remove the broken spring and fit a new one.
6: Reassemble in reverse order.
7: Connect the battery and log in.
8: Check that it is not possible to drive the truck unless the pedal is
depressed.
Description
The operator is informed about the height of the forks via the truck height
indicator system. If the height indicator is activated, it is possible to have the
forks stop automatically at a preset lifting height. Height indication shows
current lift height, measured from the floor to the upper side of the forks. The
height is shown in the CID. The height is shown in increments of 2 cm. The
measuring starts in the main lift area when the reference sensor [B58] detects
that the mast separates and the input X131:2 of the MCU [A5] goes low (0V).
The reference sensor's (calibrated) height is shown on the CID and the pulse
transducer [B19] starts the calculation of the lift height by sending pulses to
the MCU. The lift height (in mm) is sent to CID via CAN. The pulse
transducers have two channels (A and B) which relay signals with 90 phase
difference. This gives the MCU information on whether the forks are moving
up or down. In order to work correctly, height measurement must be
calibrated
Monitoring
Height indication is monitored in several ways. The height measurement
system is monitored by the MCU that checks that pulses come when the
lifting or lowering function is requested. In addition, the measured height is
compared to the stored height of the reference sensors each time they are
passed during lowering to check that it is within the error tolerance (30 mm).
The MCU also monitors whether lifting or lowering speed is abnormal or the
reference signal is missing at the expected height. Incorrect maximum height
is also detected. If the truck is started after logout, the truck will remember the
height the forks had before logout and continues calculating from there. If the
battery was disconnected at some point before the truck is started, the height
is considered "unreliable" and both travel speed and lifting/lowering speed
are limited. The height is shown as "unreliable" on the CID by having a
symbol meaning that a reference value is required.
Speed is limited until the mast is lifted or lowered enough so that the
reference sensor
[B58] has passed the reference point (where the mast is divided/joined).
14.16 Calibration
2: De first box shows which lever to calibrate. Press the down arrow to the
second box to begin calibrating the lever.
3: Move the joystick as far forward as possible and press the green button.
The value is saved in the upper box to the right.
4: Release the joystick to the neutral position, and press the green button.
The value is saved in the middle box to the right.
5: Move the joystick as far back as possible and press the green button.
The value is saved in the lower box to the right.
6: Return to the box that shows which lever to calibrate and select the next
one with +/-.
8. Repeat for all levers the steps 3 to 5. If there are not enough levers for all
positions use the factory settings by selecting the symbol at the bottom
left and press the green button.
7: Log out and then in twice in order to synchronize the MCU and the CID.
When the default values are used, they are set to the nominal values (0.5V,
2.5V and 4.5V)
1: The truck must be switched off. Press the and this menu will be
tf f
displayed.
2: Press the up and down arrows to get to tf f and then press the green
button.
3: Press the up and down arrows to get to tf f and then press the green
button. This menu will be displayed
6: Now, lift the forks. They will slowly move upward and stop when the
sensor looses the signal.
7: Measure the height to the upper side of the fork manually as close as
possible to the mast.
8: Enter the measured value in the lower right box. Use down arrow to get
there and confirm the value with the green button. The confirmed value
will be moved to the top left box while the value in the bottom right box
will be changed to the level where the signal actually changed. (A few
mm below the measured height)
to get to this symbol and then press the green button to select
valve calibration.
2: The calibration value "S" means starting value and is in mA when the
valve opens or closes. The calibration value "E" means ending value in
% when the valve is open maximally.
Parameter 375
Decides the braking distance. It is the distance from a certain height when the
speed reduction begins.
Parameter 373
Decides the creep distance. It is the distance from a certain height when the
speed is reduced to creep speed.
Parameter 371
Determines the creep speed
Below follows a description on how to set the lifting height limitation.
1: Set the creep speed distance to 100mm (parameter 373)
2: 2) Select a height to define, and lift the forks to 100 mm from that height.
3: 3) Starting from standstill, lift the forks to the defined height. Adjust the
creep speed (parameter 371) if needed.
4: 4) Lower the forks ~ 2m.
5: 5) Set the braking distance to 500mm (parameter 375).
6: 6) Lift the forks to the defined height until they stop. Adjust the braking
distance so that the forks reach the pre-defined height without passing.
The aim is to have an as short a braking distance as possible.
Slut p avsnittet
15.2.1 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.
15.2.2 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.
15.2.3 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.
15.2.4 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
Overview
Note:
It is important that the instructions for connecting and disconnecting the
quick change connectors are followed. Otherwise, both the hose and insert in
the main valve unit must be replaced.
b
a
Pos. Description
a Disassembly ring
b Assembly stop
Step 1. Step 2.
Step 3.
Step 2. Step 3.
Step 4. Step 5.
Tredo seal
The nut/connection should be tightened by hand against the stop and then
tightened to the torque indicated in the table below.
Pipe coupling
Tighten the coupling by hand and then turn it another half turn to obtain the
correct tightening torque.
Coupling set in aluminium
Description
The hydraulic oil tank, which has a capacity of approx. 22 litres, is cast as a
single piece in polyethylene MD (Medium Density). The plastic is UV
stabilised and electrically conducting to lead away static electricity.
b
a
c
Hydraulic tank, with component parts, a: Dipstick, b: filter unit bracket,
c: Pump suction hose connection.
The tank is secured in the truck with screws from the battery compartment.
Max
Min
The oil tank dipstick has two notches to indicate the max. and min. levels of
oil respectively. This distance between the notches represents approx. 2 litre.
Step 1. Step 2.
Method
1: Use the blade of a screwdriver or similar to loosen the tank lid. Then
screw it off by hand.
2: Lift up the lid together with the oil filter.
3: Fill new, clean hydraulic oil according to specifications.
4: Eventually you may need to change the air and the oil filter (See the
section on replacing the oil filter)
Screw on the tank lid by hand.
