R112 114 116 - 7575392 040

Repair manual 7575392-040
R112, R114, R116.

Document revisions:
Issue date Order Changes

number
Chapter 6: Updated with instructions for PIN codes
Bleeding the system
Chapter 8: Error codes 4:180-4:187 and 5:181-5:184
Troubleshooting
Chapter 9: Information on tilt stops
Chapter 14: Description of the height system
2015-10-01 7575392-040
New information symbols (180- and 360-degree steering)
Chapter 15: Adjustment table for pressure limiting valve
Chapter 16: Replacing the free lift chain
Chapter 20: Update with sensor B46
Chapter 22: Updated part number for Castor-USB
Chapter 23: Lubricant specification for motor shaft
Chapter 7 - Updating the maintenance schedule.
2016-10-24 7575392-040 Chapter 15 - Updating the tightening torque when replacing the
hose rupture valve, 15.12.2.
This manual contains information on the following trucks:
Model T-Code Valid from serial number

R112, R114,
1006 6308581
R116
Cesab T Codes(s): 1006

Repair manual: Table of content Model(s): R112, R114, R116
Publication Number: 7575392-040 Date: 2016-10-24 Applies from serial number: 6308581
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
Cesab 1 1 T Code(s): 1006

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
7.7.6 ..................................................................................................... 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

9.6 Operator's seat C0620............................................................................... 917

9.6.1 Overview ...................................................................................... 917
9.6.2 Description ................................................................................... 917
9.6.3 Replacing the operators seat (Basic) .......................................... 918
9.6.4 Seat switch ................................................................................... 924
9.6.5 Replacing the backrest, chair seat ............................................... 926
9.6.6 Replacing the seat plate............................................................... 929
9.7 Operator controls C0640 ........................................................................... 931
9.7.1 Overview ...................................................................................... 931
9.7.2 Description ................................................................................... 931
9.7.3 Preconditions................................................................................ 931
9.7.4 Accelerator/Brake pedal ............................................................... 932
9.7.5 Safety pedal ................................................................................. 933
9.8 Interior fittings C0680 ................................................................................ 935
9.9 Mirrors C0740 ............................................................................................ 935
9.10 Overhead guard/Roof C0810 .................................................................. 935
9.10.1 Overview .................................................................................... 935
9.10.2 Description ................................................................................. 936
9.10.3 Replacing the overhead guard roof ............................................ 936
9.10.4 Replacing the front roof support ................................................. 938
9.10.5 Replacing the rear roof support.................................................. 940
9.11 Finger-foot guard C0820 ......................................................................... 941
10. Motors C1000.............................................................................................. 101
10.1 Overview.................................................................................................. 101
10.2 Description............................................................................................... 101
10.3 Electric pump motor C1710 ..................................................................... 102
10.3.1 Overview .................................................................................... 102
10.3.2 Description ................................................................................. 103
10.3.3 Replacing the pump motor ......................................................... 104
10.3.4 Replacing the temperature sensor ............................................. 109
10.4 Steering motor C1730 ........................................................................... 1011
10.4.1 Overview .................................................................................. 1011
10.4.2 Description ............................................................................... 1012
10.4.3 Layout of the flange holes ........................................................ 1014
10.4.4 Steering servo motor replacement ........................................... 1015
10.5 Electric fan motor / fan........................................................................... 1018
10.5.1 Fan for frequency converter ..................................................... 1018
10.5.2 Replacing the frequency converter fan..................................... 1019
10.5.3 Motor compartment fan ............................................................ 1021
10.5.4 Replacing the motor compartment fan ..................................... 1022
10.6 Electric drive motor C1760 .................................................................... 1024
10.6.1 Overview .................................................................................. 1024
10.6.2 Description ............................................................................... 1025
10.6.3 Replacing the drive motor ........................................................ 1026
10.6.4 Replacing the temperature sensor ........................................... 1028
10.6.5 Replacing the RPM-sensor. ..................................................... 1030

11. Mechanical Drive Gear Unit C2000 .......................................................... 111

11.1 Overview.................................................................................................. 111
11.2 Description............................................................................................... 112
11.3 Checking the oil level............................................................................... 113
11.4 Oil change ............................................................................................... 115
11.5 Leakage from the lower cover ................................................................. 117
11.6 Replacing the drive gear.......................................................................... 118
11.6.1 Removing the drive gear ............................................................ 118
11.6.2 Fitting the drive gear................................................................. 1110
11.7 Replacing the Steering bearings ........................................................... 1111
12. Brake system/Wheels C3000..................................................................... 121
12.1 Brake system C3100 ............................................................................... 121
12.1.1 Overview .................................................................................... 121
12.1.2 Description ................................................................................. 122
12.1.3 Drive motor brake (travel brake)................................................. 123
12.2 Parking brake C3370 ............................................................................... 124
12.2.1 Overview .................................................................................... 124
12.2.2 Description ................................................................................. 125
12.2.3 Replacing the parking brake....................................................... 126
12.2.4 Replacing the dust plug.............................................................. 128
12.2.5 Replacing the hub .................................................................... 1210
12.2.6 Replacing the rubber gaiter ...................................................... 1212
12.2.7 Checking the parking brake's brake force ................................ 1214
12.2.8 Checking the parking brake air gap.......................................... 1215
12.3 Wheels C3500 ....................................................................................... 1216
12.3.1 Description ............................................................................... 1216
12.3.2 Wheel wear .............................................................................. 1217
12.4 Drive wheel C3530 ................................................................................ 1217
12.4.1 Overview .................................................................................. 1217
12.4.2 Replacing the drive wheel ........................................................ 1218
12.5 Support arm wheel C3550 ..................................................................... 1221
12.5.1 Overview .................................................................................. 1221
12.5.2 Replacing an unbraked support arm wheel .............................. 1222
12.5.3 Replacing bearings................................................................... 1224
12.5.4 Replacing the wheel bolt .......................................................... 1226
13. Steering system C4000.............................................................................. 131
13.1 Description............................................................................................... 131
13.2 Electric steering wheel C4310 ................................................................. 132
13.2.1 Overview .................................................................................... 132
13.2.2 Description ................................................................................. 132
13.2.3 Adjustment ................................................................................. 133
13.2.4 Replacing pulse transducer [B13] .............................................. 134
13.2.5 Replacing the steering console .................................................. 135
13.2.6 Replacing the wiring harness in the steering console ................ 137
13.2.7 Fit the steering console in the truck............................................ 139
13.2.8 Replacing the steering wheel ..................................................... 139
13.3 Steering unit C4330 ............................................................................... 1310
13.3.1 Description ............................................................................... 1310
13.4 Steering reference sensor (4350) .......................................................... 1310
13.4.1 Replacing the reference sensor [B17] ...................................... 1311

14. Electrical system C5000 ............................................................................ 141

14.1 Description............................................................................................... 141
14.2 OTP ......................................................................................................... 141
14.3 Battery C5110.......................................................................................... 141
14.3.1 Battery recommendations .......................................................... 141
14.3.2 Measuring discharge current ...................................................... 141
14.3.3 Measuring voltage ...................................................................... 141
14.3.4 Charging the battery ................................................................... 141
14.3.5 BDI algorithm and parameter setting.......................................... 143
14.3.6 Performance limitations due to battery status ............................ 143
14.3.7 Performance limitations due to battery status
and parameter setting .......................................................................... 143
14.3.8 CID symbol................................................................................. 143
14.3.9 Resetting the battery indicator (BDI) .......................................... 143
14.3.10 Battery weight........................................................................... 143
14.3.11 Parameter overview, battery .................................................... 144
14.3.12 Battery cable harness............................................................... 144
14.3.13 Battery cable replacement, machine part ................................. 145
14.3.14 Battery cable replacement, battery part ................................... 146
14.4 Signal / Alarm (Sound-light) C5160 ......................................................... 147
14.4.1 Horn............................................................................................ 147
14.4.2 Replacing the horn ..................................................................... 148
14.5 Main contactor C5190 ............................................................................. 149
14.5.1 Replacing the contactor.............................................................. 149
14.6 Instrument panel C5200 ........................................................................ 1410
14.6.1 Operating controls .................................................................... 1411
14.6.2 Replacing the operating controls .............................................. 1411
14.6.3 Replacing the switch for travel direction selection / horn ......... 1413
14.6.4 Replacing the controls on the operating panel ......................... 1413
14.6.5 Central Information Display (CID) ............................................ 1413
14.6.6 Replacing the CID .................................................................... 1422
14.7 Height indication .................................................................................... 1423
14.7.1 Replacing the sensor bearing................................................... 1424
14.7.2 Replacing the height reference sensor..................................... 1424
14.7.3 Hight indication wire ................................................................. 1425
14.7.4 Check and adjust the wire ........................................................ 1426
14.7.5 Replacing the height indication wiring ...................................... 1426
14.8 Travel function wiring/ fuse C5390 ........................................................ 1427
14.8.1 Chassis wiring .......................................................................... 1427
14.8.2 Operator control wiring ............................................................. 1428
14.9 Drive motor cables/resistor/fuse C5430 ................................................ 1428
14.9.1 Replacing motor cables............................................................ 1428
14.10 Transistor panel C5460 ....................................................................... 1429
14.10.1 Replacing the ACT ................................................................. 1431
14.10.2 Replacing ACH. ...................................................................... 1433
14.11 Work function harnesses / fuse C5590................................................ 1435
14.11.1 Fuse panel.............................................................................. 1435
14.11.2 Checking fuses ....................................................................... 1436
14.11.3 Roof wiring ............................................................................. 1437
14.11.4 Replacing the roof wiring ........................................................ 1437
14.11.5 Mast wiring ............................................................................. 1437
14.11.6 Replacing the mast harness ................................................... 1438
14.11.7 Check and adjust the mast wiring .......................................... 1440
14.11.8 Reach carriage wiring............................................................. 1441

14.12 Main processor MCU C5710 ............................................................ 1442

14.12.1 Replacing the MCU ................................................................ 1446
14.13 Sending units and sensors C5800....................................................... 1448
14.13.1 Inductive sensors ................................................................... 1448
14.13.2 Position sensor ....................................................................... 1448
14.13.3 Pressure sensor ..................................................................... 1450
14.13.4 Pulse transducer .................................................................... 1450
14.14 Safety sensor / - sensors C5830 ......................................................... 1452
14.14.1 Emergency switch off ............................................................. 1452
14.14.2 Emergency switch off [S21] .................................................... 1452
14.14.3 Safety pedal [B31] .................................................................. 1454
14.15 Height measurement system ............................................................... 1458
14.16 Calibration ........................................................................................... 1459
14.16.1 Calibration of the joystick ....................................................... 1459
14.16.2 Height measurement/reach movement length calibration ...... 1460
14.16.3 Reference sensor, main lift. (Screen 1) .................................. 1460
14.16.4 Pulse length for main lift sensor bearing (Screen 2) .............. 1461
14.16.5 Max. lift height. (Screen 3) ..................................................... 1461
14.16.6 Calibration of the reach carriage extension ............................ 1461
14.16.7 Valve calibration ..................................................................... 1462
14.16.8 Lowering valve, starting value. (Screen 1-S).......................... 1462
14.16.9 Lowering valve, final value. (Screen 1-E) ............................... 1462
14.16.10 Lifting height limiting............................................................. 1463
15. Hydraulic system C6000............................................................................ 151
15.1 General .................................................................................................... 151
15.2 Hydraulic hygiene .................................................................................... 151
15.2.1 Washing ..................................................................................... 151
15.2.2 Packaging................................................................................... 152
15.2.3 Handling ..................................................................................... 152
15.2.4 Storage....................................................................................... 152
15.2.5 Work procedures ........................................................................ 152
15.3 Bleeding the air from the hydraulic system.............................................. 153
15.4 Hose inspection ....................................................................................... 153
15.5 Hydraulic couplings C6230 ...................................................................... 153
15.5.1 Quick change connectors ........................................................... 154
15.5.2 Tightening torques for hydraulic connections ............................. 156
15.6 Hydraulic unit C6100 ............................................................................... 159
15.6.1 Hydraulic oil tank C6110 ............................................................ 159
15.6.2 Hydraulic hoses C6120 ............................................................ 1513
15.6.3 Filter C6130.............................................................................. 1514
15.7 Hydraulic pump C6140 .......................................................................... 1516
15.7.1 Replacing the hydraulic pump .................................................. 1517
15.7.2 Replacing the driver ................................................................. 1518
15.8 Main valve unit C6210 ........................................................................... 1520
15.8.1 Definitions................................................................................. 1522
15.8.2 Replacing a complete valve unit............................................... 1526
15.8.3 Replacing a valve ..................................................................... 1526
15.9 Control valve C6220 .............................................................................. 1532
15.10 Chassis-mounted hydraulic hoses C6230 ........................................... 1534
15.10.1 Replacing the supply hose ..................................................... 1534
15.10.2 Replacing the return hose ...................................................... 1534
15.11 Mast hydraulic conduits C6320 ........................................................... 1535
15.11.1 Fork carriage .......................................................................... 1536

15.12 Main lift cylinder C6610 ....................................................................... 1539

15.12.1 Removing the air cylinder from the mast ................................ 1541
15.12.2 Replacing the hose rupture valve ........................................... 1542
15.12.3 Dismantling the cylinder ......................................................... 1543
15.12.4 Dismantling the piston. ........................................................... 1544
15.12.5 Dismantling the cylinder head ................................................ 1545
15.12.6 Fitting the cylinder head seals. ............................................... 1547
15.12.7 Fitting the piston guide belt .................................................... 1548
15.12.8 Assembling the cylinder ......................................................... 1549
15.12.9 Assembling a mast cylinder.................................................... 1551
15.13 Free lift cylinder C6620........................................................................ 1553
15.13.1 Removing the free lift cylinder from the truck ......................... 1555
15.13.2 Replacing the hose rupture valve, free lift cylinder................. 1555
15.13.3 Dismantling the cylinder ......................................................... 1556
15.13.4 Dismantling the piston ............................................................ 1557
15.13.5 Dismantling the cylinder head ................................................ 1558
15.13.7 Fitting the piston seals............................................................ 1561
15.13.9 Assembling the free lift cylinder in the mast ........................... 1564
15.14 Reach/telescopic cylinder C6650 ........................................................ 1565
15.14.1 Removing the reach cylinder from the truck ........................... 1568
15.15 Dismantling the cylinder ...................................................................... 1569
15.15.1 Fitting the reach cylinder in the truck...................................... 1570
15.16 Tilting cylinder C6660 .......................................................................... 1571
15.16.1 Remove the tilt cylinder from the truck ................................... 1572
15.16.2 Fit the tilt cylinder in the truck ................................................. 1574
15.17 Sideshift cylinder C6670...................................................................... 1575
15.17.1 Overview ................................................................................ 1576
15.17.2 Dismantling the cylinder from the truck .................................. 1578
15.18 Dismantling the cylinder ...................................................................... 1579
15.18.1 Removing the piston rod ........................................................ 1581
15.18.3 Mounting the piston rod .......................................................... 1587
15.18.5 Refitting the cylinder in the truck ............................................ 1590
16. Mast C7000 ................................................................................................. 161
16.1 Description............................................................................................... 161
16.1.1 The available combinations of truck and mast. .......................... 162
16.1.2 Ordering replacement masts ...................................................... 162
16.1.3 Mast type and weight ................................................................. 162
16.2 Installing a mast in a newly delivered truck ............................................. 162
16.2.1 Adjusting/setting mast inclination ............................................... 163
16.3 Main mast C7100 .................................................................................... 164
16.4 Main lifting chain system C7120 .............................................................. 164
16.4.1 Check ......................................................................................... 164
16.4.2 Lubrication.................................................................................. 168
16.4.3 Replacing the free lift chain ........................................................ 169
16.4.4 Replacing the mast chain ......................................................... 1611
16.4.5 Replacing the mast harness..................................................... 1613

16.5 Fork carriage C7130 .............................................................................. 1615

16.5.1 Checking the fork carriages wear strip .................................... 1615
16.5.2 Lubricating the fork carriage..................................................... 1616
16.5.3 Replacing the fork yoke............................................................ 1617
16.6 Main mast suspension C7190 ............................................................... 1618
16.7 Forks C7410 .......................................................................................... 1618
16.7.1 Overview .................................................................................. 1618
16.7.2 Inspection procedures .............................................................. 1618
16.7.3 Repairs and testing .................................................................. 1622
17. Wiring diagram ........................................................................................... 171
17.1 Component list......................................................................................... 171
17.2 Component location................................................................................. 175
17.3 Connections........................................................................................... 1716
17.3.1 ACT [T1] ................................................................................... 1716
17.3.2 ACH [T2]................................................................................... 1716
17.3.3 CID [A1].................................................................................... 1717
17.3.4 MCU [A5].................................................................................. 1718
17.3.5 Fuse panel [A9] ........................................................................ 1719
17.3.6 Steering motor [ [A2] ................................................................ 1719
17.4 General wiring diagram ......................................................................... 1720
17.5 Detailed diagrams.................................................................................. 1722
18. Hydraulics schematics .............................................................................. 181
18.1 Component list......................................................................................... 181
18.2 Component location................................................................................. 182
18.3 Valve unit ................................................................................................. 183
18.3.1 Main valve unit ........................................................................... 183
18.3.2 Fork carriage valve..................................................................... 184
18.4 Hydraulics schematics ............................................................................. 185
18.4.1 ................................................................................................... 185
19. Tools............................................................................................................ 191
19.1 AMP connectors ...................................................................................... 191
19.2 MQS contacts .......................................................................................... 192
19.3 CPC contacts........................................................................................... 194
19.4 Other tools ............................................................................................... 195
20. Service data and grease specifications ................................................... 201
20.1 General tightening torques ...................................................................... 201
20.1.1 Galvanised, non-oiled screws .................................................... 201
20.1.2 Untreated, oiled screws.............................................................. 201
20.2 Oil and grease specification .................................................................... 202
21. Technical data ............................................................................................ 211
21.1 Mast type and weight (kg) ....................................................................... 213
21.2 IP classes on components and units ....................................................... 213
21.3 Battery sizes ............................................................................................ 214
21.4 Truck dimensions .................................................................................... 215
21.4.1 ................................................................................................... 215

Repair manual: General introduction Model(s): R112, R114, R116
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
Abbreviation Meaning Des. Explanation

ACH Alternate Current Hydraulic [T2] Motor control, hydraulics.
ACT Alternate Current Traction [T1] Motor control, drive.
BDI Battery Discharge Indicator Unit indicating the state of battery charge.
A standardised interface that enable
CAN Controller Area Network
communication between different electrical units.
Display with menu-based information system that
CID Central Information Display [A1] is used as the primary communication tool
between operator and truck.
DX Duplex Mast with two sections.
EPS Electronic Power Steering [A2] Complete steering servo with its own motor control.
ESO Emergency Switch Off [S21] Emergency switch off.
FCM Fuse Central Module [A9] Fuse panel.
FCU Fork Control Unit [A7] Unit for fork functions.
GFU General Function Unit [A8] Unit for general functions.
HPS Height Pre-Select Height pre-selection
Display that provides the operator information such
LID Load Information Display [P6]
as lift height, load weight and height preselection.
MCU Main Control Unit [A5] Main control unit.
PDA Personal Digital Assistant A compact, portable handheld computer.
PPS Personal Protection System Personal protection system.
Positive Temperature Electrical property that causes resistance to
PTC
Coefficient increase with temperature.
SF Shuttle Forks Telescopic fork unit.
Means that the instruction/chapter will be
TBD To Be Defined
supplemented at a later date.
TH Turret Head Turret head fork unit
Toyota Wireless Information
TWIS
System
TX Triplex
VNA Very Narrow Aisle Narrow aisles
VRE Very narrow aisle Rider Electric

2.3 Warning symbols

The following warning symbols are used in the repair manual:
DANGER!
DANGER! means there is a risk of accident potentially leading to death or
serious injury and material loss or damage. This is always indicated by the
warning symbol.
WARNING!
WARNING! means that there is a risk of damage to components that are
sensitive to electrostatic discharge.
Heed applicable ESD safety regulations.
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.
Identification of tools for screws and nuts

Symbols to identify tools to be used for screws/nuts:
Symbol Designation
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
Unit may be repaired without any

limitations.
Unit has limited ability to be repaired.