Step 4 Step 5
Step 4
Method
1: Undo the hose clamp where the hose is connected to the pump
2: Undo the hose clamp where the hose is connected to the tank.
3: Remove the old hose and install a new one. Remember to always use
new hose clamps.
Overview
a
f
b
Pos. Description
a Air filter cover
b Cover
c Filter bridge
d Filter
e Filter holder
f Air filter
Description
The hydraulic oil from the hydraulic system and the tank breathing air are
filtered by the return filter.
Filtering is very important for the service life of the hydraulic oil and hydraulic
system. Filtering of the hydraulic oil is by means of a filter element with a filter
rating of 10 micrometres. Once the filter element is saturated with particles,
a bypass valve opens and the hydraulic oil goes straight to the tank,
bypassing the filter element without being filtered. The air filter and filter
element can be replaced.
Precondition
Motor compartment open.
Required tools
Screwdriver or similar, approx. 6 mm
Method
Note:
When replacing the oil filter, the metal filter holder must be reused. The new
filter must not be installed without a filter holder.
1: Use the blade of a screwdriver or similar to undo the lid. Then screw it off
by hand.
2: Lift off the cap and the filter.
3: Lift up the cover over the air filter and remove the filter element.
4: Insert a new filter element in the holder.
Description
The oil pump is an inner gear wheel pump with fixed displacement that is
driven directly by the pump motor.
The metal contact surfaces require very good lubrication, placing strict
requirements on the grade of hydraulic oil, and that the motor rpm does not
drop below a specified minimum value.
a b d
a C
d
B
Disassembly
1: Remove the screws (a).
2: Separate the hydraulic pump (b) from the motor (c)
3: Remove the driver (d)
Assembly
1: Fit the new driver (d) to the pump
2: Place the pump unit (b) on the pump motor (c).
3: Tighten the screws (a)
Note: take care not to pinch the O-ring
Replacing O-rings
a b d
Disassembly
1: Remove the screws (a).
2: Separate the hydraulic pump (c) from the motor (d)
3: Undo the suction connection (b) from the pump
4: Remove the O-rings
Assembly
1: Fit the new O-rings as per the figure above, and lubricate them lightly
with some grease
2: Fit the suction connection
3: Place the pump unit on the pump motor.
4: Tighten the screws (a)
Note: take care not to pinch the O-ring
Description
The main valve block is located in the reach carriage.
Overview
Pos. Description
A1 Reach function
B1 Reach function
H1 Free lift
H2 Main lift
H3 Main lift
A Extra function
B Extra function
Nipple for pressure
M
gauge
P Pump connection
T Tank connection
Q2 Lift valve main lift
Q4 Lowering valve main lift
Q6 Reach movement in
Q7 Reach movement out
Q18 Extra function A
Q19 Extra function B
15.8.1 Definitions
The various ranges for fork movement are free lift, transition and main lift.
Free lift is the range where only the free lift cylinder is working.
The main lift is the range beyond the free lift range where only the main lift
cylinders are working.
Note that free lift, transition and main lift denote the ranges, and not the extent
to which the forks move up or down.
Note:
A DX mast does not have free lift
Connection Type
P DN12
T DN12
H1 DN12
H2 DN10
H3 DN10
A1 DN10
B1 DN10
A DN06
B DN06
a
b
c
d
e
f
Tightening torque
Lift function
Overview
Description
The lift function is activated with valve Q2. The pump rotates clockwise and
the rotational speed controls the lifting speed. The pumps starts rotating with
60 RPM, and the flow through he valve increases proportionally with the
RPM.
Lowering function
Overview
Description
The lowering function is activated via the valve Q4, where the main lift first starts
emptying of fluid, and the free lift is them emptied. The signal is a PWM signal
proportional to the lowering speed with current control
Reach function
Pressure limitation
Disassembly
1: Disconnect connector X13
2: Remove all hoses
3: Use plugs to prevent any dirt to enter the connections of the valve unit.
4: Undo the 2 screws on top of the valve unit and then remove the valve
unit.
Assembly
1: Lift the valve unit into place in the reach carriage
2: Fix the valve unit in place using 2 screws.
3: Remove the plugs
4: Connect the hoses in their respective places
5: Assemble connector X13
6: Calibrate the valves.
Disassembly
1: Disconnect the connector X13
2: Disconnect the connector to the valve you intend to replace from
connector X13.
3: Undo the nut to the coil.
4: Remove the coil from the valve.
5: Remove the valve by undoing the nut.
6: Unscrew the valve.
Assembly
1: Screw the new valve in place.
2: Torque tighten to the correct value (See table on valve tightening
torques)
3: Fit the coil onto the valve.
4: Tighten the nut to a maximum of 6.8-9.5Nm
5: Connect the wire to connector to X13
6: Assemble connector X13
Lowering valve
Description
The main valve unit is found in the reach carriage, and the lowering valve is
the valve with green wires leading to it. It is the sole adjustable electric valve
in this truck. (See Adjusting the lowering valve)
1060 mm
4: Use a stopwatch to measure the time from when the lowest weight
touches the floor until the upper weight also touches the floor.
5: Lower the forks at the max. lowering speed.
6: The time measured in accordance with the above must be 2 seconds.
7: If the time deviates from 2 seconds, it is necessary to perform an
adjustment. Undo the locknut of the valve with a 3/8" (9.5mm) spanner.
Use a 2 mm Allen key to change the valve setting: clockwise turn
increases the time/reduces the lowering speed. Turning it anti-clockwise
reduces the time/increases the lowering speed. Tighten the lock-nut, and
repeat the procedure until the lowering speed is correct.
Overview
Disassembly:
1: Remove the valve using suitable tools
Assembly
1: Screw in a valve assembly, and torque tighten it to 44.7-50.2 Nm
Adjustment
To adjust the valve you need a 1/4" (6.4mm) Allen key and a 3/4" (19.1mm)
block spanner. The tightening torque for the counter-nut is 5 Nm +-1Nm.