Larger repairs require special tools,
specialist knowledge or are not
economically feasible.
Repair of the unit requires specialist

knowledge or special equipment.
Only complete units may be replaced.

2.4.3 Other pictograms
Symbol Procedure Symbol Procedure
Visual inspection of
condition, wear and loose Component replacement.
connections.
Cleaning Measurement
Check of fluid level and Check that bolts, nuts, etc.

check for leaks. are tightened to torque.
Listening for noise. Lubrication, application.
Check of functions. Calibration
Adjustment Welding
Disassembly/removal Assembly/installation

An example of another type of pictogram is Cut cable ties:
Additional information under the pictogram can, for example, indicate the
number of cable ties to be cut.
Slut p avsnittet


Repair manual: General safety rules Model(s): R112, R114, R116
3. General safety rules

Only personnel trained in servicing and repair of this type of truck are
authorised to carry out service and repair activities.
3.1 Work safety

To make work safer and prevent accidents, always keep the following in
mind:
Keep the maintenance work site clean. Oil and water on the floor will make
it slippery.
Use the correct working posture. Service work often involves sitting on
your knees or bending over forwards. Try sitting on a toolbox, for example,
to relieve the strain on your knees and back.
Loose items and jewellery can get caught in moving parts of the truck. So
never wear loose articles or jewellery while working on the truck.
Exercise caution and always follow applicable local regulations when
working at high heights.
Use the correct tools for the work you are carrying out.
Keep all tools well maintained.
Make sure that all safety equipment including guards and covers are
properly secured and that they work as intended before starting the repair
work. If a guard or cover must be removed in order to perform the repair
work, extra care must be taken, and when the repair work is finished the
guard or cover must be refitted.
Relieve the system pressure slowly before starting work on the trucks
hydraulic system.
Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hands.
Drive unit oil and the hydraulic system oil may be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Allow the truck to cool down before changing the oil.
Only fill the hydraulic system with new and clean oil.
DANGER!
Risk of damage to the hydraulic system.
If the oil is contaminated, the hydraulic components will suffer damage.
Always use new and clean oil in the hydraulic system.
Store and transport changed oil according to applicable local directions.
Do not flush solvents, etc. down the drain unless they are intended to be
disposed of in this way.
Follow local disposal regulations.

Disconnect the battery prior to performing any welding work on the truck.
NOTE:
The battery could be damaged.
When welding with an electric welding unit, welding current may enter the
battery.
The battery must be disconnected.
Prior to welding or grinding on painted surfaces, be sure to remove the
paint at least 100 mm around the welding/grinding area by using
sandblasting equipment or paint remover.
DANGER!
Harmful gasses.
Heated paint gives off harmful gases.
Remove paint 100 mm around the welding/grinding location.

3.2 Electrical system

When working on the electrical system of the truck, remember the following:
Never wear loose items or jewellery when working with the truck.
DANGER!
Short-circuiting/Burn injury.
Short circuits and burn injuries can occur if metal objects come into contact
with live electrical connections when working on the truck's electrical
system.
Remove wristwatches, rings and other metal objects beforehand.
Always use insulated tools when working on the electrical system.
Always disconnect the battery before opening any covers to drive units or
the electrical system.
Always disconnect the battery prior to welding work using an electric
welding unit. The welding current may damage the battery.
Always disconnect the battery when carrying out maintenance or repair
work on the truck unless otherwise stated in this repair manual.
Clean electric motors using a rag or a vacuum cleaner.
Clean electrical panels, electronic cards, contactors, contacts, magnetic
valves, etc. with a dampened cloth and a cleaning agent that will not
damage the part.
NOTE:
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the logic cards.

3.3 Safe lifting

All lifting must be carried out on a level, non-slip and stable surface. Asphalt
surfaces should be avoided if possible.
To prevent the truck moving while it is being lifted, it must not be lifted with
anyone on the platform or with the tiller arm in the lowered position.
If the drive wheel, which is braked, is being lifted the other wheels must be
chocked to stop the truck from moving.
Select the lifting point so that the lift is as easy as possible, for example lifting
one corner at a time. If the truck has marked lifting points on the lower part of
the chassis, these must be used to ensure balanced lifting.
Make sure the surface where the jack is placed is clean and free of oil and
grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. If the lever is too short, more
exertion than is necessary will be required. If the lever is too long, there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing since a poorly supported truck could fall down.
Never work under a truck that is not supported by trestles and secured by a
lifting device.
Support the truck:
as close to the lifted part of the chassis as possible in order to reduce the
falling height if the truck should collapse
so the truck cannot move.
Never support the jack on trestles to achieve a higher lift.
Never work under a raised truck without it being properly supported on
trestles.

3.4 Truck modifications

Any modification of the truck must be approved beforehand. No modification
of truck may be performed that may influence the capacity, stability and safety
of the truck without prior written approval from the manufacturer, its
representative or successor.
In the case of the manufacturer no longer being in business and there being
no successor, the user of the truck may arrange for modifications on the
precondition that the user:
makes sure that an engineer with expert knowledge of industrial trucks
and their safety designs, tests and implements the modification,
files all documentation of the designs, tests and implementation of the
modification,
approves and makes the applicable changes to the capacity plate,
adhesive labels, markings and operators manual and
affixes a permanent and well visible sign to the truck stating how the truck
has been modified, together with the date of the modification and the
name and address of the company that carried out the modification work.
Slut p avsnittet


Repair manual: Operation and connection sequences Model(s): R112, R114, R116
4. Operation and connection sequences

4.1 Description
The logic cards for the truck contain microprocessors that detect switch
settings, control voltages, etc. and provide instructions for external electronic
components, relays, valves, etc.
To safeguard all preset information in the electronic module when the battery
is disconnected, all information is stored in an EEPROM circuit, i.e.non-
volatile memory. The MCU has a real time clock, which is powered by an
internal battery. Any faults detected by the microprocessor are shown on the
display.
The truck can be switched to three different operating modes:
Normal mode
Service mode
Emergency driving mode
Each of these modes is separately described in this document.
Event: 1. Battery is connected

Action(s) The battery [G1] is connected using battery cables, [X1]
Influencing elements Main contactor [Q10] off
Key relay [K20] off
Fuse [F60] +48 VDC ESO Circuit OK
Resulting conditions Login possible.
Login method controlled by parameter 503.

Event: 2a. Login via keypad

Prior event 1. Battery is connected
Action(s) The operator enters a four or five-figure PIN code, depending on the
parameter setting, + Enter green button
Influencing elements Parameter 503 = 3 or 4
CID displays:
Parameter 503 = 5 or 6
CID displays:
Resulting conditions Login approved:

CID shows a status image for approx. 2 seconds:
Main contactor [Q10] on

Key relay [K20] on
Login rejected:
CID displays:
Main contactor [Q10] off

Key relay [K20] off

Event: 2b. Login to emergency driving mode

Prior event 1. Battery is connected
Action(s) From the login screen, i is pressed, so that the CID displays the Information
screen. On the information screen, select:
and then press the green button

After the green button has been pressed, the screen shows Emergency travel
mode login and a PIN code must be entered:
Influencing elements
Resulting conditions CID shows a status image for approx. 2 seconds:
Main contactor [Q10] on

Key relay [K20] on
Event: 3. Driving in fork direction

Action(s) The travel direction selector [B36] is moved towards the forks and input
A1-X503:1 increases from approximately 2.6 V to approximately 4.7 V.
The accelerator [B32] is pressed down and input A5-X130:17 is
activated.
Influencing elements Operator parameter 3: Maximum speed in fork direction.
Operator parameter 4: Acceleration.
Emergency login.
Resulting conditions The CID's indication for driving and fork direction comes on.
Output A5-X131:12 is increased to approximately +48 V and the
mechanical brake [Q1] is released.
The drive motor is supplied with three-phase voltage from the
transistor regulator [T1].

Event: 4. Driving in the drive wheel direction

Action(s) The travel direction selector [B36] is moved towards the drive wheel
and input A1-X505:4 decreases from approximately 2.6 V to
approximately 0.6 V.
The accelerator [B32] is pressed down and input A5-X130:17 is
activated.
Influencing elements Operator parameter 2: Maximum speed in drive wheel direction.
Operator parameter 4: Acceleration.
Emergency login.
Resulting conditions The CID's indication for driving and drive wheel direction comes on.
Output A5-X131:12 is increased to approximately +48 V and the
mechanical brake [Q1] is released.
The drive motor is supplied with three-phase voltage from the
Event: 6. Braking in neutral

Prior event 4. Driving in fork direction
or
5. Driving in drive wheel direction
Action(s) The accelerator [B32] is released and input A5-X130:17 is activated.
Influencing elements Operator parameter 5: Automatic braking.
Resulting conditions The frequency of the drive motor three-phase voltage is reduced.
Event: 7. Reverse braking

or
5. Driving in the drive wheel direction
or
6. Braking in neutral
Action(s) The travel direction selector [B36] is moved to the position opposite to
the travel direction and input A1-X505:4 is changed from
approximately 2.6 V to approximately 0.6 V or to approximately 4.7 V.
Service parameter 201: Reversing
Resulting conditions The frequency of the drive motor three-phase voltage is reduced to
change the phase sequence when the motor is idling, and then
increases to a frequency that is comparable to the amount the
accelerator is pressed down.

Event: 8. Pressing on the brake pedal

or
5. Driving in the drive wheel direction
or
6. Braking in neutral
Action(s) The brake pedal [B32] is pressed down and this affects inputs A5-X130:4
& A5-X130:18 in that the voltage is increased at one of them and
reduced to a comparable degree at the other.
Depressing the brake pedal
Resulting conditions The frequency of the drive motor three-phase voltage is reduced.
When the brake pedal is pressed down more than 90% of its possible
maximum travel:
The voltage of output A5-X131:12 is reduced, and the plug brake is
activated, and at a speed of 1.5km/h, the mechanical brake [Q1] is
activated.
When stationary:
When the pedal is pressed down more than 90% of its possible
maximum travel, the voltage at output A5-X131:12 is reduced and the
mechanical brake [Q1] is activated.
Event: 9. Reach carriage operation: Out:

Action(s) The control for the reach carriage [B21] is moved away from the
operator, and input A1-X505:4 increases from approximately 2.6 V to
approximately 4.7 V at the end position of the control.
Resulting conditions The pump motor is supplied with three-phase voltage from the
Voltage is reduced on output A5- X131:24 :OUT.REACH OUT
Current flows through the proportional valve [Q7]
The proportional valve [Q7] is opened in proportion to the current
flowing through it.

Event: 10. Steering

Action(s) The steering wheel is rotated taking effect on the following inputs:
A1-X504:13 STEER SENSOR 1 PULSE A
A1-X504:4 STEER SENSOR 1 PULSE B
A1-X504:11 STEER SENSOR 2 PULSE A
A1-X504:2 STEER SENSOR 2 PULSE B
Resulting conditions Information is sent via the CAN bus to the steering servo electronics.
The motor of the steering servo turns the drive unit so that speed and
direction corresponds to the movements of the steering wheel.
Event: 11. Reach carriage operation: In

Action(s) The control for the reach carriage [B21] is moved towards the operator and
input A1-X505:4 is reduced from approximately 2.6 V to approximately 0.6
V at the end position of the control.
Resulting conditions The pump motor is supplied with three-phase voltage from the transistor
regulator [T2].
Voltage is reduced on output A5- X131:10 :OUT.REACH IN.
Current flows through the proportional valve [Q6]
The proportional valve [Q6] is opened in proportion to the current flowing
through it.

Event: 12. Fork lifting

Action(s) The control for the fork lift [B20] is moved towards the operator, and
input A1-X505:3 is reduced from approximately 2.6 V to approximately
0.6 V at the end position of the control.
Resulting conditions The pump motor is supplied with three-phase voltage from the transistor
regulator [T2].
Voltage is reduced on output A5- X131:21 OUT MAST LIFT).
Current through the On/Off valve Q2 and the mast begins to lift.
Event: 13. Fork lowering

Action(s) The control for fork lift [B20] is moved away from the operator, and
input A1-X505:2 increases from approximately 2.6 V to approximately
Resulting conditions Main lift:
Output A5-131:21 OUT(PWM) MAIN MAST LOWER reduces the
voltage
Voltage is maintained on output T2- 108 OUT.(PWM) MAST LOWER
The proportional valve [Q4] is opened in proportion to the current
flowing through it
If the truck is equipped with a height indicator:
The speed between the main lift and the free lift is reduced when it
enters this range.

Event: 14. Fork tilt, backwards/upwards

Action(s) The control for fork tilt [B22] is moved towards the operator and input
A1-X505:5 is reduced from approximately 2.6 V to approximately 0.6 V
at the end position of the control.
Output A5-X131:37 OUT.AUX DIRECTION A reduces the voltage.
Output A5-X131:11 OUT.AUX DIRECTION B remains high.
Current flows through the coil [Q18].
The tilt cylinder is pressurised via the non-return valve.
No current flows through the coil [Q9].
Event: 15. Fork tilt, forward/downward

Action(s) The control for fork tilt [B22] is moved away from the operator and input
A1-X505:5 increases from approximately 2.6 V to approximately 4.7 V
Resulting conditions Output A5-X131:37 OUT.AUX DIRECTION A remains high.
Output A5-X131:11 OUT.AUX DIRECTION B reduces the voltage.
The oil in the tilting cylinder is drained to the tank.
No current flows through the coil [Q9].
Event: 16. Sideshift, right

Action(s) The control for side-shift [B23] is moved towards the operator and input
A1-X505:6 is reduced from approximately 2.6 V to approximately 0.6 V
Influencing elements Sideshift as an optional function.
Output A5-X131:37 OUT.AUX DIRECTION A remains high.
Output A5-X131:11 OUT.AUX DIRECTION B reduces the voltage.
Voltage is reduced at output A5-X131:38 OUT.AUX.
The piston rod end of the sideshift cylinder is drained to the tank.

Event: 17. Sideshift, left

Action(s) The control for side-shift [B23] is moved away from the operator and
input A1-X505:6 increases from approximately 2.6 V to approximately
Influencing elements Sideshift as an optional function.
Output A5-X131:11 OUT.AUX DIRECTION B remains high.
Output A5-X131:37 OUT.AUX DIRECTION A reduces the voltage.
Voltage is reduced at output A5-X131:38 OUT.AUX.
The piston rod end of the sideshift cylinder is pressurised.
Event: 18. Logout

Prior event 2. Login
Action(s) The operator presses the red button.
Resulting conditions The login screen is displayed and login is possible.
The screen to be displayed is determined by service parameter 503.
Event: 19. Emergency lowering

Prior event
Action(s) The emergency lowering valve is opened mechanically.
Resulting conditions Oil flows from the free and main lift cylinders, via the emergency
lowering valve, to the tank.


Repair manual: Parameters Model(s): R112, R114, R116
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.

5.2 Parameter settings

To be able to change operator parameters without a service key, parameter
503 must be set to 3 or 5.
With the service key, you can change operator parameters by going to the
configuration menu and then selecting the parameter to be changed for a
specific operator profile.
Without the service key, via the configuration menu you can read the value of
a parameter, but not change it.

Parameter menu (PAR)
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).

5.3 Operator parameters

The operator parameters for the logged-in operator profile can be set from
the Operator parameter menu.
a
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.
For parameters 2 to 5, a row of bars are displayed. The number of bars

depends on how many steps the selected parameter can be adjusted by. The
filled bars show the current parameter value.
When parameter values are chosen, the selected value is indicated by an
arrow above the bar for that value. The value is changed using the +/- keys
and is stored when the green button is pressed.

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
Connection to logged-in operator

The operator parameters can be adjusted individually to the available log-in
profiles. The parameters connection to the operator is done by a combination
of operator and parameter numbers where the single digit always
corresponds to the parameter.
Parameter
Operator
range
1 1 10
2 11 20
3 21 30
4 31 40
5 41 50
6 51 60
7 61 70
8 71 80
9 81 90
10 91 100

s
10
9
8
7
6
5
4
3
2
1
v
s: steering sensitivity, v: travel speed,

snail: low speed range, hare: high speed range
If the steering feels too sluggish or unresponsive in any of the low or high
speed ranges, the corresponding value is changed upwards or downwards
through the setup screen for driver parameter 1.
On the setup screen, the low speed range is represented by a snail and the
high speed range by a hare.
Defa Maxi Incre
Par. Description Min. Unit
ult mum ment
1L Steering movement in 1 5 10 1
relation to steering wheel
1H movement, parameter 1 5 10 1
screen display
1 257 1285 2570 1

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
Help table for steering parameter readout in TruckCom

The parameter shown via TruckCom is a combination of the sensitivity values
low speed and for high speed.
Valid combinations can be read out by seeking the value in the table and read
off the value for the snail and the hare.
Examples:
1538 gives parameter values for low speed = 2 and high speed = 6.

5.3.2 Description
Parameter 2, 3 Maximum travel speed

These two parameters are used to limit the maximum travel speed for the
logged-in operator profile.
For parameters 2 and 3, 100% corresponds to a travel speed of 10 and 9 km/
h respectively
Defa Maxi Incre
ult mum ment
Maximum speed, drive wheel
2 1 10 10 1 10%
direction
Maximum speed, fork
3 1 10 10 1 10%
direction
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.
Parameters 4 and 5 Acceleration/Deceleration

These two parameters can be used to get a smoother acceleration/
retardation where the application or operator profile so requires.
Defa Maxi Incre
ult mum ment
4 Acceleration 3 8 10 1 10%
Automatic braking at
5 3 8 10 1 10%
reduction of speed control

5.4 Service parameters
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
Parameter 101/104 Service/Log-out

Defa Maxi Incre
ult mum ment
101 Service intervals 0 0 5000 1 h
104 Time to automatic log-out 0 20 120 1 min
Parameter 101 gives the truck's service interval in B-hours.

Use this parameter to determine the service interval of the truck. The buzzer
sounds and a spanner is shown on the CID when the service counter is at
zero. The counter shows the time that has passed since the last service
intervention.
If an earlier service intervention is required, simply activate this parameter
without adjusting the time.
If the value is set to '0', then no service interval is set and the CID's hour meter
screen does not show the 'S' field Remaining time to service.
Parameter 104 gives the time, in minutes, before automatic log-out takes
place if the truck is inactive.
If the value is set as 0, logout takes place after 4 hours.

Parameter 107/108 Battery

Defa Maxi Incre
ult mum ment
107 Battery size 1 9 20 1
Battery status when
108 acceleration and lift speed 0 5 20 5 %
are limited
Parameter 107 specifies the capacity of the battery on the truck.

The parameter can be used to compensate for different ways of driving by:
increasing the value to discharge the battery even more
reducing the value if the battery is discharged too much.
For recommended parameter settings see the table below.
Value: R116 Battery
9 620A
11 465A
14 310A
It is necessary to specify the type of battery the truck is equipped with. In

order to set the meter for the batterys level of discharge, the following should
be taken into account:
Acid density when the battery is fully charged, to check the quality of
battery. This value should be in the range 1.27-1.29.
Please note that the acid density may vary between different battery
brands.
When the lifting capability is reduced (the battery discharged to 80 %) the
value should be close to 1.14 but not lower.
Freely ventilated batteries
See the table for recommended parameter settings for free ventilated
batteries.
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.

Verifying the parameter setting for freely ventilated batteries

1. Charge the battery.
2. Operate the truck in its normal application until the battery indicator
indicates a discharged battery (0% in the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
hours.
Note:
Do not allow any charging or discharging during this time.
4. Measure the acid weight of the battery at room temperature.
If the acid weight is less than 1.14 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.
Battery type Battery voltage while resting, Uend

Hawker Evolution 48.48 V

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 105/106/114/115/117 (Travel alarms 1 and 2)

There are two dedicated outputs for travel alarm on the MCU. One has by
default been assigned to the buzzer and one to the warning lamp. Both can
be configured regarding frequency and activation pattern.
Note:
The "travel alarm 1" function is activated by parameter 1104 and the "travel
alarm 2" function is activated by parameter 1102.
Defa Maxi Incre

ult mum ment
Frequency for output of travel
105 0 1 2 1
alarm 1
Frequency for output of travel
106 0 0 2 1
alarm 2
Activation pattern for travel
114 0 0 255 1
alarm 1 X131:23
Activation pattern for travel
115 0 0 255 1
alarm 2 X131:36
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

Parameters 109/110/111/112/117 Collision sensor

Be sure to set the parameters for collision sensitivity upon installation of the
truck.
If a collision sensor is installed on the CAN bus, this registers when the truck
bumps against something. If a collision exceeds a certain force, set by
parameters 110 and 111, it is interpreted as a collision, and the truck speed
is reduced to creep speed, a signal is heard and error code 2:106 is
displayed. For setting how the alarm is to be given when the collision sensor
is activated, see parameter 117.
Information about the collision is stored in the truck's internal memory. The
last ten registered collisions can be displayed together with operator identity
via the PIN code. Additional information is available via TruckCom where
collision levels and time indications can also be read.
See the table below for information about the possible values:
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Resetting procedure for
109 0 0 4 2
logged data
Collision sensor sensitivity in
110 0 0 100 1
the X-axis (forward/reverse)
Collision sensor sensitivity in
111 0 0 100 1
the Y-axis (right/left)
Resetting procedure after
112 0 0 1 1
collision
117 Collision sensor's alarm 0 0 1 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
X-direction is movements in the truck's fork/drive wheel line and Y-direction

is movements sideways.
Note:
If the parameter value for the collision sensor is set to 0 (zero), this will
disable the collision sensor function as well the logging function. This
should only be done when T.W.I.S. is present.
Practical tests have shown that a value of 15 or higher corresponds to a
powerful collision. The absolute value is, however, affected by local
conditions and driving style and therefore a different value may be necessary.
Parameter 112 states the condition for how the truck is to be taken into
operation again after the collision sensors have been triggered:
Value Function
0 Login with a special PIN code is required
1 The truck must be restarted
The PIN code required to reset the collision sensor is entered in the login
profile Block: 10, Profile: 1.
Service parameters, travel functions

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.
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Braking force when reversing
201 50 100 100 10 %
the travel direction
Parameter 202/203/204 Adjusting erroneous, maximum travel speeds
These parameters are used to reduce the speeds which are normally set as
maximum travel speeds in connection with warnings or faults.
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Adjusting the crawl speed
202
max. 2.5 km/h
Adjusting the half-speed max.
203 30 100 100 10 %
4 km/h
Adjusting the safety speed
204
max. 1.3 km/h
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.
Parameter 208 - Creep speed in travel direction control

With this parameter, the creep speed function can be removed in the travel
direction control. This function is available when the travel direction selection
is activated for 1 second.

The parking brake must first be released before the truck can begin to travel.
If '0' is indicated, then the feature will be inactive.
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Creep speed in travel direction
208 0 1 1 1
control activated (1 km/h)
Value Function
0 Inactivated
1 Activated
Parameter 213 Permanently reduced maximum travel speed

Parameter 213 can be used to adjust the trucks maximum travel speed
permanently.
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Setting the trucks maximum 0.1
213 0 100 100 5
travel speed km/h

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.
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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
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OTP speed reduction when
degree
215 cornering, 1 5 45 1
s
initial angle
degree
216 cornering, 1 44 45 1
s
final angle

Service parameters, hydraulics

Overview
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
Parameters 301/302 Extra valve function

These parameters are used for setting which functions and valves the
hydraulic lever will activate.
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301 Extra valve function 1 0 0 3 1
302 Extra valve function 2 0 1 3 1
Value Valve Note

1 Q9
Switches the function between the valves,
2 Q18/Q19
which changes the direction of movement.
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.

Parameters 305/306 Maximum oil pressure through valve Q18

These parameters set the max oil pressure for the valve(s) that have been

chosen for use in parameters 301 - 302.

The oil comes via valve Q18, output A on the main valve block.
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Extra valve function 1, output
305 A. Maximum oil pressure 10 100/82 100 1
through valve Q18
Extra valve function 2 output A.
306 Maximum oil pressure through 10 100/82 100 1
valve Q18
Parameters 309/310 Maximum oil pressure through valve Q19

These parameters set the max oil pressure for the valve(s) that have been
The oil comes via valve Q19, output B on the main valve block.
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309 B. Maximum oil pressure 10 100/82 100 1
through valve Q19
Extra valve function 2 output B.
310 Maximum oil pressure through 10 100/82 100 1
valve Q19
Parameters 313/314 Closing time
These parameters set the time for the closing of the valve(s) that have been
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Extra valve function 1, time for
313 closing valve selected in 0 25 100 1
parameter 301
Extra valve function 2, time for
314 closing valve selected in 0 50 100 1
parameter 302
Parameters 317/318 Maximum oil flow through valve Q18

These parameters set the max oil flow for the valve(s) that have been chosen
for use in parameters 301 - 302.
The oil comes via valve Q18, output A on the main valve block.

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317 A. Maximum oil flow through 12 69 300 1
valve Q18
318 A. Maximum oil flow through 12 50 300 1
valve Q18
Parameters 321/322 Maximum oil flow through valve Q19

These parameters set the max oil flow for the valve(s) that have been chosen
for use in parameters 301 - 302.
The oil comes via valve Q19, output B on the main valve block.
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321 B. Maximum oil flow through 12 47 300 1
valve Q19
322 B. Maximum oil flow through 12 40 300 1
valve Q19
Parameters 325/326 Opening/closing time valve Q19
These parameters set the opening and closing times for valve Q19 when this
is used in connection with the valve selected in parameters 301 - 302.
The first two figures XX (xxyy) when programming, give the opening time and
the last two YY (xxyy) the closing time.
However, 0 will not be displayed if this is the first figure.
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Extra valve function 1, output A.
325 101 0505 9999 1 20 ms
Opening/closing time valve Q18
Extra valve function 2, output A.
326 101 0505 9999 1 20 ms
Parameters 329/330 Opening/closing time valve Q19

These parameters set the opening and closing times for valve Q19 when this
is used in connection with the valve selected in parameters 301 - 302.
The first two figures XX (xxyy) when programming, give the opening time and
the last two YY (xxyy) the closing time.
However, 0 will not be displayed if this is the first figure.

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Extra valve function 1, output B.
329 101 0505 9999 1 20 ms
Extra valve function 2, output B.
330 101 0505 9999 1 20 ms
Parameter 341/342 Reducing the lifting/lowering speed
With these parameters, the forks lifting/lowering speeds can be reduced,
which will apply to all operators.
Parameter 341 is used to reduce the lifting speed while parameter 342 is
used to reduce the lowering speed.
The function is affected without activating any input on the MCU.
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341 Reduction of lifting speed 30 100 100 10 %
342 Reduction of lowering speed 30 100 100 10 %
Parameter 343 Reduction of reach speed

Here the reach movement speed can be reduced for the truck, which will
apply to all operators.
The function is affected without activating any input on the MCU.
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343 Reduction of reach speed 30 100 100 10 %
Parameter 345- Lift/lower sensitivity

Used to set the sensitivity of the joystick
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Reduction of joystick lift/lower
345 40 40 80 10 %
sensitivity
Parameters 346/347 Ramping speeds

Parameter 346 Ramping speed for the reach movement. Used to set the
reaction in the movement.
Recommendations based on the type of loads being handled.
The value 3 is used for loads up to 500kg
The value 1 - 2 is used for loads between 500kg and 1000kg
The value 0 - 1 is used for loads heavier than 1000kg

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.
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346 Reduction of lifting speed 0 0 3 1
347 Reduction of lowering speed 0 0 4 1
Parameters 371/373/375/378 Height limitation

The parameters in the range 371 378 are used to set the height limits.
NOTE:
The height limitation is activated by factory parameter 1103.
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371 Creep speed, lifting 0 5 100 1 %
373 Creep distance, lifting 0 35 100 1 mm
375 Braking distance, lifting 0 550 1000 10 mm
Maximum stop
377 0 10 100 1 mm
tolerance

Parameter 371 states the creep speed as a percentage of the maximum

speed, for lifting and lowering respectively, when close to the programmed
stop height.
Parameter 373 defines the range around the stop height, for lifting and
lowering respectively, where the creep speed applies.
Parameter 375 defines the range within which braking can take place from
the maximum speed to creep speed, for lifting and lowering respectively.
Parameter 377 states the tolerance for the stop height as "a p377". If the
lifting or lowering movement cannot be stopped within the tolerance, a fault
code is given together with an acoustic alarm.
P377
P371
P373
P375

Parameter 380 Lift height limits

Parameter 380, is used to program lift height limits. The limits are set with
parameter 387.
NOTE:
The lift height limitation function is activated by factory parameter 1103.
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380 Lift height limitation 1 10 10 15000 10 mm
Parameter 387 Configuring the lift height limitations

Parameter 387 specifies whether the lift height limitation is to be activated
and if it is to be possible to lift above it:
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Configuration of lift height
387 0 1 2 1
limitation
:
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
Parameter 503 Login method

This parameter is used to define the type of login for the truck and whether
the operator is to have the possibility of changing the operator parameters.
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503 Login method 3 3 6 1
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 508/509/512/513 CID configuration

This group of parameters is used to configure the CID with regard to displays,
buzzer and in which truck family it is fitted:
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508 Display of height information 0 0 1 1
509 Buzzer activation 0 15 15 1
512 Truck family 4 4 4 1
513 Date format 0 0 1 1
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

5.5 Factory parameters
5.5.1 General factory parameters

Warning!
Risk of personal injury and material and property damage.
All factory parameters affect the truck's configuration and performance.
Changes may only be made by a person who has undergone training
concerning parameter setting and who can verify having a good knowledge
of how the truck is affected in the event of changes to the factory parameters
and how changes to factory parameters are made.
Note:
Changes to the factory parameters are registered in the truck's software. The
registration indicates the time of the change and the person who performed it.
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
Parameter 1001 - Truck type

The type of truck that the programme should adapt operation data for is set
using this parameter.
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1001 Truck type 0 0 3 1
Value P1001 Configuration

0 Unknown truck type
1 1 =R112
2 2 = R114
3 3 = R116
Parameter 1002 Mast type

Specifies the mast the program should adapt the operational data to.
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1002 Mast type 0 0 2 1

0 1.6t DX
1 1,6t TX
2 2,0t TX
Parameter 1003 Hydraulic pump

Specifies the type of pump that the program should adapt
the operational data to.
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1003 Hydraulic pump 0 0 1 1

0 Considerable
1 Small

Parameter 1007 Activation of hydraulic levers

Parameter 1007 specifies how many hydraulic functions will be activated and
the number of levers that are connected to the electronics. This means that
these are controlled safely.
Note:
For other settings, see parameters 301 - 330
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1007 Lever activation 0 1 2 1

0 Lift, reach
1 Lift, reach, tilt
2 Lift, reach, tilt, sideshift
Parameter 1009 Height indication

Specifies the type of height indication that the programme should adapt the
operator data for.
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Type of height
1009 0 0 1 1
indication

0 No height indication
Height indication
1 (pulse transducer) in
main lift

5.5.2 Factory parameters, activation of options

Warning!
Risk of personal injury and material and property damage.
All factory parameters affect the truck's configuration and performance.
Changes may only be made by a person who has undergone training
concerning parameter setting and who can verify having a good knowledge
of how the truck is affected in the event of changes to the factory parameters
and how changes to factory parameters are made.
Note:
Changes to the factory parameters are registered in the truck's software. The
registration indicates the time of the change and the person who performed
it.

Overview
Par. Description
1101 180 degree steering
1102 Warning lamp
1103 Lift height limitation
1104 Travel alarm
1105 Working lights
1106
cornering
1107 ANSI braking norm
Parameters for activating options can only have the values

'0' Option not activated
'1' Option activated.
If an option is activated, it may require the corresponding equipment on the
truck. Certain options also affect other parameters
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

5.5.3 Factory parameters, calibration
Description
Note:
All calibration parameters are set via the CID's calibration functions and must
not be changed via the parameter menus.
Defau Maxi Incre

Par. Description Min. Unit Comments
lt mum ment
1251 Lowering valve end point 80 100 120 1 %
1252 Maximum height 0 0 15000 1 mm
Lowering valve starting
1253 0 150 200 5 mA
point
1254 Height reference 0 6000 6000 1 mm
1255 Pulse length 15000 19930 25000 1 mm*10
1256 Extension length 1000 1000 10000 1 -
Calibration of hydraulic
1351 32767 0 -32767 1
lever 1
1352 32767 0 -32767 1
lever 1
1353 32767 0 -32767 1
lever 2
1354 32767 0 -32767 1
lever 2
1355 32767 0 -32767 1
lever 3
1356 32767 0 -32767 1
lever 3
1357 32767 0 -32767 1
lever 4
1358 32767 0 -32767 1
lever 4
1361 32767 0 -32767 1
lever 1
1362 32767 0 -32767 1
lever 1
1363 32767 0 -32767 1
lever 2
1364 32767 0 -32767 1
lever 2
1365 32767 0 -32767 1
lever 3
1366 32767 0 -32767 1
lever 3
1367 32767 0 -32767 1
lever 4
1368 32767 0 -32767 1
lever 4



Repair manual: Installation Model(s): R112, R114, R116
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.
6.2 Transporting the mast

When transporting the mast alone, you must properly anchor all loose parts.
The guides must be secured so that they cannot glide apart. Chains and any
hoses must be fastened so that they cannot come loose or be damaged. The
entire mast is then anchored on load pallets or another suitable support for
transport.
6.3 Transporting the truck

There are two ways to transport the truck when the battery is not installed.
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 Taking into operation

DANGER!
Risk of moving the centre of gravity.
Due to the weight of the mast, the battery must be in position in the truck
before the mast is fitted.
6.4.1 Battery
Placing the battery

Check that the battery is of the correct weight as shown on the truck's
identification plate. The weight of the battery affects the stability and braking
capacity of the truck.
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

4. Retract the mast to its innermost position.

5. Pull the handle at the bottom on the right in front of the operator seat to
release the battery lock.
6. Extend the reach carriage.
7. Switch off the truck.
8. Insert the new battery.
9. Lock the battery.
10. Connect the battery connector to the battery.
11. Start the truck.
12. Retract the reach carriage to its innermost position. Make sure that the
battery is locked in place.
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.