To increase the pressure, the pressure limiting valve is adjusted clockwise,
and to lower the pressure, the valve is adjusted counter-clockwise.
Adjustment table
Note: Important information: Every turn equals 36 Bars, this may be used to
adjust the valve correctly.
Description
The valve is placed in the fork carriage and exists in two versions, one for fork tilting
and one for sideshifting.
Overview
Tilt function
Overview
Pos. Description
A,B Pressure port from main valve
1.2 User connection from tilting cylinder
Sideshift function
Pos. Description
A,B Pressure port from main valve
1.2 User connection from tilting cylinder
3.4 User connection from sideshift cylinder
Q9 On/Off valve, sideshift and tilt function
Overview
Disassembly
1: Remove the hose from the pump
2: Plug the pump connection
3: Undo 2 clips to release the hose.
4: Remove the hose from the valve.
5: Plug the hose connection
Assembly
1: Remove the plug from the valve
2: Fit the hose to the valve connection
3: Remove the plug to the connection in the pump
4: Fit the hose in the pump connection
5: Fit the 2 clips to release the hose.
Overview
Disassembly
1: Remove the hose from the tank
2: Plug the connection in the tank
3: Undo 2 clips to release the hose.
4: Remove the hose from the valve.
5: Plug the hose connection
Assembly
1: Remove the plug from the valve
2: Connect the hose to the valve
3: Remove the plug to the connection in the tank
4: Connect the hose to the tank
5: Fit the 2 clips to release the hose.
Overview
Disassembly
1: Unhook the hose from the bracket
2: Remove the hose from the cylinder
3: Plug the connection
4: Remove hose no. 1 at the split.
5: Remove hose no. 2 at the split
6: Remove the hose clips along the mast
7: Remove the hose from the valve
8: Plug the connection to the valve
Assembly
1: Remove the plugs at the valve connection
2: Connect the hose to the valve
3: Connect hose no. 2 at the split
4: Fit the hose clips along the mast
5: Connect hose no. 1 at the split
6: Connect the hose to the cylinder
7: Hook the hose to the bracket
Overview
Disassembly
1: Remove the hose from the cylinder
2: Plug the connection to the cylinder
3: Remove the hose to the valve unit
4: Plug the connection to the valve
Assembly
1: Remove the plug from the valve
2: Connect the hose to the valve
3: Remove the plug from the cylinder
4: Connect the hose to the cylinder
5: Wipe clean and test the functions.
Disassembly
1: Check that the tilt is in the lowered position
2: Remove the hydraulic pipe at the tilt cylinder
3: Plug the connection to the valve
4: Remove the hydraulic pipe at the control valve
5: Plug the connection
Assembly
1: Remove the plugs at the control valve connection
2: Fit the hydraulic pipe to the control valve
3: Remove the plugs on the tilt valve
4: Fit the hydraulic pipe to the tilt valve
5: Test the functions.
Overview
Cylinder nomenclature
c
d
Pos. Description
a Piston rod
b Cylinder head
c Air hose connection
d Circlip
e Cylinder pipe
f Piston
g Cylinder bottom
d
e
Pos. Description
a Wiper
b Piston rod seal
c Guide belt
d O-ring and stay ring
Pos. Description
a Guide belt
f
i
c
d
h
Step 4.
Step 5.
Tools required
Lint-free cleaning material
Ratchet handle
KM-socket KM8 or hook spanner
Method
1. Clean the cylinder from dirt, etc.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
2. Secure the cylinder pipe firmly and make sure that the piston and rod are
not jammed.
3. Loosen the cylinder head using a hook spanner or a KM socket.
4. Remove the cylinder head.
5. Carefully pull the piston rod out of the sheath pipe.
Method
Step 1. Step 2.
Step 3.
Step 4.
Method
The cylinder heads of the main lift cylinders can have different appearances.
The procedure for dismantling is similar for all models.
Note:
Be careful not to scratch the cylinder head.
1. Start by removing the wiper.
2. Remove the piston rod seal.
3. Remove the guide belt. The band has slits and can be removed by hand.
4. Turn the cylinder head and remove the O-ring and support ring.
Step 2. Step 3.
Step 4. Step 5.
Step 6.
Method
1. Make sure the correct seals are at hand and free from defects.
2. Clean the surfaces that are to have a new seal using lint-free material.
Check if there is any damage on the surfaces.
Note:
Never reuse old seals.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
Note:
Be careful with the seals that are sensitive. They must only be deformed
with soft bends.
3. Fit the O-ring and the supporting ring. Check that the supporting ring
ends up in the correct place.
4. Fit the guide belt.
5. Fit the piston rod seal. Make sure it is fitted the correct way round.
6. Fit the wiper. Make sure it locates correctly in its groove.
Step 2. Step 3.
Method
1. Make sure the correct guide belts are at hand and free from defects.
2. Clean the surfaces that are to have a new guide band using lint-free
material. Check if there is any damage on the surfaces.
Note:
Never reuse old guide bands.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
3. The guide band has slits and is easy to fit by hand.
Step 2.
Step 3. Step 4.
Tools required
Assembly grease, Kluber GL 261 or similar
Loctite 243
KM socket KM8
Tightening wrench, 150 Nm
Method
1. Lubricate the piston with hydraulic oil.
2. Fit the piston rod in the cylinder pipe.
3. Apply assembly grease to the wiper and guide belt in the cylinder head.
4. Fit the cylinder head onto the piston rod.
5. Apply Loctite 243 on the threads.
6. Tighten the cylinder head using the KM socket. Torque tighten to 150 Nm.
7. Fit the cylinder to the mast according to 15.12.9 Assembling a mast
cylinder
8. Check the cylinder for leakage by first running the main lift unloaded and
then loaded. There must be no leakage or uneven running.
g
b
a
f
i
c
d
h
Cylinder nomenclature
c
d
Pos. Description
a Piston rod
b Cylinder head
c Air hose connection
d Circlip
e Cylinder pipe
f Piston
g Cylinder bottom
Pos. Description
a Wiper
b Guide belt
Nomenclature for piston
Pos. Description
a Piston seal
b Guide belt
c Circlip
d Piston
Tools required
Step 1.