6.5 Dismantling the mast
Step 1 Step 3
Step 2
Step 4 Step 5 Step 6

Step 10 Step 11a Step 11b
Step 11c Step 12 Step 13
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.

6.5.1 Dismantling the working light.

If the truck is to be transported in a container, it may be necessary to remove
the working light.

6.6 Putting into operation.
6.6.1 Installing the mast in the truck.

Step 1
Step 2 Step 3
Step 4a Step 4b

Step 5 Step 7
Step 6
Step 8 Step 9 Step 10a

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.
9: Fit the locking ring, but do not tighten it.

10: Install the adjusting screws (Figure 10a) and adjust the mast so that
spacing between the mast and the eccentric cams is the same (Figure
10b). There should be no more than 5 mm difference on each side.
11: Fit the lock screws with the washers, but do not tighten.
12: Place the mast against the bottom part of the reach carriage, and fit the
bolts and washers into the lower bracket (do not tighten).
13: Check how many shims are needed on each side after marking. Left and
right side are decided by the operator's position. Check that the
inclination backward is 90 10. They are supplied in the bag (A). If there
are different amount of shims on either side, these are marked as per the
figure, R (right) and L (left). If they are not marked, both sides must
have the same amount of shims.
The shims B are for 1.6 and 2.0 ton masts. The shims C are for 2.5 ton
masts.
14: Adjust the lateral inclination so as to be within 90 6. Check that the
screws to the eccentric lock ring are not too tight. Turn the eccentric
inserts so that the factory markings are in line with the bracket in the
reach carriage, see Figure 14.
Note: This is to ensure that the correct mast setting made at the factory is
maintained.
. 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.

6.6.2 Fitting the working light.

When the truck has arrived from being transported, fit the lights according to
the Figure.


Repair manual: Maintenance Model(s): R112, R114, R116
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.
During the truck's warranty period: If repairs/servicing have been carried

out by non-authorised personnel, or if non-approved spare parts are used,
the truck warranty ceases to be valid.

7.2 Safety precautions for maintenance work

Only personnel trained in servicing and repair of this type of truck are
authorised to carry out service and repair activities.
Do not carry out any maintenance work on the truck unless you have
completed the appropriate training and possess the required knowledge to
perform such work
Always keep the maintenance work site clean. Oil or water makes the floor
slippery.
Never wear loose objects or jewellery when working with the truck
DANGER!
Short-circuiting/Burn injury.
Short circuits and burn injuries can occur if metal objects come into contact
with live electrical connections when working on the truck's electrical
system.
Remove wristwatches, rings and other metal objects beforehand.
Always disconnect the battery connector when carrying out maintenance
or repair work on the truck unless otherwise stated in this repair manual.
Always disconnect the battery connector before opening the covers for the
drive unit and the electrical system.
Relieve the system pressure slowly before starting work on the trucks
hydraulic system
Use some paper or a stiff piece of cardboard when checking for possible
oil leaks. Do not use your hands
Bear in mind that the oil in the drive unit or the hydraulic system can be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Only fill the hydraulic system with new and clean oil
DANGER!
The hydraulic system can be damaged.
If the oil is contaminated, the hydraulic components will suffer damage.
Always use new and clean oil in the hydraulic system.
Store and dispose of used oil in accordance with local directives
Do not flush solvents, etc. used for cleaning into drains that are not
intended for this purpose. Follow applicable local regulations with regard
to disposal.

Disconnect the battery when welding on the truck

Note:
The battery could be damaged.
When welding with an electric welding unit, the 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 blasting or
using paint remover
DANGER!
Harmful gasses.
Heated paint gives off harmful gases.
Remove all paint within 100 mm of the welding/grinding site.
7.3 Maintenance instructions
7.3.1 Cleaning and washing

Cleaning and washing the truck is an important factor in maintaining truck
reliability.
Carry out general cleaning and washing each week.
Note:
Risk of short circuiting.
Risk of damage to the electrical system.
Disconnect the battery before washing by pulling out the battery connector.
7.3.2 High-pressure washers

High-pressure washers may only be used on metal surfaces.
Under no circumstances may high-pressure washers be used in the truck's
motor compartment.
When using a high-pressure washer, the jet must be directed in such a way
that it does not damage electric cables, electric sensors, hydraulic hoses or
decals.
Lifting chains, piston rods and end pieces of hydraulic cylinders, ball and
roller bearings including those that are fully enclosed must not be
exposed to the jet, as there is a risk that water may penetrate and cause
corrosion.
After washing with a high-pressure washer, all the bearings and chains must
be lubricated/greased as specified in the maintenance instructions.
7.3.3 Degreasing agents

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

7.3.4 Cleaning the exterior

Remove rubbish, etc. from the wheels daily
Degreasing agents can be used as needed, in line with the previous
section.
Rinse off loose grime using tepid water.
Note:
Seizing, corrosion.
Risk of damage to mechanical parts.
Once washed, the truck should be lubricated as set out in the maintenance
instructions.
7.3.5 Cleaning the chain

We recommend you to replace a chain that is very dirty.
Dirty chains should be cleaned before they are lubricated, e.g. by washing
with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated directly
after cleaning.
Note:
Exercise care with degreasing agents as these can contain abrasives.
7.3.6 Cleaning the motor compartment

Cover electric motors, connectors and valves prior to washing.
Note:
Risk of damage to the electrical system.
Electrical components must not be washed with high-pressure washers.
Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
Rinse off loose grime using tepid water.
7.3.7 Electric components

Clean electric motors using vacuum cleaner or a rag.
Clean electric panels, logic cards, contactors, connectors, magnetic
valves, etc. with a rag moistened with water and a suitable detergent.
Note:
Risk of damage to electrical components.
Do not break the warranty seals on the electronic circuit boards.

7.4 Symbols
Symbol Measure Symbol Measure Symbol Measure

Visual inspection of
Component
condition, wear and Listening for noise.
replacement.
loose connections.
Cleaning Measurement Check of functions.
Check of fluid level and Check tightening of

Lubrication, application.
check for leaks. bolts, nuts, etc.

7.5 CCrack detection

The aim of an inspection is to discover any damage, crack, deformation or
similar that may impair safety. The individual performing the checks must be
a trained service technician.
7.5.1 Visual inspection

1. Clean the surfaces to be inspected, ensure adequate lighting.
2. The surfaces are to be subjected to a careful visual inspection for cracks
and, if necessary, a non-destructive crack indication check. See section
"7.5.2 Crack detection".
3. If a crack has been identified, contact the service organisation of the truck
manufacturer for further information.

7.5.2 Crack detection
Crack detection with liquid penetrant

1. Clean around the area in question (type Bycotest C10).
2. Apply penetrant (type Bycotest RP20).
3. Penetration time 20 min.
4. Wipe away penetrant with remover.
5. Apply developer (type Bycotest D30A).
6. Development time approx. 10 min.
7. Crack detection.
8. Etch a horizontal line at the tip of the crack (see illustration of the
principle below) to know far it must be ground out during repair.
Crack detection with magnetic yoke

1. Clean around the area in question.
2. Apply the magnetic yoke.
3. Apply magnetic particle liquid (type Bycotest C101).
4. Inspect with a UV lamp.
5. Etch a horizontal line at the tip of the crack (see illustration of the
principle below) to know far it must be ground out during repair.

7.6 Safety checks

Interval: 1000 h unless local regulations prescribe more regular checks.
Must also be carried out after large repairs.
Position Measure Ref.
Check that all warning signs and machine plates are in

place and are legible. For position, see ????.
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.
Inspect the attachment of the roof cassette, the roofs

0810.1
attachment to the machine housing and for any cracks.
Check the brake force of the parking brake. Tightening

3370.1
torque 62 Nm.
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.
Check the function of the presence sensor (seat switch).

Exit the truck and check that the control for operating the
0620.1
forks does not function when you are not sitting on the
seat.

7.7 Periodic maintenance
7.7.1 Every 500 operating hours/180 days
7120.1
7120.2
7120.3
3370.1
5110.1
5110.2
5110.3


5110.1 Open all the battery's cell plugs and check the
electrolyte level. This should be 10-15 mm above the
top edge of the cell plates. Top up as needed.
5110.2 Check that none of the power cable connections to
the battery, truck and charger are damaged or have
overheated.
5110.3 Visual check to ensure that the battery cell and
terminal protectors are undamaged.
7120.1 Visual check of wear to lifting chains, chain bolts,

chain mountings and chain sprockets
7120.2 Adjustment of lifting chains, check the tightening

torque of lock nuts and inspect the cotter pins.
7120.3 Lifting chains:

3370.1 Play in non-braked position


Together with 500-hour service
0620.1
0350.2 0350.1 3370.1

3370.2
3370.3
2550.1
0840.1
0390.2
0390.1

Perform 500-hour service together with the following 1,000-hour

service:
0000 Chassis Check for visible damage or cracks. See
section "7.5 CCrack detection".
0350 Check for visible damage or cracks. See section

"7.5 CCrack detection".
0350.1 Beam contact surfaces for reach carriage rollers

0350.2 Check for wear and fastening of the each carriage

stops
0390.1
Inspect the battery lock for correct installation and

possible wear.
0390.2 Check the locking of the roller bed
0620.1 Operator's seat mounting and adjustment functions

0840.1 Tilt stop wear and sealing

2550.1 Gear rim (after careful cleaning)

2550.2 To be changed after the first 1000h, with no further

change after that.
3370.1
Check the air gap of the parking brake.
3370.2
Check the parking brake torque, 41 Nm (nominal). -


3370.3
Check the parking brake, its wiring harness and contacts.

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


3530.1 Remove strings and other rubbish

3530.2 Tread depth wear

3530.3 Wheel bolts (140 Nm)

3550.2 Tread wear

4310.1 Mounting and locking

5110.8 Connection of the battery connector to the copper

bars
5430.1 Wear and damage to the wiring harness

5430.2 Wiring harness fitting and connections

5590.2 Wear to the mast cabling

5590.3 Restrictions (strain) on mast cabling

6120.2 Wear to hoses in reach carriage and mast

6600.2 The mounting of the hydraulic cylinders

j



7110.1 Play reducer and mast beams

7130.1 Check the functionality and wear of the tilt stop.

7190.1 Mast fixing points, upper and lower
7190.2 Eccentric ring position in the upper mast fixing -

should not have rotated
7190.4 Play of side guides
7190.5 Side guides
7190.7 Check the eccentric rollers
7190.8 Lubricate the eccentric rollers
7400.1 Check for visible damage or cracks. See section

- Check the function of the presence sensor (safety

pedal). It must not be possible to drive the truck
when the pedal is not pressed.
- Check the emergency switch off.


:
7190.3
0000.2
5000.3
3370.2
5110.7
5110.9
0390.3
3550.1
1700.1
2550.2
5000.2

Perform 500-hour and 1000-hour services together with the following

2000-hour service:

0000.2 Securing devices for cables

0390.3 Bearing for battery rollers

0390.11 Wear to battery cover

3550.1 Rotation and abnormal noise from bearing
5000.2 Attachment of electrical panel

5110.7 Force required to disconnect the battery connector

5110.9 Wear to battery tray guiding elements
7190.3 Wear and bearings of reach carriage side guide


3000-hour service:

2550.2 The gear mounting bolts in the chassis

3370.2 Braking force

5000.3 Power cables for motor controls


5200.1
5110.4
5110.5
5110.6
0640.1
6140.1
1700.1
5000.1
5390.1
5590.1


4000-hour service:

1700.1 Motor shaft (splines)

7.7.6

5000-hour service:
Position Component Type of work Work to be carried out

6140.1 Hydraulic Replace Oil filter and air filter
system
7.7.8 Annual status inspection

Position Component Type of work Work to be carried out

0640.1 Operator Check Functions relating to controls, steering
area wheel, brake, pedals, horn and emergency
switch off
1700.1 Motors Check-tighten Power cable connections. Torque
tightening.
5000.1 Electrical Cleaning Electrical panel
system
5110.4 Battery Check Measure the battery fluid density with an
acid density meter
5110.5 Battery Check Measure the battery temperature at the
centre of the battery
5110.6 Battery Cleaning Suck up any excess fluid from the battery
tray
5200.1 Electrical Check Wear and damage to the truck's displays
system
5390.1 Electrical Check Wear to wiring harness
system
5590.1 Electrical Check Wear and damage to wiring harness,
system including
protective cover, in reach carriage

Risk of damage to electrical components.
Do not break the warranty seals on the electronic circuit boards.

Repair manual: Troubleshooting Model(s): R112, R114, R116
8. Troubleshooting
8.1 Auxiliary functions
8.1.1 Error log menu
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.

8.1.2 Error information menu
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
8.1.3 Diagnostic screens
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/

Screen 1 CID analogue inputs
Function Conn. Unit

~0.5 V / 4.5 V max
1 Lift/lowering lever X505:3
~2.5 V released
~0.5 V / 4.5 V max
2 Traversing lever X505:4
~2.5 V released
~0.5 V / 4.5 V max
3 Tilt lever X505:5
~2.5 V released
~0.5 V / 4.5 V max
4 Sideshift X505:6
~2.5 V released
5 - - -
~0.5 V left / 4.5 V
6 Travel direction selector X503:1 right ~2.5 V
released
7 - - -
8 - -
9-10 - - -

Screen 2 CID digital inputs
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

Screen 3 MCU analogue inputs
Function Conn. Unit

1 X130:2
2 X130:16
3 X130:30
4 X130:3
~0.5 V released
5 Accelerator X130:17
~4.5 V max.
~1.5 V released
6 Safety pedal X130:31
~3.5 V max.
~0.5 V released
7 Brake pedal, signal 1 X130:4
~4.5 V max.
~4.5 V released
8 Brake pedal, signal 2 X130:18
~0.5 V max.
9 X130:32
10 Battery voltage + X130:5 V

Screen 4 MCU digital inputs
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

Screen 5 MCU digital outputs
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 6 Pulse-width modulated outputs
MCU signal Value

1 PWM1 X131:26 V
2 PWM2 X131:40 V
3 PWM3 X131:13 V
4 PWM4 X131:41 V
5 DO17 X131:39 V
6 PWM6 X131:12 V Parking brake
ACH signal
PWM1 T2:108 A Lowering valve
PWM2 T2:109 A
ACT signal
PWM1 T1:108 A
8 PWM2 T1:109 A

Screen 11 Temperatures
Unit C
1 ACT motor temperature

2 ACT cooling flange temperature
3 ACH motor temperature
4 ACH cooling flange temperature
5 EPS motor temperature
Screen 12 Voltages
A recently charged battery should

be ~ 51 V
1 Supply MCU
A battery under 48 V must be
charged
2 +15 V from MCU
3 +5 V from MCU
Should be the same value as for
4 Supply ACH
Supply MCU
5 Supply ACT
Supply MCU
6 Supply EPS
Supply MCU
All voltages are given in volt.

Screen 13 travel function
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
B1 Brake pedal
~4.5 V: depressed all the way
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

Screen 14 Steering function
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

Screen 15 Displays information about lifting/lowering
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

Screen 16 Displays reach in and reach out information.
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
P Rpm
speed

Screen 17 Displays tilt and sideshift information.
Function Unit
100%
0 when the
L1 Tilt lever
lever is not
activated
100%
0 when the
L2 Sideshift lever
lever is not
activated
P Rpm
speed

8.2 Initial troubleshooting
Begin troubleshooting
CID lit? No Troubleshooting without

indications
Yes
Blocking Yes Troubleshooting using

symbol blocking symbol
displayed?
No
Yes Troubleshooting using

Error code
error code
displayed?
No
Troubleshooting
without indications

8.3 Troubleshooting using blocking symbol
Symbol Cause Hints

Software failure Create a truck report and save it.
Reinstall truck software. Use the latest software, even if this
involves an update.
Check the truck parameters against the saved truck report.
Reactivation of requested function The activation sequence for a requested function is not
required correct.
The latest function used must be redone from the start.
The MCU does not know if the seat If the indication is intermittent, this may be due to gaps in the
switch [B49] is affected. cable connections or the sensor's mechanical mounting.
If the indication is shown constantly, check that MCU digital

input X130:41 changes status when the seat is loaded; CID
diagnostic screen 4/pos 12.
1: If the input remains low, the sensor's function and the

wiring harness must be checked for any break in
conductors 27, 40 and 83.
2: If the input is constantly high, the sensor's function and the
wiring harness must be checked for short-circuiting
between conductors 27 and 83.
3: If there is a voltage at input X130:41 when the seat is not
loaded, but the input status shows this, the MCU must be
replaced.

Symbol Cause Hints

The control sequence performed in Perform the control sequence in the right order.
the wrong order. If the indication is intermittent, this may be due to gaps in the
or cable connections or mechanical fault in the sensor.
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.
Normal values are:

approx 1.5 V when the pedal is free
approx 3.5 V when the pedal is depressed fully.
If the value on the diagnostic screen does not change:

Replace the pedal
Update the truck's software to the latest available
version.
Replace the MCU.
If the value on the diagnostic screen changes:

Update the truck's software to the latest available
version
Replace the MCU.

Symbol Cause Hints

ACT or ACH signal that the The truck has been used more intensively than its maximum
temperature exceeds 85 C. specification. Let the truck cool down.
Fan [G3] and/or [G6] not working:
Fan testing can be done using the CID service functions
Fan control, MCU output X131:9, can be checked via CID

diagnostic screen 5, pos 9.
The motor control heatsinks are dirty and must be cleaned.
If there is not 48 V between [G3:1] and [G3:2]: Check the

wiring harness and the MCU.
If there is 48 V between [G3:1] and [G3:2]: Check the fan.
If there is not 48 V between [G6:1] and [G6:2]: Check the

wiring harness and the MCU.
If there is 48 V between [G6:1] and [G6:2]: Check the fan.
The MCU detects that the Check that the emergency switch off is not depressed.
emergency switch off [S21], ESO, is Check that fuse F60 is complete.
depressed. Check that MCU digital input X131:5 changes status when the
emergency switch off buttons are operated, CID diagnostic
screen 4/pos 22.
If the input does not change status, the function of the

emergency switch off button and the wiring harness must be
checked for any break in conductors 20, 21 and 22.
Replace the MCU if there is a voltage at input X131:5,
conductor 21, when the emergency switch off button is not
pressed, but the input status shows it is so.
The hour meter reading to the next Carry out service and reset parameter 101 to the agreed
service has reached 0. service interval.