Step 3, KM 8/ = 58 mm.
Step 2.
Step 4.
Step 5.
Tools required
Lint-free cleaning material
hook spanner
Method
1. Clean the cylinder from dirt, etc.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
2. Secure the cylinder pipe firmly and make sure that the piston and rod are
not jammed.
3. Remove the cylinder head using a hook spanner.
4. Remove the cylinder head.
5. Carefully pull the piston rod out of the sheath pipe.
Method
1: The guide band is slit, and it is easy to remove by hand. Make sure that
you do not scratch the sealing surface.
.
Step 1. Step 2.
Method
Note:
Be careful not to scratch the cylinder head.
1. Start by removing the wiper.
2. Remove the guide belt. The band has slits and can be removed by hand.
Step 2. Step 3.
Step 4.
Method
1. Make sure the correct seals are at hand and free from defects.
2. Clean the surfaces that are to have a new seal using lint-free material.
Check if there is any damage on the surfaces.
Note:
Never reuse old seals.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
Note:
Be careful with the seals that are sensitive. They must only be deformed
with soft bends.
3. Fit the guide belt.
4. Fit the wiper. Make sure it locates correctly in its groove.
Step 2.
Step 3.
Step 4.
Method
1. Make sure the correct seals are at hand and free from defects.
2. Clean the surfaces that are to have a new seal using lint-free material.
Check if there is any damage on the surfaces.
Note:
Never reuse old seals.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
3. Fit the piston seal, make sure it is fitted the correct way round.
4. Fit the guide belt.
Step 2.
Step 3.
Step 4.
Step 5.
Step 7.
Step 6.
Tools required
Assembly grease, Kluber GL 261 or similar
Loctite 243
Hook spanner 150 Nm
Method
1. Lubricate the piston with hydraulic oil.
2. Fit the piston rod in the cylinder pipe. Push the piston only so far as to
conceal the circlip in the cylinder pipe.
3. Spray Decordyn 350 into the cylinder pipe, then press in the piston rod all
the way to the bottom.
4. Apply assembly grease to the wiper and guide belt in the cylinder head.
5. Fit the cylinder head onto the piston rod.
6. Apply Loctite 243 on the threads.
7. Tighten the cylinder head using the hook spanner. Torque tighten to 150
Nm.
8. Check the cylinder for leakage by first running the free lift unloaded and
then with a load. There must be no leakage or uneven running.
Overview
The reach cylinder is located in the reach carriage.
The reach cylinder is a double-acting cylinder.
The direction of the cylinder is governed by the main valve.
Cylinder nomenclature
b
c
d
e
f
Pos. Description
a Piston rod head
b Circlip
c Cylinder head
d Oil coupling x 2
e Piston rod
f Piston
g Locking nut
h Cylinder bottom
a
b
c
Pos. Description
a Wiper
b Seal
c Piston rod seal
d Guide belt
a
b
Pos. Description
a Pressure element
b Piston seal
c Guide belt
Step 3. Step 4.
Step 5.
Tools required
Lint-free cleaning material
Small screwdriver
Method
1. Empty the cylinder of oil and clean off any contaminants, etc .
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
2. Secure the cylinder pipe firmly and make sure that the piston and rod are
not jammed.
3. Press the cylinder head inwards.
4. There is a hole in the cylinder head to facilitate removal of the locking
ring. Use a small screwdriver and push out the locking ring.
Note:
Be careful not to damage the surfaces.
Carefully pull out the cylinder head, piston rod and piston.
Overview
The fork tilt cylinder is located on the mast behind the lower edge of the fork
yoke.
The cylinder is double-acting, which means it is the oil pressure that moves
the piston back and forth in the cylinder. When the piston is pressed out, the
lower edge of the fork yoke is moved outwards, and, in doing so, the forks are
tilted upwards.
n
s mm
Step 4: s = 17, n = 4
b
c
e
d
n
i
s mm f h
Step 6: s = 5, n = 2
g
j
m
n n
k l
s mm
Step 8: s = 6, n = 2
o
Method
Note:
Clean the surfaces around the cylinder connections before removing the
cylinder from the truck. When the oil couplings have been removed, the
cylinder couplings must be plugged to protect the cylinder from dirt.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
1. Raise the fork carriage to a comfortable working height.
2. Remove the forks.
3. Remove the spring clip for dismantling the side-shift (b) or rod (a).
4. Loosen the screws (k) and remove the stop lug (l).
5. Secure the fork yoke (c) with a rope and lift it out of the way using an
overhead crane.
6. Unscrew the screws (d) in order to remove the sliding block (f) and
remove plate (e).
7. Loosen the nut/screw (o)
8. Unscrew the screws (j) from the fork carriage (m).
9. Remove the tilt cylinder.
10. Knock out the tension pin (h) and remove the plate (g).
11. Remove the forks.
12. Remove the spring clip for dismantling the side-shift (b) or rod (a).
13. Loosen the screws (k) and remove the stop lug (l).
14. Secure the fork yoke (c) with a rope and lift it out of the way using an
overhead crane.
15. Unscrew the screws (d) in order to remove the sliding block (f) and
remove plate (e).
16. Loosen the nut/screw (o)
17. Unscrew the screws (j) from the fork carriage (m).
18. Remove the tilt cylinder.
19. Knock out the spring pin (h) and remove the plate (g)
n
s mm
Step 2: s = 6, n = 2
b
c
n e
d
s mm
Step 3: s = 5, n = 2
i
Mv = 10.2 Nm
f h
g
n j
m
s mm
Step 4: s = 6, n = 2
n
k l
n
s mm
Step 6: s = 17, n = 4 o
Method
Note:
When fitting these components, it is very important that no dirt etc. enters
the hydraulic system.
1. Fit plate (g) and lock it using the tension pin (h).
2. Fit the tilt cylinder with screws bolts (j).
3. Fit the gliding block (f) with screws (d) and fit the plate (e).
4. Tighten the gliding block with screw/nut (o) until the stud (n) can barely
rotate.
5. Lift the fork yoke (c) back into position using an overhead crane.
6. Fit the stop lug (i) with screws (k).
7. Refit the side-shift (b) or stay (a).
8. Attach the forks.
Overview
Sideshift is used to move the forks sideways. Instead of repositioning the
machine only the forks are moved to be in correct position to pick or deposit
the load. Movement is +/-75 mm. The cylinder, which is located on the fork
yoke, is double-acting, which means it is the oil pressure that moves the
piston back and forth in the cylinder.
15.17.1 Overview
Cylinder nomenclature
b
c
d
e
f
Pos. Description
a Piston rod head
b Circlip
c Cylinder head
d Oil coupling x 2
e Piston rod
f Piston
g Locking nut
h Cylinder bottom
a
b
c
Pos. Description
a Wiper
b Seal
c Piston rod seal
d Guide belt
a
b
Pos. Description
a Pressure element
b Piston seal
c Guide belt
Method
1. Put the truck in service mode and go to the pressure equalisation mode
in the service menu. Push the lifting lever to the lowering position to start
the pressure equalisation sequence. All the valves are opened slightly
and any residual pressure in the system is equalised.
2. Remove the forks.
3. Remove and plug the hydraulic lines onto the cylinder.
4. Use circlip pliers to remove the circlips from the cylinder spigots.
5. Remove the cylinder
Step 3. Step 4.
Step 5.
Tools required
Lint-free cleaning material
Small screwdriver
Method
1. Empty the cylinder of oil and clean off any contaminants, etc .
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
2. Secure the cylinder pipe firmly and make sure that the piston and rod are
not jammed.
3. Press the cylinder head inwards.
4. There is a hole in the cylinder head to facilitate removal of the locking
ring. Use a small screwdriver and push out the locking ring.
Note:
Be careful not to damage the surfaces.
Carefully pull out the cylinder head, piston rod and piston.
Step 1.
Tools required
Step 2. Step 3.
n
s mm
Step 6.
Tools required
Ratchet handle
Socket 19 mm
Method
1. Secure the piston rod onto the piston rod head. Make sure the rod also
has support.
Note:
Always protect the piston rod from sharp edges.
2. Remove the guide belt.
3. Remove the piston seal.
4. Remove the pressure element
5. Unscrew the locking nut, 1 X M12.
6. Remove the piston and cylinder head.
Note:
Make sure that the cylinder head surfaces are not damaged by the piston
rod thread.
7. Make sure that there is no other damage to the pipe and rod.
Step 1.
Step 2. Step 3.
Step 4.
Method
1. Start by removing the wiper.
2. Remove the piston rod seal.
3. Remove the guide belt. The band has slits and can be removed by hand.
4. Remove the last seal.
Note:
Be careful not to damage the surfaces.
Step 2.
Step 3. Step 4.
Step 5. Step 6.
Method
1. Make sure the correct seals are at hand and free from defects.
2. Clean the surfaces that are to have a new seal using lint-free material.
Check if there is any damage on the surfaces.
Note:
Never reuse old seals.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
Note:
Be careful with the seals that are sensitive. They must only be deformed
with soft bends.
3. Fit the seal.
4. Fit the guide belt.
5. Fit the piston rod seal. Make sure it is fitted the correct way round.
6. Fit the wiper. Check that it locates correctly in the groove.
n
s mm
Step 5. Step 6.
Step 7. Step 8.
Method
1. Cover the threads of the piston rod with a mounting ring. Apply assembly
grease inside the cylinder head and fit the cylinder head onto the piston
rod.
Note:
The wiper is very soft, so be careful that it does not bend when fitting.
2. Fit the piston onto the piston rod.
3. Fit the locking nut, 1 x M12, over the piston rod and tighten it to torque 60
Nm.
4. Make sure the correct seals are at hand and free from defects.
5. Clean the surfaces that are to have a new seal using lint-free material.
Check if there is any damage on the surfaces. Minor damage can be
removed by polishing with fine sandpaper.
Note:
Never reuse old seals.
Note:
Use a clean rag and make sure that no dust from the rag or other particles
that could damage the cylinder remain on the surface.
Note:
Be careful with the seals that are sensitive. They must only be deformed
with soft bends.
6. Fit the pressure element.
7. Fit the piston seal. Check that the pressure element and seal are fitted
correctly.
8. Fit the guide belt. The band has slits and can be fitted by hand.
Step 1. Step 2.
Step 3. Step 4.
Step 5.
Method
1. Lubricate the piston with hydraulic oil.
2. Fit the piston rod in the cylinder pipe.
3. Press the cylinder head inwards.
4. Fit the spring ring. Make sure it locates correctly.
5. Pull the piston rod backwards until the cylinder head returns to its correct
position.
6. Before the cylinder is taken into operation, it must be vented of air. This is
done by fitting the cylinder in the truck and letting it work 10 slow, full
strokes. There must be no leakage or uneven running.
16.1 Description
The mast and reach carriage are available in a number of different sizes that
can be combined in a specific way. The reach carriages and mast that are
suitable for the truck are determined by factors such as the width between the
support arms, load capacity and the lift height of the mast.
2: Attach the clinometer to the side of the mast and measure. Tolerance 6
min lateral inclination as per the figure
16.4.1 Check
Chain refers to the chain, chain anchor and lock between the chain and chain
anchor. The chain must unladen when it is inspected.
The chains are exposed 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.
Inspection
Cause/Identification Procedure
point
Replace if
Chain bolt Inspect the chain bolt
damaged
Chain bolt Replace if
Inspect cotter pins
locking damaged
Retighten the locking nuts to the correct
Chain mounting
torque and inspect the cotter pins.