Symbol Cause Hints

The reference sensor has not been If the forks are raised, lower them fully so that [B] is affected by
activated the reference rail.
If main lift is not activated, the mechanical drive to the pulse
transducer [B19] must be checked.
The CID's diagnostic screen 4, pos 7 and 8.
.
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]
Applicable combinations are:

[B58]
Main lift in bottom position: 1
Main lift raised: 0
If the signals do not correspond with the mast's position,
the switches may be confused.
Brake activated at start-up The brake pedal was active during login.
Start the truck without touching the pedals.
The brake does not release.

CID diagnostic screen 3, pos 7: ~0.5 V,
pos 8: ~4.5 V when the brake pedal is completely released:
The brake pedal must be completely released in order to start

driving.
If the diagnostic screen shows that the brake is not completely
released, 7: > ~1 V and 8: < ~4 V, the brake pedal may have
mechanically seized in the partly or completely pressed down
position.

8.4 Troubleshooting using error codes

The first digit of the error code identifies the subsystem where the error code
has arisen.
Troubleshooting using
error codes
Error Yes
CID, warnings and
code
No
Error Yes MCU and

code miscellaneous
No
Error Yes
Drive system error
code
No
Error Yes
Hydraulic system error
code
No
Error Yes Steering system,

code warnings and errors
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.
.
Code Error category/action taken

number
n:0nn Caution. Generally an information code. No change
in truck behaviour.
n:1nn Warning. Some functions may be disabled or
reduced. See the specific error code to see what
action has been taken.
n:2nn Error. Selected parts of the hydraulic system are
disabled. See the specific error code to see what
action has been taken.
n:3nn Error. The truck is braked by the plug braking and/or
the parking brake until it comes to a halt. It is not
possible to drive. The steering may be disabled if
there is a steering error. To see what action has been
taken, see the specific error code.
n:4nn Error. The truck is braked by the plug brake until it
stops. Once the truck has stopped, or after 5
seconds, the relays for the main power supply and
key are switched off.
n:5nn Critical error.
Main contactor and key relay opens.
The error codes are subdivided into smaller categories based on the last two
digits of the code (see below).
Error code, type of error

Code Description
number
n:n00n09 Miscellaneous error codes.
n:n10n19 CAN-related error codes
n:n20n39 Error codes related to specific units.
n:n40n59 Error codes for short-circuited output data.
n:n60n79 Error codes for output data from open electrical
circuits
n:n80n99 Faulty signals from sensors.

8.4.1 CID, warnings and errors
Indicator. Cause Hints

1.003 Minor incompatibility in program Update the truck's software to the latest
version. available version.
The software versions in the MCU and
CID do not match each other.
The MCU does not support some of the
functions used by the CID, or vice versa.
1.010 CAN 1 communication warning. 1. Check that CAN 1 is intact in terms of
The CID CAN module received too many wiring harness, final resistance and
erroneous messages. contacts.
2. Disconnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 66 ohm.
3. Deactivate and disconnect the DHU
and collision sensor. Then reconnect
them one by one to find out which unit
causes the communication error.
1.431 External +5 V is outside the permitted 1. Disconnect the joysticks, buttons and
range. sensors connected to [X505:1] one at
a time and check if the error code
disappears.
2. Check the CID's internal wiring
harness.
3. Replace the CID.
1:500 Software failure Update the truck's software to the latest
available version.
1.501 CID has detected an error in the Update the truck's software to the latest
MCU's program execution. available version.
1.503 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
1.504 The software for CID and MCU are not 1. Update the software for CID, MCU and
compatible. other units to the latest available
Not possible to log in. versions.
2. Check that the software
are compatible.
1:505 CID configuration error 1. Wrong CID log-in ID
Not available


1:506 CID position error 1. CID position is wrong.
Not available
1:507 The software for CID and MCU are not Update the truck's software to the latest
compatible. available version.
The software versions in the MCU and
CID do not match each other.
The MCU does not support some of the
functions used by the CID, or vice versa
1.510 Communication error CAN 1. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
contacts.
[X41:4] is 54 66 ohm.
and collision sensor. Then connect
gives rise to the communication error.
1.512 Communication disturbance CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 66 ohm.
1.514 MCU or CID has not received a 1. Check that CAN 1 is intact in terms of
response within 70 ms via CAN1. wiring harness, final resistance and
1.516 contacts.
[X41:4] is 54 66 ohm.
1.520 Internal +5 V is outside the permitted Replace the CID
range.


1.540 Key relay [K20] Break in the control 1. Check that there is no break in the
circuits coil of the control circuit.
2. Check the contacts [X131] and [X504]
the relationship between [K20:A1]
[X131:5] as well as [K20:A2]
[X504:17].
3. Replace the CID [A1].
1.580 Key Relay [K20] Contacts welded 1. Check the key relay's function and that
there is no connection between
[K20:1] and [K20:2].
2. Check for the presence of a short
circuit that may cause improper
feeding of [X504:7], e.g. from
[X504:16], [X504:17] and [X504:18].
3. Replace the CID [A1]
1.581 Key relay [K20] does not close Check if the MCU input [X131:6] switches
status when the key relay is activated,
diagnostic screen 4, pos 25:
If the input does not change status:

Check that fuse [F73] is intact.
Check the key relay's function and that
there is a relationship between [K20:1]
and [K20:2] when the relay is drawn.
Check that wire 27 from the key relay to
fuse box is intact.
Replace the CID.
If the input changes status:
Update the CID's software.
Replace the CID [A1].

8.4.2 MCU and other warnings and errors

2:001 Error in the error log 1. Delete the error log
2. Update to the latest software
2:002 The MCU is programmed using Download or adjust the parameters to
standard values for parameters. correspond with the truck model and
equipment.
2:003 MCU memory error. 1. Backup the truck's parameters.
Backup data, hour meter and error log
2. Update to the latest software.
may be affected.
3. Check parameters and hour meter.
4. Copy the truck configuration from CID to
MCU.
2:004 Error in check sums of backup data. 1. If MCU or CID has been changed, copy
Normally shown after replacing MCU or the truck configuration from the MCU or
CID. CID unit which has not been replaced to
the new unit.
2. Backup the truck's parameters.
4. Check parameters and hour meter.
2:005 Hour counter reading to service = 0. Carry out servicing and reset the S counter
using TruckCom.
2:006 Full error log buffer. Shows that errors which would normally be
No indication, logged only. logged in the error log may have been lost.
2:007 MCU's internal memory full 1: Restart the truck.
2: If the error persists, update the truck's
software to the latest available version.
3: Report the fault to the manufacturer.
2:008 Application time. Set when the application (20ms) takes
No indication, logged only. longer than 18ms.
1. Rectify the error code that occurred in
direct conjunction with this error code.
2. Report the fault to the manufacturer.
2:009 Tick time. Set when tick time (1 ms) takes longer than
No indication, logged only. 0.7 ms.
1. Rectify the error code that occurred in
direct conjunction with this error code


2:010 Communication disturbance CAN 1. 1. If the CAN key is connected: Try using a
MCU has received too many incorrect CAN-key with a later production date.
telegrams.
2. Check that CAN 1 is intact in terms of
contacts.
resistance between [X41:3] and [X41:4]
is 54 66 ohm.
4. Deactivate and disconnect the DHU and
collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the
communication error.
2:011 Communication disturbance CAN2. 1. Check that CAN 2 is intact in terms of
MCU has received too many incorrect wiring harness, final resistance and
telegrams. contacts.
[X130:22] is 54 66 ohm.
3. Disconnect EPS, ACT and ACH. Then
2:021 Not correctly logged out by the truck The truck was not switched off correctly. The
battery was disconnected before the truck
was logged out.
2:022 The MCU does not have the same The code is not displayed, only added to the
software it had when last started up. error log to show that the software has been
Shown when the software has been updated.
updated.
2:101 Incorrect type of truck. Use TruckCom to save the parameter
Factory parameters not loaded. values.
If the MCU has been replaced:
Run a Change MCU in TruckCom.
Enter the truck's parameter list.
Check parameter 1001 Truck type. If it
is not correct, all parameters must be
checked.
Copy the truck configuration from CID to
MCU


2:102 Lift height limitation - Stop height error. 1. Lifting: check/adjust parameters 371,
373 and 375.
2. Adjust parameter 377
2:103 Lifting height limiting. If the truck is equipped with height
Lifting height limiting is activated and indication, activate this using factory
height measurement is deactivated. parameter 1009 = 1.
If the truck does not have height indication,
deactivate the lifting height limiting using
parameter 1103 = 0.
2:106 Collision locking. If parameter 112 = 0: Use the special PIN
A collision value exceeding what has code to reset the collision sensor.
been input via parameters 110 and 111 If parameter 112 = 1: Restart the truck to
has been detected. reset the collision sensor.
The truck can only be driven at reduced
speed.
2:107 Truck at standstill
The truck can only be driven at reduced
speed.
2:141 Wrong digital output in fan 4: Check that the wiring and connectors
are intact and correctly connected.
The fan output is short-circuited to the
motor controller 5: Check the functionality of the fan
2:161 Wrong digital output in fan 1. Check that there is no break in
conductor X131:9, conductor 33 and
Fan output has an open circuit.
conductor 27 leading to fan G3.
2. Check that cables and contacts are
undamaged.
3. Check output DO9 via the CID's
diagnostic screen 5, pos 9:
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]


2:401 Internal program error 1: Restart the truck.
2:403 The permitted time for reading 1: Restart the truck.
analogue
signals has been exceeded.
2:415 Problem in CAN 1. Software error, report error to manufacturer
2:420 Battery voltage under 33.6 V. 1. Check the battery voltage.
2. Check that the battery cable (X1) is
undamaged and free from oxidation.
3. Check that the voltage between
[X130:19] and [X130:32] corresponds to
the measured battery voltage.
4. Replace the MCU
2:421 Battery voltage over 59.5 V. 1. If the error code occurs in association
with strong motor braking directly after
charging: Log out/log in.
2. If the error code occurs during motor
braking during normal driving:
Check all power cabling between the
battery and transistor regulator for
breaks, poorly tightened screws/nuts
and oxidation.
2:431 +5 V for external sensors under +4.9 V. 1. Make sure that no short circuit or other
high load is present in the sensor, safety
pedal or pedal unit for speed and
braking.
2. Check the wiring harness to the
components above.
3. Replace the MCU and check the
function of the sensor, safety pedal and
accelerator and brake pedal unit.


2:432 +5 V for external sensors over +5.1 V. 1. Check that there is no short circuit
between conductor 55 and any
conductor with voltage higher than
5 V, e.g. battery voltage.
2. Check the function of
Sensor
Safety pedal
Pedal unit for accelerator and brakes.
3. Replace the MCU
2:433 +15 V for external sensors under +12 V. 1. Check that there is no short circuit or
high load in sensor [B19].
2. Check the wiring harness to the
components above.
3. replace the MCU and check the function
of sensors [B18] and [B19].
2:434 +15 V for external sensors over +16.5 1. Check that there is no short circuit
V. between conductor 29 and any
conductor with voltage higher than
15 V, e.g. battery voltage.
2. Check the function of sensor [B19].
3. Replace the MCU.
2:435 Internal +7.5 V under +7 V. Replace the MCU
2:436 Erroneous external signal +5 Replace the MCU
Internal +7.5 V over +8 V.


2:501 Check sum error, parameters 1: Restart the truck.
Check for uninitiated parameters that 2: Check the value of all parameters. Check
have values such as -32768 that
no parameter has the value
-32768
Note:
The calibration parameters (1300-1399)
may
have a value very close to the value
indicated
above.
If any parameter is found to have the
value
-32768
Set the value to the default value or the
correct
value for the specific truck.
If no parameter is found to have the
value
-32768
Change the value of one parameter in
each
category operator parameters (1-99),
service
parameters (101-999), factory parameters
(1001-1199) and calibration parameters
(1200-1299).
Save the changes and restart the truck.
You
should see an hourglass on the CID display
to confirm that the values are being copied
from the MCU to the CID.
Reset the values you changed in the
previous
set to their original values.
Restart the truck.
The program should now perform a
checksum
found in both the MCU and the CID.
3: Backup the truck's parameters.
4: Update to the latest software.
5: Check parameters and hour meter.
6: Replace the MCU.


2:502 Serious software error, MCU. 1: Restart the truck.
2: If the error persists: update the truck's
3: Report the fault to the manufacturer
2:503 error in check sum, factory 1. If MCU or CID has been changed, copy
parameters. the truck configuration from the MCU or
Normally shown after replacing MCU or CID unit which has not been replaced to
CID. the new unit.
2. Backup the truck's parameters.
4. Check factory parameters.
2:504 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
2:505 MCU has detected an error in the CID's 1: Update the truck's software to the latest
program execution. available version.
2: Report the fault to the manufacturer
2:510 Initialisation error CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
is 54 66 ohm.
3. Deactivate, disconnect and reconnect
the units from CAN1 individually to find
the device giving rise to the initialisation
error.
2:511 Initialisation error CAN 2. 1. Check that CAN 2 is intact in terms of
contacts.
[X130:22] is 54 66 ohm.
error.


2:512 Communication disturbance CAN 1. 1. Check that CAN 1 is intact in terms of
The MCU has problems sending wiring harness, final resistance and
messages via CAN 1. contacts.
is 54 66 ohm.
3. Deactivate and disconnect the DHU and
collision sensor. Activate and then
2:513 Communication disturbance CAN 2. 1. Check that CAN 2 is intact in terms of
The MCU has problems sending wiring harness, final resistance and
messages via CAN 2. contacts.
[X130:22] is 54 66 ohm.
error.
2:514 Login error DHU. Check that parameter 503 corresponds to
No log-in answer from DHU the truck's equipment:
1. Check that it is possible to connect
TruckCom to the DHU.
If it is possible to connect them, check
the DHU's configuration.
2. Check that the DHU's green LED is lit.
If the LED is not lit: Check the DHU's
supply voltage: The battery voltage
between [A82:1] and [A82:8].
If there is a battery voltage: Replace
the DHU.
contacts: Disconnect the battery. Check
that the resistance between [A82:2] and
[A82:3] is 54 66 ohm.
2:515 CAN 2 sends buffer
2:531 Internal +5 V under +4.9 V. Replace the MCU


2:532 Internal +5 V over +5.5 V. Replace the MCU
2:533 Internal +15 V under +14.25 V. Replace the MCU
2:534 Internal +15 V over +15.75 V. Replace the MCU
2:537 Internal supply for digital outputs under Replace the MCU
9.7 V.
2:538 Internal supply for digital outputs over Replace the MCU
12 V.
2:540 Short circuit in output for main 1. Check that the main contactor coil is not
contactor [Q10]. short circuited.
2. Check that there is no short circuit in
connection [X131:7], wire 31.
3. Replace the MCU and check the main
contactor's function.
2:555 Valid time for startup exceeded. 1. Check that fuse [F73] is intact.
2. Check that the wiring harness and
contacts are intact and correctly
attached.
2:556 Valid time for shutdown exceeded. 1. Turn off the truck by disconnecting the
battery.
2. Restart the truck and log in.
2:560 Error on digital output 3 1. Check that there is no break in the main
Break in output for main contactor contactor coil.
[Q10].
2. Check that there is no break between
connection [Q10:A2] and [X131:7],
wire 31.
3. Check that there is a battery voltage
between [Q10:A1] and B-.
If there is not battery voltage.
Check that the emergency switches are
not pressed.
Check that fuse F60 is intact
4. Log in to emergency travel mode to
reset the status of the main contactor.
5. Check the function of the main
contactor.
6. Replace the main contactor.
7. Replace the MCU.


2:580 Main contactor [Q10] Contacts 1. Check the main contactor's function and
welded that there is no relationship between
[Q10:1] and [Q10:2].
2. Check that there is no short circuit that
can cause improper supply to [X131:5].
2:581 Main contactor [Q10] Activated but 1. Check fuse [F71]
the MCU is unaware of this.
2. Check the main contactor's function and
that there is a relationship between
[Q10:1] and [Q10:2].
3. Check that there are no breaks in
conductor 8 between the main contactor
and the fuse panel, as well as conductor
23 between the fuse panel and
[X131:15].
2:598 The selected truck model is not 1: Check that the correct software is
permitted installed in the truck
2: Check that the latest version of
TruckCom is used.
2:599 The license key used to set parameter 1: Check that parameter 499 has the
499 is wrong correct value
Note: only for trucks in field testing
2: Perform a truck report and send it to the
factory to obtain the correct value.

8.4.3 Drive system error

3:001 Plug brake error 1. Check the battery.
The motor cannot use the plug brake 2. May occur when braking with a fully
adequately according to the braking charged battery.
norm. The ACT cannot supply
sufficient power to the motor with the 3. Inspect the battery cables.
result that this cannot maintain the
speed required. May occur when
driving downhill.
3:081 Seat switch active for more than Check input DI12 via the CID's diagnostic
20 minutes. screen 4, pos 12:
When the seat is loaded the signal should

read '1' and when unloaded '0'.
If the signal does not change:
Check that the wiring harness and
contacts are undamaged.
Replace the seat switch Comfort [B49]
and Basic [S89]
Replace the MCU.
If the signal changes:
Log off and disconnect the battery for
approx 1 minute.
Connect the battery, log on and check
that the error indication has
disappeared.
Update the truck's software to the latest
available version.
Replace the MCU.


3:180 Safety pedal output voltage Check that safety pedal output voltage is
incorrect. within the interval 1.5 V to 3.5 V. The
CID's diagnostic screen 3, pos 6:
If the output voltage is outside these

limits:
Check that the voltage is between 4.5 V
and 5.5 V between [B31:1] and [B31:3].
Check that there is no break, short
circuit or incorrect feed to [X130:31],
conductor 84.
If the output voltage is within limits, but
that changes when the pedal is
operated:
Replace the pedal [B31].
available version.
Replace the MCU.
3:305 Motor temperature over 180 C. 1. Check that the resistance in the drive
The truck is braked by the plug brake motor's temperature sensor is
until it stops. between 550 ohms and 650 ohms. At
150 C the resistance should be 600
ohm.
2. Check that the fan for the motor
compartment works and that the
ventilation openings are not blocked.
3. Check that the drive motor is not
damaged.


3:314 The MCU or ACT has not responded 1. Check fuse [F73].
via CAN2 within 70 ms.
3:316 The truck is braked until it stops.
contacts. Disconnect the battery.
Check that the resistance between
[X130:8] and [X130:22] is 54 66
ohm.
3. Check that the ACT's green LED is lit
constantly.
If the LED is not lit:
Check that the ACT has a supply
voltage of 48 V between [K1:9] and [B-].
Replace ACT.
If the LED is lit:
Replace ACT.
3:320 ACT Voltage for motor power supply Check
outside specified limits.
1. Fuse F71
3:322 The truck is braked until it stops.
2. Fuse F1
3. That the main contactor [Q10] is
closed and that the contacts are not
burned.
4. That the wiring harness between the
battery and the ACT is intact and not
oxidised.


3:323 Overcurrent ACT. Check
The truck is braked until it stops.
1. That the battery voltage is correct at
the connection to the ACT.
2. That the battery harness is
undamaged and there is no
connection between B+ and
B-.
3. That the motor cables are undamaged
and there is no connection between
them or with B-.
4. The motor windings' resistance to the
motor yoke, there should be no
relationship.
5. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.
3:325 Temperature error Check that the cooling fan for the ACT
The ACT's cooling element is over and ACH is working normally. CID Service
125 C. function:
If the fan is working normally:

Clean the ACT's cooling element and
associated ducts. If the error returns the
fault is probably an internal ACT
problem.
If the fan does not work normally:
If there is not 48 V between [G3:1] and
[G3:2]: Check the wiring harness and
the MCU.
If there is 48 V between [G3:1] and
[G3:2]: Check the fan.


3:328 Short circuit in the ACT, the drive Check
motor or the motor cables.
1. That the motor cables are undamaged
and there is no short circuit between
them or with B-.
2. The motor windings' resistance to the
relationship.
3. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.
3:329 Measurement/Calibration error in the 1. Log off and cut off voltage to the truck
ACT's current measurement. for at least one minute.
The shift in the current measurement
2. Restart the truck and log in again
is too large
The truck is braked until it stops. 3. Check the wiring harness between the
motor and the ACT.
If the fault persists:
Replace ACT.
3:333 The ACT's internal 15 volts is outside Check
the specified limits.
Fuse F73
The battery voltage [ACT K1:9] and B-.
If the voltage differs from the battery
voltage:
Check that wire 27 between the fuse
box and the ACT, is undamaged and
that the connections are not oxidised.
If the voltage is the same as the battery
voltage:
Replace ACT.


3:380 Break or short circuit in the speed Loosen the sensor and remeasure [B11:1]
sensor [B11]. and [B11:4], 1 = + and 4 = -. The
resistance should be approx 160 kOhm.
If the resistance measurement
suggests a break/short circuit in the
sensor:
Replace the sensor.
excludes a break/short circuit:
Check conductors 10 and 11,
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
any break/short circuit.
If the conductors are undamaged:
Replace ACT.
3:381 Loss of one channel in the speed Loosen the sensor and remeasure [B11:1]
sensor and [B11:4], 1 = + and 4 = -. The
sensor:
Replace the sensor.
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
Replace ACT.


3:382 No current or earth to speed sensor. Loosen the sensor and remeasure [B11:1]
The truck is braked until it stops. and [B11:4], 1 = + and 4 = -. The
sensor:
Replace the sensor.
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
Replace ACT.
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.

limits:
circuit or incorrect power supply to
[X130:17], conductor 87/GY.
operated:
Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.
Replace the MCU.


3:387 The voltage from the brake pedal Check that brake pedal, signal 1, output
[B32], signal 1, is outside the voltage is within the interval 0.25 V to
specified limits. 4.75 V. The CID's diagnostic screen 3,
Driving is blocked and the truck is pos 7:

limits:
circuit or incorrect power supply to
[X130:4], conductor 85/WH.
operated:
Replace the MCU.


3:388 The voltage from the brake pedal Check that brake pedal, signal 2, output
[B32], signal 2, is outside the voltage is within the interval 0.25 V to
specified limits. 4.75 V. The CID's diagnostic screen 3,
Driving is blocked and the truck is pos 8:

limits:
conductor 86/BK.
operated:
Replace the MCU.


3:389 Too large discrepancy between both Check that both the brake pedal signals'
brake pedal signals. output voltages follow each other and that
Driving is blocked and the truck is one is inverse to the other.
V = brake pedal's output voltage,

pos = Brake pedal depression
The CID's diagnostic screen 3, pos 7 and
8:
If the output voltage does not change

normally:
Check that there is no poor relationship
or faulty supply of [X130:4], conductor
85/WH and [X130:18], conductor 86/
BK.
If the output voltage changes normally:
Replace the MCU.


3:390 The voltage from the travel direction Check that the travel direction selector
selector [B36] is outside the specified output voltage is between 0.25 V and
limits. 4.75 V when the selector is moved to the
Driving is blocked and the truck is respective end positions. The CID's
brought to a stop with the plug brake. diagnostic screen 1, pos 6:

limits:
and 5.5 V between [X503:7] and
[503:8].
conductor 94/GY.
that changes when the selector is
affected:
Replace PCB A6 with sensor.
available version.
Replace the MCU.
3:440 Error in PWM 6 output 1. Check that solenoid [Q1] has the
Output to parking brake is short- correct voltage, 48 V
circuited
2. Check output [X131:12]
3:460 Error in PWM 6 output 1. Check that solenoid [Q1] has the
Break in output to parking brake correct voltage, 48 V
2. Check output [X131:12]
3:461 Error in parking brake 1: Check that solenoid [Q1] has the
Broken output to parking brake. correct voltage, 48 V
The parking brake does not brake when 2: Check that the parking brake is
required. activated when you are stationary and
Driving is blocked and the truck is pressing down on the pedal
3: Replace the MCU
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


3:500 Unexpected error 1: Update to the latest software version
Unknown error, maybe version
2: Software error, report to manufacturer.
mismatch in ACT and MCU
3:520 Error at upstart 1. Check fuse
ACT was started wrongly, it did not
respond or set the log-in message
within 10 seconds

8.4.4 Hydraulic system error

4:180 No pulses from the main lift height sensor 1: Check the height sensor, battery voltage
on lift/lowering. or wiring harness as well as the wire for
the height indicator
2: Recalibrate the valve (Q4)
3: The fork load may be too heavy on
lifting.
4:181 Measured height deviates by more than 1: Check the signal from the height sensor
30 mm when the main lift's reference in diagnostic screen 15
sensors are affected.
2: Check that the wire for the height
indicator, the wiring and connectors are
intact and correctly connected
4:184 Excessive lifting/lowering speed. Check the lifting and lowering speeds
Lifting and lowering movement blocked. CID diagnostic screen 15, pos S
The lifting and lowering speeds should be

maximum
450 mm/s when lifting and 550mm/s when
lowering. If the speed is above 1000 mm/s,
the error code is generated.
If the speed is correct:
Check the pulse sensor.
If an error indication arises when
lowering:
Calibrate [Q4].
Adjust [Q4], maximum opening point.

(cont.)


(cont.) Excessive lifting/lowering speed. If the error indication persists
4:184 Lifting and lowering movement blocked. after calibration/adjustment:
Check that there is 15 V between [B19:1]
and [B19:4]. If there is not 15 V,
conductors 29 [X130:37] for [B19:1] and
30 [X130:20] for [B19:4] must be checked.
If the conductors are intact: Replace the
MCU.
Check that conductors 75/[X130:12] and
76 [X130:26] are intact.
Replace the height indicator wire
Replace the height sensor [B19].
Replace the MCU
4:186 The main lift's reference sensor does not Check the height indicator wire
switch status as expected.
Check the sensors B19/B58
Lift/lowering speed reduced.
Check that the height on the display tallies
with the actual fork height.
4:187 Invalid lifting height. 1: Activate the reference sensors by lifting
The forks estimated height is lower than the and lowering the forks
lowest possible level - including tolerance of
2: Check all parameters relating to height.
150 mm - or 50 mm above the maximum
Recalibrate if they are wrong.
lifting height according to parameter 1252.
Lift/lowering speed reduced.
4:200 Unknown error 1. Download new software to the ACH. If
Unknown hydraulic error, maybe version this involves an update, the software for
mismatch in ACH and MCU the MCU, the CID and other units may
Hydraulic movements blocked also need to be changed.
2. Report the fault to the manufacturer
4:201 Levers for hydraulic functions not 1. Calibrate the hydraulic levers.
calibrated
2. Check the activation of the hydraulic
Hydraulic movements blocked
levers with parameter 1007.


4:205 Temperature error 1: An overload in the hydraulic system may
Motor temperature over 180 C. generate this error code.
2: Check that the resistance in the pump
motor's temperature sensor is between
550 ohms and 650 ohms. At 150 C the
resistance should be 600 ohm.
3. Check that the fan for the motor
compartment works and that the
ventilation openings are not blocked.
4. Check that the pump motor is not
damaged.
4:214 The MCU or ACH has not responded via 1. Check fuse [F73].
CAN2 within 70 ms.
4:216 Hydraulic movements blocked
contacts. Disconnect the battery. Check
that the resistance between [X130:8] and
[X130:22] is 54 66 ohm.
3. Check whether the ACH's green LED is
lit constantly.
Check that the ACH has a supply voltage
of 48 V between [K1:9] and [B-].
Replace ACH.
If the LED is lit:
Replace ACH.
4:217 Communication error to service tool
See 4:205.
4:220 ACH Voltage for motor supply outside Check
specified limits.
Fuse F71
4:222 Hydraulic movements blocked
See 4:205. Check that the wiring harness and
connectors are intact and correctly
connected.


4:223 Overcurrent ACH. Check
That the battery voltage is correct when
connected to the ACH.
That the battery wiring harness is
undamaged and there is no relationship
between B+ and B-.
That the motor cables are undamaged
and there is no relationship between them
or with B-.
The motor windings' resistance to the
relationship.
Test using a new motor controller. If the
error persists, the fault is probably an
internal motor problem. Replace the
motor and refit the old controller.
4:225 The ACH's cooling element is over 125 C. Check that the cooling fan for the ACT and
Hydraulic movements blocked ACH is working normally. CID Service
function:
If the fan is working normally:

Clean the ACH heat sink and associated
duct. If the error returns the fault is probably
an internal ACH problem.
If the fan does not work normally:
There is a voltage to the fan, replace the
fan.
There is no power to the fan, check the
fan's wiring harness. If the wiring harness
is intact: replace the MCU.


4:228 Short circuit in the ACH, the pump motor Check
or the motor cables.
That the motor cables are undamaged
and there is no short circuit between them
or with B-.
The motor windings' resistance to the
relationship.
Test using a new motor controller. If the
error persists, the fault is probably an
internal motor problem. Replace the
motor and refit the old controller.
4:229 Measurement/Calibration error in the Log off and cut off voltage to the truck for
ACH's current measurement. at least one minute.
Restart the truck and log in again.
Replace ACH.
4:233 The ACH's internal 15 volts is outside the Check
specified limits.
Fuse F73
The battery voltage [ACH K1:9] and B-.
If the voltage differs from the battery
voltage:
Check that cable 27, between the fuse
box and the ACH, is undamaged and that
the connections are not oxidised.
If the voltage is the same as the battery
voltage:
Replace ACH.
4:240 Error in the lifting valve 1. Check the solenoids, power supply,
Short circuit in the circuit for raising the connectors and wiring harness.
lift [Q2].
2. With power to the truck cut off and fuse
Lifting blocked.
F73 removed: Check that the resistance
in the coil to valve [Q2] is approx. 48
ohms, [X131:21]
3. Replace ACH.


4:241 Short circuit in the circuit for lowering the 1. Check the solenoids, power supply,
lift [Q4]. connectors and wiring harness.
Lifting and lowering are blocked.
ohms, [T2:108] in ACH .
3. Replace ACH.
4:246 Short circuit in the circuit for function 1: Check the solenoids, power supply,
AUX1 [Q9]. connectors and wiring harness.
AUX functions are blocked.
2: With power to the truck cut off and fuse
ohms, [X131:38]
3: Replace the MCU.
4:248 Short circuit in the circuit for function 1. Check the solenoids, power supply,
AUX, direction A [Q18]. connectors and wiring harness.
ohms, [X131:37]
3. Replace the MCU.
AUX, direction B [Q19]. connectors and wiring harness.
AUX blocked.
ohms, [X131:11]
3. Replace the MCU.
4:252 Short circuit in the circuit for the fork 1. Check the solenoids, power supply,
carriage's Out movement [Q7]. connectors and wiring harness.
Reach carriage's movement blocked.
ohms, [X131:24]
3. Replace the MCU.


4:253 Short circuit in the circuit for the fork 1. Check the solenoids, power supply,
carriage's In movement [Q6]. connectors and wiring harness.
ohms, [X131:10]
3. Replace the MCU.
4:260 Break in output for lifting valve 1. Check the solenoids, power supply,
[Q2]. connectors and wiring harness.
Lifting blocked.
ohms, [*X131:21]
3. Replace ACH.
AUX [Q9]. connectors and wiring harness.
AUX functions are blocked
ohms, [*X131:38]
3. Replace ACH.
4:268 Break in the circuit for function AUX 1: Check the solenoids, power supply,
direction A [Q18]. connectors and wiring harness.
2: With power to the truck cut off and fuse
ohms, [X131:37]
3: Replace the MCU.
4:269 Break in the circuit for function AUX, 1. Check the solenoids, power supply,
direction B [Q19]. connectors and wiring harness.
ohms, [X131:11]
3. Replace the MCU.


4:272 Break in the circuit for the fork carriage's 1. Check the solenoids, power supply,
Out movement [Q7]. connectors and wiring harness.
Reach carriage's movement blocked
ohms, [X131:24]
3. Replace the MCU.
4:273 Break in the circuit for the fork carriage's 1. Check the solenoids, power supply,
In movement [Q6]. connectors and wiring harness.
ohms, [X131:10]
3. Replace the MCU.
4:280 The voltage for the lifting/lowering lever is Check that the output voltage is min 0.3 V
outside the permitted range. and max 4.7 V in each position, from joystick
[B20], CID's diagnostic screen 1, pos 1:
Lifting and lowering are blocked
If the voltage at any time is outside the

specified limits:
Check 5 V between [B20:1] and [B20:2].
Check that cable 50/BK is intact, [B20:3]
to [X505:2].
Replace the joystick [B20].
Replace the CID.
If the voltage is within the specified
limits:
available version.
Replace the CID.


4:281 Input signal from joystick reach outside Check that the output voltage is min. 0.3 V
specified limits. and max. 4.7 V in each end position, from
Reach movement blocked. joystick [B21], CID diagnostic screen 1, pos
2:

specified limits:
and [B21:2].
Check that cable 51/BN is intact, [B21:3]
to [X505:11].
Replace the CID.
limits:
available version.
Replace the CID.


4:282 Input signal from joystick tilt outside Check that the output voltage is min. 0.3 V
specified limits. and max. 4.7 V at each end position, from
Tilt movement blocked. joystick [B22], CID diagnostic screen 1, pos
3:

specified limits:
and [B22:2].
Check that cable 52/OG is intact, [B22:3]
to [X505:17].
Replace the CID.
limits:
available version.
Replace the CID.


4:283 Input signal from joystick AUX2/sideshift Check that the output voltage is min. 0.3 V
outside specified limits. and max. 4.7 V in each end position, from
AUX1/sideshift blocked. joystick [B23], CID diagnostic screen 1, pos
4:

specified limits:
and [B23:2].
Check that cable 53/YE is intact, [B23:3]
to [X505:3].
Replace the CID.
limits:
available version.
Replace the CID.
4:285 Break or short circuit in the speed sensor Loosen the sensor and remeasure [B12:1]
[B12]. and [B12:4], 1 = + and 4 = -. The
All hydraulic functions blocked. resistance should be approx 160 kOhm.
If the resistance measurement suggests
a break/short circuit in the sensor:
Replace the sensor.
If the resistance measurement excludes a
break/short circuit:
[B12:1]/[K1:11] and [B12:4]/[K1:6], for any
break/short circuit.
Replace ACH.
4:288 The speed sensor has lost the signal Check
All hydraulic functions blocked.
That the wiring harness is intact and
correctly fitted.
Replace the sensor [B12]


4:292 Bad pulse signal or no pulse signal from 1: Check the main lift sensor and its
main lift sensor when lifting or lowering connectors. There may be a short
mast. circuit.
4:520 ACH start up error. Check whether the ACH's green LED is lit
constantly.
Check fuse [F73].
Check that the ACH has a supply voltage
of 48 V between [K1:9] and [B-].
Replace ACH.
If the LED is lit:
Replace ACH
Check that CAN 2 is intact in terms of
contacts. Disconnect the battery. Check
that the resistance between [X130:8] and
[X130:22] is 54 66 ohm.
4:561 Short circuit in the circuit for lowering the 1. With power to the truck cut off and fuse
lift [Q4]. F73 removed: Check that the resistance
ohms, [*T2:108] in ACH
2. Replace ACH.

8.4.5 Steering system, warnings and errors

5:010 The EPS CAN module has received or 1. Check that CAN 2 is intact in terms of
sent too many faulty messages. wiring harness, final resistance and
5:011 contacts. Disconnect the battery.
Check that the resistance between
[X130:8] and [X130:22] is 54 66 ohm.
2. Update the truck's software to the latest
available version.
3. Replace the steering motor.
4. Replace the MCU.
5:080 EPS han no connection with the Check
reference sensor [B17]
That the wiring harness and connector
are intact and correctly fitted.
Replace the steering angle sensor [B17]
5:081 Reference sensor [B17] has no Check
connection
That the wiring harness and connector
are intact and correctly fitted.
Replace the steering angle sensor [B17]
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.