Replace if the
chain cannot go
into the wheel or if
Check the flanges and marks/wear from
Chain wheel it can slip off the
the chain.
side of the wheel
(i.e. damage to
the flange)
If there has been insufficient lubrication,
Replace the
Noise there will be metallic friction on the chain
chain.
and this will result in noise.
Surface rust is easy to recognise as the
chain will be reddish brown. Deep-seated Replace the
Surface rust
rust has generally started and the strength chain.
of the chain is impaired.
Fretting corrosion results in a reddish-
brown powder being visible on the outer Replace the
Rusty links
plates. It can also look as if the chain chain.
bleeds if it is lubricated.
Inspection
Cause/Identification Procedure
point
P = Pitch.
H2 = Nominal disc height.
P
H3 = Minimum disc height
A new lifting chain has a specific nominal
disc height, defined as H2 in the figure. As
H2 H3 the truck is used, the lifting chain wears
radically on the side that runs over the
chain wheels. The minimum disc height is
defined as H3 in the figure and denotes the Replace the
Outline wear minimum permitted value of the disc chain.
height.
Maximum permitted outline wear is
5% of height H2. If a lifting chain
reaches the maximum level of wear,
the chain must be replaced.
The nominal and minimum disc heights for
the respective lifting chains are stated in
the table under Stretching.
Inspection
Cause/Identification Procedure
point
Inspection
Cause/Identification Procedure
point
16.4.2 Lubrication
Mineral and synthetic oils can be used to re-lubricate Rexnord chains.
Note:
The lubricant may not contain substances such as molybdenum disulphide,
PTFE or similar.
A lifting chain must be relieved of the weight of the fork carriage, hanging free,
when it is lubricated.
The chains are sprayed with lubricant. 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 lubricant must comply with the viscosity requirements at the respective
temperatures set out in the table below.
Note:
Do not use a special rust protective agent to preventrust on the lift chains.
These agents impair lubrication of the chains. Regular lubrication is the best
method to prevent rusting.
Ambient
Viscosity class Recommended products*
temperature
> -40C
VG 15 Klberoil 4UH 1-15, Klber Lubrication
< -30C
> -30C Klberoil 4UH 1-68N, Klber Lubrication
VG 68
< +5C Anticorit LBO 160 TT, Fuchs DEA
Klberoil 4UH 1-150N, Klber Lubrication
> +5C
VG 150 Anticorit LBO 160, Fuchs DEA
< +45C Rexoil, Rexnord Kette
> +45C
VG 220 Klberoil 4UH 1-220N, Klber Lubrication
< +80C
Method
1:
Method
1:
Method
1: List the mast to a suitable working height and secure the middle and
inner guides with blocks.
2: Retract the locking pin and remove the nuts on the lower part of the mast
chain.
3: Retract the locking pin and remove the nuts on the upper part of the mast
chain.
4: Pull the chain from the upper part of the mast so that the whole chain
comes out.
Method
1: Install the chain by first pulling it from the top, and then pulling
downwards.
2: Fit the screws and the locking pin to the upper part of the mast chain.
3: Fit the screws and the locking pin to the lower part of the mast chain.
Method
1: Lift the fork carriage and secure it with a block.
2: Disconnect the connector [Q19].
3: Cut up the tie straps and release the wiring.
4: Undo the jump-off protection on the roller above the free lift cylinder.
5: Disconnect the spring in the fork carriage.
6: Undo the cable fastener in the lower mast (there are wires)
7: Undo the fasteners and tie straps in the upper part of the mast to release
the wiring.
8: Pull the wiring outside the mast.
9: Remove the reach carriage cover.
10: Disconnect the connector [X14]
11: Pull out the wiring harness.
Method
1: Feed the mast wiring harness and connector [Q9] from below and along
the mast and keep the wiring harness on the right side of the twin hoses.
2: Continue through the mast beam and then via the underside of the twin
hoses and up onto the cable reel.
3: Feed the wiring harness so far that the spring bracket is level with the
bracket on the truck.
4: Attach the spring to the bracket.
5: Attach the two wires of the frame wiring harness to the lower cable plinth.
6: Continue with the frame wiring harness up and over the middle cable
roller.
7: Attach the next spring bracket inside the bracket of the fork carriage.
8: Connect cable connector [Q9] to the fork carriage connector.
9: Collect all superfluous wiring and tie it together with cable ties in a
suitable location.
10: Feed the remaining wiring harness to the reach carriage and connect
with connector X14
11: Collect all superfluous wiring in the reach carriage and tie it together with
cable tie
12: Fit the cover to the reach carriage.
13: Place the cable brackets on the studs.
14: Tie together the mast wiring harness and the twin hoses and the height
indication wiring harness 10 cm above and below each bracket
respectively.
2. Check the gap (c) between the stop lug and the fork yoke as well. At the
maximum tilt angle, the play must not exceed 1 mm.
3. Inspect and adjust the gap by inserting a 1 mm feeler gauge between the
fork yoke and the stop lug. The feeler gauge can be removed when the
forks are tilted down. Tighten the four screws to 45 11 Nm.
4. The gap can be adjusted with the screws on the stop lug and then locked
(see the screws and locks marked with arrows)
Step 1
Step 2
Step 3
Step 4
Method
Start by lifting the fork carriage to a suitable work height before proceeding
with the exchange and removal of the forks.
1: Remove two hoses from the cylinder and remove the cylinder attached to
the fork carriage and the fork yoke.
2: Remove two fork stops
3: Remove the tilt stop that is attached with four screws.
4: Use suitable lifting equipment and lift out the fork yoke. Remember to lift
out the yoke from the fork carriage at the same time as you lift so that it
does not catch anywhere.
5: Lift in the new fork yoke. Also remember to hold out the fork yoke in order
to guide it into place.
6: Perform steps 1 to 3 in reverse order to finish off the replacement and fit
the forks.