5:182 Signal from the steering angle sensor 1. Check the mechanical fastening of
- incorrect by 180. steering angle sensor [B17].
5:184 Travel speed limited to
2. Compare with the direction arrows
maximum 4 km/h.
and check that the signal from the steering

angle sensor changes status twice for
every complete turn of the steering wheel,
CID diagnostic screen 14, pos 2:
If the signal does not change status:

Check that there is battery voltage
between [B17:1] and [B17:3].
Check that conductor 57/[B17:2] to
[X901:11] is intact and does not receive
an incorrect 48 V supply.
Replace steering angle sensor.
available version.
Replace the MCU.
If the signal changes status:
Replace the MCU.
5:185 EPS reports an error during reference 1: Check the wiring harness (*X901:11)
- run or reference run not completed 2: Check the reference sensor (B17)
5:186 within 15 seconds.


5:300 The servo steering does not react as 1. Restart the truck.
& expected.
2. In the error log/list: Check other
5:304 Driving is disabled and the truck is
simultaneous error codes.
braked to a stop with plug braking.
If there are other error codes, correct
these before continuing with
troubleshooting.
3. Check the steering servo's wiring
harness.
4. Replace the steering servo.
5:301 Steering servo power stage fault. 1. Check fuse [F72].
Driving is disabled and the truck is
2. Check that there is a battery voltage
between conductors 250/[X901:8] +
[X901:16] and 40/[X901:7] + [X901:15].
5:302 The MCU cannot transfer the Update the truck's software to the latest
parameters to the steering servo. available version.
5:303 The steering servo does not respond 1. Check fuse [F72].
on start up.
1. Check that the wiring harness and
connected.
2. Replace the steering servo (A2).
5:320 The steering servo voltage is below 1. Check the battery voltage.
24V.
2. Check fuse [F72].
braked to a stop with plug braking. 3. Check that the wiring harness and
connected
5:325 EPS has been using too much power 1. Check that there are no objects
in too little time. blocking the steering movement (Drive
See 5:300. wheel)
5:326 The steering servo power stage is
below -40C or above +85C.
See 5:300.


5:335 Internal error in the steering servo. 1: Download software to EPS, even if the
See 5:300. truck already has the latest version.
5:336 Restart the truck (the first startup after
installing new firmware takes a longer
time than a normal startup), do not cut
the power.
2: Replace the steering servo if the error
code returns once the truck has
started.
5:380 Error in steering sensor 1: Check that the wiring harness and
Supply error Steering sensor 1. connectors are intact and correctly
Driving is disabled and the truck is connected.
2: Replace the steering sensor (B13)
Supply error Steering sensor 2. connectors are intact and correctly
Driving is disabled and the truck is connected.
Abnormal pulse frequency from the connectors are intact and correctly
steering sensor. connected
2: Replace the steering sensor (B13).
5:383 Error in steering sensor 1. Check that the wiring harness and
Steering sensors 1 and 2 different connectors are intact and correctly
signals. connected.
2. Replace the steering sensor (B13)
Power supply error Steering sensors connectors are intact and correctly
1 and 2. connected.
5:385 Error in reference sensor 1: Turn the steering wheel so that the
The signal from the reference sensor sensor (B17) starts to detect the
does not match the EPS steering correct steering angle.
angle.
This is a warning that the green
directional arrow may be pointing in
the wrong direction.
Truck travel disabled


5:414 CAN 2 communication error 1. Check fuse [F64] & [72].
The MCU or steering servo have not
5:416 responded via CAN2 within 70 ms.
The truck is brought to a stop by the plug
contacts. Disconnect the battery.
brake.
Check that the resistance between the
points 2 and 10 is 54 66 ohms.
4. Replace the MCU
5:421 The steering servo's direct voltage is 1. Check the wiring harness and fuse
above 78 V. (F64).
brake.
5:422 Short circuit in the steering servo
brake.
See 5:414.
5:435 Internal error in the steering servo.
5:438 brake.
See 5:414.
5:439 Anomaly in steering angle
brake.
See 5:414.
5:500 Unknown steering servo error. 1. Update the truck's software to the latest
All functions are stopped available version.
5:501 Error in the MCU Update software
The steering servo has detected an
error in the MCU.
8.5 Troubleshooting without indications
8.5.1 Mechanical brake (3000)
Error Cause Hints

Brake does not release Voltage too low. Check the truck battery. Charge if
necessary.
Break in voltage supply. Check wiring harness to the brake.
Restart the truck.

Error Cause Hints

Too much play. Adjust the play.
Worn friction disc. Replace the friction disc.
Coil defective. Replace the brake.
Too little play. Adjust the play.
Brake does not brake Voltage remains when truck Check the truck battery and its
is switched off. connections.
Grease on friction surfaces. Replace the friction disc and
readjust the play.
Uneven braking effect Voltage too low. Check the truck battery. Charge if
necessary.
8.5.2 Steering (4000)
Error Cause Hints

No steering manoeuvre Error in steering sensor 1. Replace the steering sensor
when the steering wheel is [B13]. [B13].
turned.
2. Check that all the CID inputs
from the steering pulse sensors
change status when the steering
wheel is turned, CID diagnostic
screen 2, pos 1 4:
Slut p avsnittet

Repair manual: Chassis C0000 Model(s): R112, R114, R116
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 Floor C0330
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.
9.3.3 Replacing the floor

Remove the inner engine cover
See section " Removing the inner motor cover".
Removing the floor
Step 1 Step 2
Method
1: Remove the screws.
2: Remove the connector [X10].

Adjusting the floor
Removing the inner motor cover

Removing the floor
See section " Removing the floor".
Method
1: Disconnect the cable fittings.
2: Remove the side guard.
3: Lift and turn the floor pipe to the desired position. (There are 3 positions).
4: Undo the screws in the wall mount, and adjust to the desired level.
5: Reassemble the step-up plastic.
6: Refit the wiring harness.
Fitting the floor
See section " Fitting the floor".

Fitting the floor
Step 1 Step 2
1: Connect the connector [X10].

2: Fit the screws.

9.3.4 Protective covers
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.
Replacing the top cover

Removing the steering arm covers
See section " Removing the steering arm covers".
Removing the top cover
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.

Fitting 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".

Replacing 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.

Replacing the cover, wiring harness
Removing the cover, wiring harness
Step 1
Method
1: Remove the cover
Fitting the cover, wiring harness
Step 1
Method
1: Fit the cover.

Replacing the elbow panel
Removing the elbow panel
Method
1:

Fitting the elbow panel
Method
1:
Replacing the motor cover
Removing the motor cover
Method
1: Undo the two screws on top.
2: Undo the screw on the side.
3: Lift away the motor covers.

Fitting the motor cover
Method
1: Put back the motor cover
2: Screw in the side screw.
3: Fit the screws on the top.

Replacing the inner motor cover

See section " Removing the motor cover".
Step 1 Step 2
Method
2: Lift away the inner motor cover.
Fitting the inner motor cover
Step 1 Step 2
Method
1: Put back the inner motor cover
2: Fit the screw.

Replacing the front knee cover

Removing the front knee cover
Step 1 Step 2
Method
2: Take off the front knee cover.
Fitting the front knee cover
Step 1 Step 2
Method
1: Put back the front knee cover
2: Fit the screws.

See section " Fitting the steering arm covers".
9.4 Support arm C0350

Please get in touch with Tech Support in case of problems with the support
arms.
9.5 Battery compartment parts C0390
9.5.1 Overview, battery support
Pos. Description
a Battery roller
b Battery stop
c Battery locking device

9.6 Operator's seat C0620
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.
9.6.3 Replacing the operators seat (Basic)
Removing the operators seat (Basic)
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.

Fitting the operators seat (Basic)
Step 4 Step 5
Method
1: Put back the operators seat.
3: Fit the rear screws.

Adjusting the operators seat (Basic)
Method

Removing the operators seat (Comfort Low, Comfort High)
Step 1 Step 2 S
Method
2: Undo the rear screws.
3: Push back the seat.
4: Undo the front screws.
5: Disconnect the connector [X47].

Fitting the operators seat (Comfort Low, Comfort High)
Method
1: Put back the operators seat.
3: Push back the seat.
4: Fit the front screws.

Adjusting the operators seat (Comfort Low, Comfort High)
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.

9.6.4 Seat switch
Replacing the seat switch (Comfort)
Removing the seat switch (Comfort)
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.

Removing the seat switch (Comfortt)
Step 4
Method
1: Fit a new switch.
2: Connect the connector [B49].
3: Turn back the cover.
4: Fit the back rest cover.

9.6.5 Replacing the backrest, chair seat
Removing the backrest (Comfort Low, Comfort High)
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?)

Fitting the backrest (Comfort Low, Comfort High)
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.

Removing the seat pad

Removing the backrest
See section " Removing the backrest (Comfort Low, Comfort High)".
Method
1: Split the connector [X62] if there is one.
2: Loosen the screws at the back of the seat.
3: Push the seat forwards until it comes loose from the frame.
Fitting the seat pad

Method
1: Position the seat pad.
2: Secure the seat with two screws.
3: Connect the connector [X62] if there is one.
Fit the backrest
See section " Fitting the backrest (Comfort Low, Comfort High)".

9.6.6 Replacing the seat plate

Removing the operators seat
See section " Removing the operators seat (Basic)".
See section " Removing the operators seat (Comfort Low, Comfort High)".
Removing the seat plate
Step 1 Step 2
Method
1: Undo the four screws to the seat plate.
2: Lift away the seat plate.

Fitting the seat plate
Step 1 Step 2
Method
1: Put back the seat plate.
2: Fit the screws of the seat plate.

9.7 Operator controls C0640
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.

If the accelerator is depressed before the safety pedal is depressed or the

operator is sitting in the seat, the accelerator must be released then
depressed again.
9.7.4 Accelerator/Brake pedal
Replacing the accelerator/brake pedal

Removing the floor
Removing the accelerator/brake pedal
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.

Fitting the accelerator/brake pedal
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
9.7.5 Safety pedal
Replacing the safety pedal

Removing the floor

Removing the safety pedal
Step 1 Step 2
Step 3
Method
1: Disconnect the connector [B31].
3: Lift out the safety pedal from the floor plate.
Fitting the safety pedal
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

9.8 Interior fittings C0680
9.9 Mirrors C0740
9.10 Overhead guard/Roof C0810
9.10.1 Overview
Pos. Description
a Protective overhead guard

9.10.2 Description
The truck has a corrugated roof mounted on two supports.
9.10.3 Replacing the overhead guard roof
Removing the overhead guard roof
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.

Fitting the overhead guard roof
Method
1: Put back the roof.
2: Fit the bolts on the right side.
3: Fit the bolts on the left side.

9.10.4 Replacing the front roof support

Remove the overhead guard roof

See section " Removing the overhead guard roof".
Removing the front roof support
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.

Fitting the front support
Method
1: Put back the support.
2: Fit the screws around the rubber bushing.
3: Fit the screws in the lower bracket.

9.10.5 Replacing the rear roof support

Removing the overhead guard roof
See section " Removing the overhead guard roof".
Removing the rear roof support
Step 1 Step 2
Method
2: Lift out the support.
Fitting the rear support
Step 1 Step 2
Method
1: Put back the support
2: Fit the screws.

Fit the overhead guard roof

See section " Fitting the overhead guard roof".
9.11 Finger-foot guard C0820
Replacing a finger guard
Removing the finger guard
Step 1 Step 2
Method
2: Lift away the finger guard.

Fitting the finger guard
Step 1 Step 2
Method
1: Put back the finger guard.
2: Fit the screws.



Repair manual: Motors C1000 Model(s): R112, R114, R116
10. Motors C1000

10.1 Overview
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 Electric pump motor C1710
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

10.3.3 Replacing the pump motor

Remove the seat plate
See section " Removing the seat pad".

Removing the pump motor
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.

Fitting the pump motor
Step 7. Tightening torque 20 Nm+/

-2

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).
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)".

10.3.4 Replacing the temperature sensor

It is not possible to replace the motor's internal temperature sensor. If a fault
occurs with the temperature sensor the internal sensor is replaced by an
external sensor.
The temperature sensor may be mounted ether to the left or to the right of
the connection socket,
depending on which side is easiest to reach and the length of the
wire of the replacement sensor.
Removing the temperature sensor
Step 1 Step 2
Step 3 Step 4

See section " Removing the seat plate".

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.
Installing the external temperature sensor
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.
See section " Fitting the seat plate".

10.4 Steering motor C1730
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
F64 A2: Electronic Assy,

B Pos
Steer Servo
M
B59 X901:2/:10 CAN 2
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

The steering motor is made up of three main components mounted installed

as one unit:
a: Steering servo electronics [A2].
b: The motor [M6], which is a brushless synchronous motor with
permanently magnetised rotor.
c: A two-stage planetary gear, which has a gear wheel on its output shaft in
direct contact with the gear ring on 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.

10.4.3 Layout of the flange holes
b
a
View from the underside of the steering motor: a: Attachment, b: Guide, c:
Threaded hole for removing steering motor.

10.4.4 Steering servo motor replacement

Removing the steering servo motor
Step 1 Step 2 Steps 3 and 4
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.

Fitting the steering servo motor
Step 1 Step 2 Step 3. Tightening torque 46 Nm
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.


Fitting the inner motor cover
See section " Fitting the inner motor cover".
Lubrication of the steering servo motor ring gear

10.5 Electric fan motor / fan
10.5.1 Fan for frequency converter
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.

10.5.2 Replacing the frequency converter fan

Removing the floor
Removing the frequency converter fan.
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.

Fitting the frequency converter fan
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

10.5.3 Motor compartment fan
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.

10.5.4 Replacing the motor compartment fan

Removing the motor compartment fan.
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.

Fitting the motor compartment fan
Step 1 Step 2 Step 3, tightening torque

4Nm.
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].

10.6 Electric drive motor C1760
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.

10.6.3 Replacing the drive motor

Removing the floor
Removing the brakes
See section " Removing the parking brake".
Removing the drive motor
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.
Fitting the drive motor
Step 1. Tightening torque 24 Step 2 Step 3. Tightening torque 20 Nm

Nm +/- 2
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 motor cover".
10.6.4 Replacing the temperature sensor

Removing the floor
Removing the temperature sensor
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.
Installing the external temperature sensor
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

10.6.5 Replacing the RPM-sensor.
Removing the RPM-sensor
Step 4

Removing the floor
Method
1: Disconnect the connector [B11]
2: Detach the cable bracket.
3: Remove the sensor screw.
4: Remove the RPM-sensor.

Fitting the RPM-sensor
Step 4. Tightening torque 5 Nm +/-1
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



Repair manual: Mechanical Drive Gear Unit C2000 Model(s): R112, R114, R116
11. Mechanical Drive Gear Unit C2000

11.1 Overview
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.

Repairable Torque Preconditions Instruction

The truck parked on a level surface.
Oil change The drive gear turned so that the level
and drain plugs are easily accessible.
Leakage from the lower cover. The truck parked on a level surface.
Checking the oil level
Removing the drive gear
Replacing the steering bearing
Installing the drive gear
Reparerbarhet 1: C2000 Drive gear
11.3 Checking the oil level
Step 1. Step 2. Step 3.

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.

11.4 Oil change

Note:
Handle the used oil in accordance with applicable environmental regulations.
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 1 Step 3. Step 4
Step 7
Step 5
Step 8. Step 9 Step 10

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.
Model Gearbox Volume

R112-R116 GK25 3.3 L

11.5 Leakage from the lower cover
Step 2 Step 3. Step 4
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.

11.6 Replacing the drive gear
11.6.1 Removing the drive gear
Step 6 Steps 8 and 9
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.

8: Lower the gear onto the floor.

9: Extract the gear in a lying down position.
Note:
The gear weighs approx. 60 kg.

11.6.2 Fitting the drive gear
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.

11.7 Replacing the Steering bearings
Removing the steering bearings
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.
Fitting the steering bearing
1: Insert the new bearing, using two screws as guides.

2: Apply Loctite 243 to six of the screws and screw them into the holes with
openings down towards the drive gear.
Screw the other screws into place too.
3: Torque tighten the screws cross-wise to 34 Nm
Slut p avsnittet


Repair manual: Brake system/Wheels C3000 Model(s): R112, R114, R116
12. Brake system/Wheels C3000

12.1 Brake system C3100
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.

12.1.3 Drive motor brake (travel brake)

The truck is braked primarily by means of regenerative braking using the
drive motor. Plug braking can be obtained in three different ways. These are:
Releasing the accelerator when the truck is in motion
Changing the direction of travel using the travel direction selector, at the
same time as pressing the accelerator
Pressing down the brake pedal.
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.
Changing the direction of travel

When the direction of travel is changed during operation, the motor brakes
the truck so that the direction of travel can be changed. Here motor braking is
regulated by the position of the accelerator - the further the pedal is pressed
down, the greater the force involved in braking.
The braking force when changing direction of travel can be adjusted using a
service parameter.

12.2 Parking brake C3370

DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function being
partly or completely lost.
Only the actions described in this section may be done to the parking brake
and the instructions must be followed strictly.
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
New brake Worn brake

(mm) (mm)
Air gap, pressure disc to magnet 0.2+0.15-
0.65
housing 0.05 mm

12.2.3 Replacing the parking brake

Removing the parking brake
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.

Fitting the parking brake
Step 4. Tightening torque

10.1 Nm +/- 1.1 Step 5
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.

Checking the brake unit's air gap

See section "12.2.8 Checking the parking brake air gap".
Check that the brake releases
Cross reference
12.2.4 Replacing the dust plug

Removing the dust plug
Step 1
Method
1: Remove the dust plug

Fitting the dust plug
Step 1
Method

12.2.5 Replacing the hub

Removing the hub
Step 1 S Step 3
Step 4 Step 5
Method
1: Remove the dust plug.
3: Undo the screws of the brake unit.
4: Remove the brake unit.
5: Remove the hub and the guide key.