16.7.1 Overview
a
b
d
L
e
c
Inspection
The forks must be thoroughly inspected by trained personnel. The aim of an
inspection is to discover any damage, malfunctions, deformation or similar
that may impair safety. A fork with such defects must be taken out of service
and must not be used until it has been repaired in a satisfactory manner and,
where necessary, tested. See section "16.7.3 Repairs and testing".
Inspection intervals
Forks in operation must be inspected at intervals of no more than twelve
months and whenever a defect or permanent deformation is discovered. In
the case of demanding applications, more frequent inspections may be
necessary.
Surface cracks
The fork (a) must be subjected to a thorough visual inspection for cracks and,
if necessary, a non-destructive crack detection check. Pay particular attention
to the upper and lower hooks (c and d), including their attachments to the
back of the fork carriage (b). The fork must be taken out of service if surface
cracks are discovered.
c
b
Position lock
Check that the position lock (if included in the delivery) is in good condition
and fully functional. If any fault is found, the fork must be taken out of service
until it has been repaired in a satisfactory manner.
Marking legibility
If the marking on a fork as per ISO 2330 is not clearly legible, the fork must
be taken out of service.
Excerpt from ISO 2330:
10 Marking
Label
10.1 At the position indicated in the figure (on either face), each fork
shall be marked permanently with the following:
a) the specified fork arm capacity C, in kilograms;
b) the specified load centre D, in millimetres;
c) the manufacturer's identification;
d) the month and year of manufacture or the agreed serial number.
10.2 The truck manufacturer's identification and part number may
be shown if needed.
c
b
Repairs
Only the fork manufacturer or a specialist of equivalent expertise may
determine if the fork may be repaired and then used again. Repairs must only
be carried out in accordance with the recommendations of the fork
manufacturer. It is not recommended that surface cracks or wear be repaired
by welding. If repairs are required to rectify the fork, the fork may then need
to be heat-treated in a suitable manner.
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
B32
B31
Figure 7
B49
S89
X47
Comfort
X26
Basic
Figure 8
12V
X44 24V
F66
X21
Figure 9
B17
X21
X22
B90
Figure 10
X24
P5
27
126
X21
Figure 11
Red
Blue
40
109
X50
Black
Red
Figure 12
A1 A2
27
X20:2
192
E4
X20:1
E3
Figure 13
X15 X14
X13
X11
X12
Figure 14
B58
B19
X15
Figure 15
Duplex mast
Q9
X14
Figure 16
Triplex mast.
Q9
X14
17.3 Connections
Connections, CID
Connection Function
X503:1 OUT 5VDC
X503:7 Ground, analogue
X503:8 Height limit
X504:2 Steering sensor 2B
X504:3 IN Earth
X504:4 Steering sensor 1B
X504:5 Earth steering sensor
X504:6 CAN L 1
X504:8 CAN L 1
X504:9 CAN H 1
X504:11 Steering sensor 2A
X504:12 +5VDC steering sensor 2
X504:13 steering sensor 1 A
X504:14 +5VDC steering sensor 1
X504:15 CAN H1
X504:16 Status emergency switch
X504:17 OUT key relay
X504:18 +48VDC
X505:1 OUT +5VDC
X505:2 Lever lifting/lowering
X505:3 Sideshift
X505:4 Travel direction switch
X505:5 Horn
X505:10 Ground, analogue
X505:11 Reach movement
X505:17 Tilt
Connections, MCU
Connection Wires Designation Active In/
Out
X130:1 55 Current source +5 V 5V Out:
X130:4 85 Brake pedal, reference 1 (min.max.) 0.5-4.5 V In
X130:5 70 Voltage measurement, battery 48 V In
X130:6 90 Ground, analogue 0V
X130:8 220 CAN2 low 0.5-2.5 V In/Out
X130:12 75 Height sensor - forks, upper free lift, pulse A 48 V In
1)
Connections, MCU
Connection Wires Designation Active In/
Out
X131:24 Output, reach carriage, out
X131:25 Output, horn
X131:27 119 Earth, service key 4.5-2.5 V In/Out
X131:34 34 Fan, chassis 0-48 V Out:
X131:37 62 Valve for AUX, direction A 0-48 V Out:
X131:38 66 Valve for fork tilt/fork reach carriage 0-48 V Out:
X131:42 120 CAN1 low 0.5-2.5 V In/Out
1.
Connections, EPS
X901:2 CAN high 2
X901:3 Out 12VDC for reference sensor
X901:6 Input possible
X901:7 Ground
X901:8 +48VDC
X901:10 CAN low 2
X901:11 Input reference steering
X504:12 OUT earth for reference sensor
X504:15 Ground
X504:16 +48VDC
40
X1 G1 X1
1 1 + -
32
21
32
F73
7,5A
21
7,5A
26
F61
21
A1
1
K20
A2
2
3A Q10
25 F60 20 1
S21
2 21
8
250A 7,5A
27 27 2 1 F1 F71
8 B+
ACT 25
8
40 B-
T1
1
27
14 92
B1
Q1
11 27 1 2
105 U
Q2
10 V
M DRIVE MOTOR 1 2
40
85 +12V DC SUPPLY
B11 M1
1 2 12 103 W Q6
1 2
+ B
Q7
27
4 3 13 104 220
CAN 2 L 100
1 2
- A
219 Q9
CAN 2 H 99
120?
1 2
8
B+ B19
40
B- ACH
19 92
B2
T2
16 PUMP MOTOR
105
M3
41 88 GND ID B58
U
27
1 2
41 89 INP. CONTROLLER ID
V
M
3
W
15 85 +12V DC SUPPLY
27
B12
1 2 17 103
+ B
B31
1
4 3 18 104 CAN 2 L
220 3
2
- A
90/BU
27
40
1 4
30A
F72
(X901:8) +48VDC POWER SUPPLY
3A
(X901:16) +48VDC POWER SUPPLY EPS
F64 9
(X901:6) INP.ENABLE A2
40 (X901:7) GND POWER
40 (X901:15) GND POWER M
203 (X901:3 OUT. 12DC FOR REFERENCE SENSOR M6
B17
27
G3 CAN 2
27 1 2
M
G4
27 +
M -
7,5A
F62
40
32
21
MCU A5
40 (X131:14) GND, POWER
40
22 (X131:1) INP.+48VDC POWER MCU
21E.S.O. STATUS (X131:5)
32
PTC
24
(X504:9) +48VDC POWER
23 (X131:15) MAIN CONT./CAP CH.
40
59
(X131:21) OUT. MAST LIFT
P4 42 (X504:16) +5VDC, STEER SENSOR 1
60 (X131:10) OUT. REACH IN
OUT.HORN (X131:25) 88 3 1
4 2 B13
61 (X131:24 )OUT.(PWM) REACH OUT 3 43 (X504:13)
1 STEER SENSOR 1 PULSE A
62 (X131:38) OUT. AUX + A
63
OUT.AUX Dir. A (X131:37) 126 45 4 B 44 (X504:11)
OUT. TRAVEL ALARM (X131:23)
- 2
STEER SENSOR 1 PULSE B
+ B35 WH/OR
66 OUT.AUX Dir. B (X131:11) INP.HORN REQUEST (X503:6) 2 A6 Sig.
INP. +5VDC 1
-
45 (X504:3) GND, STEER SENSORS
29 INP.TRAVEL DIR. + B36
(X130:37) OUT.+15VDC CHANGE REQUEST (X503:1) 3 Sig. INP. GND 4 BU
-
75 (X130:12) INP.HEIGHT SENSOR Main Lift A 46 (X504:15) +5VDC, STEER SENSOR 2
6 48
45 8 (X504:12) STEER SENSOR 2 PULSE B
27
B
30 (X130:20)OUT.GND.DIGITAL - OUT. +5V (X505:1) 1
A60
INP.+5VDC +
B20
SIG.
73 (X131:2) INP. LIFT HEIGHT REF. OUT. GND (X505:2) 2 INP.GND -
B21
INP.LIFT/LOWER (X505:3) 3 OUT.B20 +
SIG.
INP.REACH IN/OUT (X505:4) 4 OUT.B21 -
B22
INP.TILT (X505:5) 5 OUT.B22 +
SIG.
CAN1
117
15v (X130:23)
119 (X504:1) CAN1 H
119 R102 120?
H (X131:27) 120 (X504:10) CAN1 L
R101 120?
L (X131:42) 120 118
CAN 1
CAN2
218
(X130:33) Gnd 117
219 1 CAN 1
(X130:22) H BU
220
(X130:8) L
2 SERVICE KEY
119
3 X41
33 OUT. FAN, CONTROLLERS (131:9)
120 4
CAN 1
34 OUT. FAN, CHASSIS (X131:34
27
Pictur
Pos. Component type Function Other
e
1 Valve unit Main valve block
Fork carriage
2 Valve unit
valve
3 Lift cylinder Free lift Piston cylinder
4 Lifting cylinder Main lift Plunge cylinder
5 Pump Oil pump
6 Tank hydraulic oil tank
Return ripe oil
7 Filter
filter
Electro-hydraulic pump
8 Motor
motor
Non-return valve, spring- Safety valve free Gives a controlled lowering
9
loaded (hose rupture valve) lift speed in case of a broken hose
Non-return valve, spring- Safety valve Gives a controlled lowering
10
loaded (hose rupture valve) mainlift speed in case of a broken hose
3.
9.
10.
2.
8.
5.
6.
7.
1.
Cv1
A1
Cv2 B1
B
H3
H1 Q6
Q7 H2
T
P
Q19
Q18 Rv2
Q4 Q2 A
Rv1
1
2
3
4
Q9
A B
Pos. Description
1 Tilting connection
2 Tilting connection
3 Side shift connection
4 Side shift connection
A Extra function connection
B Extra function connection
Q9 Side shift movement
18.4.1
19. Tools
19.1 AMP connectors
PT = Power Timer (4.8, 5.8, 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tool for crimping pins
2=213549 (JPT) For 0.52.5 mm2
1
2
1
2
183593 Pin/sleeve removal tool
Tool Usage
7513225 Service instrument (CAN)
Tool Usage
651154 Support block
1/4" 254526 Plugs (male part) for valves with WEO type
3/8" 254527 quick change connector
1/2" 254528
Tool Usage
7509180 Door latch
Tool Usage
651217 Inclinometer for mast tilt
Tool Usage
11-1021 Lifting tool for mast guide
0
38
Slut p avsnittet
Strength class:
8.8 10.9 12.9
M3 1.1 1.6 2.0
M4 2.8 3.8 4.7
M5 5.5 7.7 9.3
M6 9.5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075
Strength class:
8.8 10.9 12.9
M3 1.2 1.7 2.1
M4 2.9 4.0 4.9
M5 5.7 8.1 9.7
M6 9.8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
Ambient Viscosity
Recommended products* Usage
temperature class
> -40C
VG 15 Klberoil 4UH 1-15, Klber Lubrication Chains
< -30C
> -30C Klberoil 4UH 1-68N, Klber Lubrication
VG 68 Chains
< +5C Anticorit LBO 160 TT, Fuchs DEA
Klberoil 4UH 1-150N, Klber Lubrication
> +5C
VG 150 Anticorit LBO 160, Fuchs DEA Chains
< +45C Rexoil, Rexnord Kette
> +45C
VG 220 Klberoil 4UH 1-220N, Klber Lubrication Chains
< +80C
Slut p avsnittet
Weight with
Weight without Weight with Weight without
Lifting Lifting fork carriage
fork carriage fork carriage fork carriage
height, mm height, mm (kg)
(kg) (kg) (kg)
21.4.1
h1
h4
h 23
h3
h6
h2
l7
h7
b1
b4
b3
h8 b5
h13 s e
m1 m2
l2
y
l l2 wa
l1