Fitting the hub
Step 1 Step 2 Step 3. Tightening torque 10.1 Nm

+/- 1.1
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].


12.2.6 Replacing the rubber gaiter

Removing the rubber gaiter
Step 1 Step 2
Method
2: Remove the rubber gaiter.

Fitting the rubber gaiter
Step 1 Step 2
Method
1: Fitting the rubber gaiter.
2: Connect the connector. Fit the motor cover.

12.2.7 Checking the parking brake's brake force

Checking the parking brake's brake force
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.

12.2.8 Checking the parking brake air gap

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.

12.3 Wheels C3500
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

12.3.2 Wheel wear

H H
Type mm Normal Minimum

measurement, mm dimensions,
(H) mm
Drive wheel D = 330 30 15
Support arm wheel D = 25 12.5
280
12.4 Drive wheel C3530
12.4.1 Overview
b
c
Pos. Description
a Wheels
b Conical washer
c Wheel nut

12.4.2 Replacing the drive wheel
Removing the drive wheel

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.

Fitting the drive wheel
Step 1. Step 2.
Step 3. Tightening Step 4.

torque 140 Nm
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 Support arm wheel C3550
12.5.1 Overview
e
d
a
b c
Pos. Description
a Shaft
b Circlip
c Bearing
d Circlip
e Spacers
f Spacers

12.5.2 Replacing an unbraked support arm wheel
Removal of an unbraked support arm wheel
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.

Fitting of an unbraked support arm wheel
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.

12.5.3 Replacing bearings

Dismantling the drive wheel
See section " Removing the drive wheel".
Removing the bearings
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.
Assembling the drive wheel

See section " Fitting the drive wheel".

12.5.4 Replacing the wheel bolt

Dismantling the drive wheel
See section " Removing the drive wheel".
Method
1: Remove the damaged wheel bolt.
Damaged threads: With stud tool
Broken wheel bolt:
Opt. 1 Drill a hole in the centre of the bolt and screw out the bolt using
a screw extractor for an M14 bolt.
Opt. 2 If the bolt cannot be removed with the screw extractor.
Centre-punch the centre of the bolt; be precise when centring the punch.
Pre-drill a 5 mm hole through the bolt.
Drill out the stud using a 11.5 mm drill bit.
Try to remove the remains of the bolt using pliers or a similar tool. If this
cannot be done, clear the thread using an M14x1.5 thread tap.
2: Apply a string of Loctite 270 to the wheel bolt thread.
3: Fit the new wheel bolt using a stud tool and torque tighten to 80 Nm.
Assembling the drive wheel
See section " Fitting the drive wheel".

Repair manual: Steering system C4000 Model(s): R112, R114, R116
13. Steering system C4000

13.1 Description
The steering system is electric and uses a "Steer-By-Wire" design. As a
result, there is no mechanical contact between the steering wheel and the
steering drive wheel.
CAN1 CAN2
CID MCU EPS
Steer-by-Wire The steering wheel pulse transducer produces a double

pulse train to CID and data is sent to MCU, which processes incoming data
and creates a setpoint that is sent to the steering servo. The steering motor
then runs until the actual value matches the setpoint.
Steering is progressive, which means that when the truck is operated at low
speed the steering wheel gearing ratio is higher than at high speeds. This
allows the truck to be operated in a safe and efficient manner. The steering
characteristics can be adapted to the operators experience and
requirements. Steering sensitivity and progressiveness can be increased or
decreased as is required, see .
The pulse transducers in the steering wheel are connected to the CID [A1]
and data is sent from the CID via the CAN1 bus to the MCU.
CID continually monitors the pulse train from the steering wheel pulse
transducer. Because of this, any errors from the pulse transducer or
interruptions in the wiring harness are detected immediately.
The MCU processes steering data together with steering parameters to
create a setpoint that is sent to the steering servo via CAN2. The steering
servo carries out and monitors the steering angle change.
The MCU monitors the steering servo and CAN buses, so any electrical faults
in the pulse transducer, cables or electronic unit result in automatic shutdown
of the truck drive function.

13.2 Electric steering wheel C4310
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.
The pulse transducer is monitored as follows:

The pulse trains from the two transducers must have reached the same
level within a defined period of time.
Pulse train frequency must not exceed a defined value.


13.2.3 Adjustment
Turn the control (a) to set the steering wheel angle.

Turn the control (b) to set the arm angle.
Hold the button (c) depressed and pull out/slide in the steering wheel to
set the length. Release the button at the desired length and pull out the
steering wheel until it locks into place.
Please note that the steering arm is not locked in the upward direction. This
makes it easier to raise it when getting into the truck.

13.2.4 Replacing pulse transducer [B13]

The steering wheel module has a pulse transducer fitted under the steering
wheel. The pulse transducer can be replaced without having to remove the
steering console from the truck.
If the wiring harness inside the steering console must be replaced, the entire
steering console should be removed from the truck.
Method
1: Switch off the truck and disconnect the battery connector.
2: Remove four screws (a) (torx 10) from the underside of the steering
wheel module.
3: Remove the bottom panel (b).
b 4: Remove the disc with the logo from the centre of the steering wheel.
5: Remove two screws (c) (torx 20) and the washer (d).
a 6: Remove the steering wheel (e) and the spacer (f).
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.

13.2.5 Replacing the steering console
Removing the steering console
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.


2: Expose the steering console by removing the screw (a) on the right-hand
side of the tiller arm and remove the panel.
3: Remove the screw (b, c, d) in order to remove the panel. (Missing

illustration)
4: Undo the contact unit (c) by the wall.
d
c
5: Remove the three screws (d) that hold the steering console in place and
remove the steering console from the truck.

13.2.6 Replacing the wiring harness in the steering console

1: Remove four screws (a) from the underside of the steering wheel
module.
2: Remove the bottom panel (b).
3: Remove two screws (c) together with the pulse transducer.

4: Remove the top panel (d).
d
5: Undo the connector unit (e) by the transducer.

6: Remove the screws and sleeve (g) by the steering wheel module joint.
7: Unscrew the adjusting screw (f) all the way so that the steering wheel
module is free of the steering console.
e
f

8: Prise the button (h) free of the steering console.

9: Remove the two screws (k) and remove the casing (j) from the steering
console.
10: Remove the panel (m) from the steering console
DANGER!
Take care when removing springs. Risk of injury.
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
14: Place a new cable and reassemble in reverse order.

13.2.7 Fit the steering console in the truck

1: Place the steering console on the truck.
2: Tighten the three screws d securing the steering console; tightening
torque 2 Nm.
3: Connect the contact unit (c) by the wall.
c
4: Refit the panels around the steering console.
13.2.8 Replacing the steering wheel
(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 Steering unit C4330
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
CAN DSP HALL

EFFECT
SENSOR
F/B
HALL
EFFECT
SENSOR
B59 EN = Activate, CAN = Controller Area Network, B59 =

PS = Power unit,
Reference sensor, DSP = Digital Signal Processor, PWM = Pulse Width
Modulation, F/B = Feedback
Integrated in the steering unit is a signal processor that decodes information
from the CAN input and activates the steering motor via a pulse-width
modulated, three-phase current that determines the movement direction and
speed of the motor.
Feedback of motor movement is handled via a Hall sensor in the steering
motor that detects the extent and direction of motor movement.
When a truck with the 180 steering option is started, a reference run is
performed to check the steering and update the actual steering angle.
13.4 Steering reference sensor (4350)
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".

13.4.1 Replacing the reference sensor [B17]

The sensor does not need adjusting on replacement.
a 1. Remove the screw securing the old sensor.
2. Undo the connector unit for the sensor.
3. Fit the new sensor and screw it in tight.
4. Connect the wiring harness; The routing of the wiring harness should be
according to Fig. 1. The wiring harness must not be routed as shown in
Fig 2, as there is a risk of the connector coming loose.
Fig 1. Fig 2.


Repair manual: Electrical system C5000 Model(s): R112, R114, R116
14. Electrical system C5000

14.1 Description
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
Travel speed reduction - steering angle

The truck's travel speed is reduced depending on the current steering angle.
The function is activated using parameter 1106.
This is adjusted using parameter 215 for the initial angle and parameter 216
for the final angle.
Note:
Each time the truck is started, a reference calibration is made and the
steering wheel is turned to the 0 steering angle.
14.3 Battery C5110

The truck is designed to be powered by a lead-acid traction battery with a
nominal voltage of 48 volts.
Check that the battery in the truck is a 48 V traction battery having a weight
within the minimum/maximum values stated on the identification plate.
14.3.1 Battery recommendations

WARNING!
Risk of personal injury and material damage
If battery sizes other than those recommended are used, the trucks stability
may be affected.
Only use the recommended battery sizes or verify with the maker of the truck
that the planned battery fulfils the requirements set regarding stability.
14.3.2 Measuring discharge current

Discharge current is measured via a shunt resistor. The MCU evaluates the
measured value.
14.3.3 Measuring voltage

<This section is reserved for future use>
14.3.4 Charging the battery

Use an automatic battery charger intended for charging traction truck
batteries.

The charger shall have an automatic maintenance charging feature for a

certain period after the main charging period has been completed. This
eliminates the risk of overcharging the battery and the need to monitor the
charging procedure is reduced to a minimum.
The charger shall have a minimum charging current as indicated in the
following table:
Battery (Ah) Charger (A)
300 480 50 70
480 730 80 110
730 900 130 150

14.3.5 BDI algorithm and parameter setting

The battery size service parameter is set as standard to the largest size
(capacity) of the battery used. This prevents damage to the battery. If the
customer uses a battery with a smaller capacity and this parameter is not
adjusted, the battery will not be used to its full capacity. For a detailed
description of how to set the parameter, refer to the parameter section of the
manual.
The CID battery charge symbol shall indicate 0% when the remaining
capacity is 20% or less.
14.3.6 Performance limitations due to battery status

When the CID battery charge symbol indicates 0%, truck acceleration is
limited to 30% of maximum performance and lift speed is limited to 0% of
maximum performance, i.e. it is not possible to lift the forks.
14.3.7 Performance limitations due to battery status and

parameter setting
When the CID battery charge symbol indicates a very low level (selected with
the service parameter), truck acceleration and lift speed are limited to 70% of
maximum performance.
14.3.8 CID symbol

The battery charge symbol (located in the upper right-hand corner of the CID
display) comprises eight boxes that correspond to the charge status of the
battery. When the battery is fully charged, all boxes are black. When it is fully
discharged, all boxes are white.
The low battery voltage symbol (located in the top edge of the panel) flashes
- + when the charge level is below 10% and remains lit when the level is 0%.
14.3.9 Resetting the battery indicator (BDI)

The battery indicator (100%) is normally reset upon login if B+ is measured
to >50V. This could create problems if you replaced the MCU on a truck out
in the field. It is therefore possible to reset the battery indicator manually by
changing a service parameter setting and then logging in.
14.3.10 Battery weight

Battery weight is an input parameter to Optipace that is used to calculate the
highest permissible performance and is indicated with a factory parameter.

14.3.11 Parameter overview, battery
Par. Description
107 Battery size
Battery status when acceleration and lift speed are
108
limited
109 Resetting (4 = BDI reset)
14.3.12 Battery cable harness
Overview
X1

14.3.13 Battery cable replacement, machine part
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.

14.3.14 Battery cable replacement, battery part
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 Signal / Alarm (Sound-light) C5160
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.

14.4.2 Replacing the horn
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

14.5 Main contactor C5190
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
14.5.1 Replacing the contactor
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

14.6 Instrument panel C5200
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.

14.6.1 Operating controls
14.6.2 Replacing the operating controls
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

14.6.3 Replacing the switch for travel direction selection / horn

1: Undo the 6 screws and remove the lower section
2: Undo the 4 screws and remove the plastic cover
3: Undo the 9 screws and remove the plastic cover for the levers
4: Remove the connector to A6
5: Undo the 4 screws and remove the travel direction selector / horn
14.6.4 Replacing the controls on the operating panel

1: Undo the 6 screws and remove the lower section
2: Undo the 4 screws and remove the plastic cover
3: Undo 1 screw to the metal plate holding the controls
4: Use a small screwdriver to remove the controls.
14.6.5 Central Information Display (CID)
1 2 3
4 5 6
+ 7 8 9
C 0
A Central Information Display (referred to as CID), with its menu-based

information system, is used as the main instrument of communication
between the operator and the truck.
The CID contains coloured LED symbols and a monochrome display
graphics. To the right of the display there is a keypad with the figures 0 to 9
and the buttons green (I) and red (O).
In logged-out mode, display backlighting is switched off if there has been no
activity for 5 minutes. Once the keypad is activated, the lighting is switched
on again.
In logged-in mode, the display is always lit.

Information symbols
Symbol Description Symbol Description

Truck Truck
Reach carriage fully Reach carriage fully or

retracted. partly extended. Five-
stage indication.
Battery status
8 levels of charging are

indicated.
Completely full = Fully
charged.
Symbol Description Symbol Description Symbol Description

Information Timer Time
mode
Date, time and
hour meter.
Operator Program
version.
Indicates the
active operator
profile.
Login
Login method Login method Login method
Login via ID unit
Login with PIN PIN code login
or unit connected
code verified by
to the MCU
T.W.I.S.
Reading ID unit. Emergency
Waits for driving
identification via
ID unit
Height preselector.
Height pre- Pick up Deposit
selection active
Delete height

Driver parameter symbols Overview

Steering response Max speed,
drive wheel direction
Max speed, Acceleration

fork direction
Automatic brake
Steering sensitivity at Steering sensitivity at

high speed. low speed.
NOTE: The symbol is
also used as a catch
symbol.

Catch symbols Overview

Height limit. Seat switch.
Function reactivation. Temperature
Safety pedal Service
Looking for upper Brake activated at start-

reference sensor. up.
Main lift started. Program version

incompatible.
ESO (Emergency
Switch Off)

Service symbols Overview

Service symbols are displayed either as a selection for a service function or
as an indication of which service functions are active.

Service mode.
Service function for Pressure relief

operating the mast.
Service function for Service function for

main cylinder bleeding. testing the fans
Calibration mode Calibration of

proportional valves.
Control calibration. Calibration of the load

cells.
Calibration of sensors.
Configuration mode Resets chosen

parameter to standard
value.
Settings of the operator PIN code
and service
parameters.
PIN code, disable PIN code
Diagnostics. Read-out of the error

log.
Read-out of the Emergency driving

collision sensor log mode.

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
*
Overview of the functions that are accessible with

the CAN key or TruckCom.
a: Login procedure, j: Logged in,

h: Also accessible with special PIN code

*: This function is not available.
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
a. Travel direction - left.

Flashes when no travel direction is selected, comes on permanently
when travel direction is the same as drive wheel direction.
b. Stop.
The truck has been stopped due to a critical fault.
c. Warning.
Comes on when a warning is active.
d. Travel direction - right.
Flashes when no travel direction is selected, comes on permanently
when travel direction is the same as fork direction.
e. Parking brake:
Is lit when the parking brake is engaged
f. Low battery.
Battery capacity is low: flashing when 10% remaining, on permanently at
0%.
g. Extra.
Comes on when an extra hydraulic function is selected.

14.6.6 Replacing the CID
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

14.7 Height indication
Overview
Overview
B19
B58
X15

Description
14.7.1 Replacing the sensor bearing
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
14.7.2 Replacing the height reference sensor
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

14.7.3 Hight indication wire
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)

14.7.4 Check and adjust the wire

The wire is attached to the top and the bottom of the mast. The upper bracket
is attached to a spring that is tensioned when one adjusts the bottom of the
mast where the wire lock is.
The wire adjustment must be 80mm 10mm at the upper bracket at the top
of the mast.
14.7.5 Replacing the height indication wiring
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

14.8 Travel function wiring/ fuse C5390
14.8.1 Chassis wiring
Removing the chassis wiring

1: Start by disconnecting the connector X500
2: Remove the extra socket X21
3: Remove the connectors to the emergency stop switch
4: Undo 2 nuts from the connector Q10 to remove the wiring harness.
5: Disconnect the connectors to relay K20
6: Remove the wiring harness from the chassis by undoing the cable clips.
7: Disconnect the connector X17
9: Disconnect the connector A82 if the truck is equipped with TWIS,
otherwise open the wiring clip.
10: Undo the four screws to the fuse box and remove it
11: Remove the wiring harness from the chassis by undoing the cable clips.
12: Disconnect connector G3 from the fan
13: Disconnect the connectors X130 and X131 from the MCU
14: Disconnect the connector X22 from the collision sensor, otherwise undo
the wiring from the cable clip.
15: Disconnect the connectors T1 and T2 from ACT/ACH
16: Remove the wiring from the ACH
17: Remove wire X21/B17
18: Undo the cable clips
19: Disconnect the connectors B1 from the temperature sensor and B11
from the speed sensor
20: Disconnect connector G1 from the brake
21: Disconnect connector A2 from the steering motor
22: Disconnect the connector B2 from the temperature sensor and B12 from
the speed sensor.
23: Remove the wiring from the cable clips in two places
24: Disconnect the connectors X11 and X12 that go to the reach carriage
wiring harness.
25: Remove the wiring harness from the cable clips.
26: Disconnect P4 to the horn
27: Disconnect the connector G4 from the fan and X47 to the operator's seat.

14.8.2 Operator control wiring
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
14.9 Drive motor cables/resistor/fuse C5430
14.9.1 Replacing motor cables

14.10 Transistor panel C5460
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

Error LED flashes or is unlit

Power is fed via two terminal screws B+ and B-. B+ is secured with a
250A fuse.
LED Status
Off The regulator has no power, or it has power but does not work
On: The regulator is working properly, no error messages
A warning has been generated. This may lead to a reduction in the maximum
Flashing slowly
power available to the motor
An error is detected. This can cause the motor controller to

Flashing quickly
cut off power to the motor.
The motor controller software is in the start-up mode, cause either by an

Intermittent flashing
ongoing download or by missing or defective software.
Flashing slowly Rest mode activated

14.10.1 Replacing the ACT

Removing the floor.
Removing the covers.

Cross reference
Removing the ACT.
Step 4 Step 5
Method
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

Fitting the ACT.
Step 1: 8Nm +- 1 Step 2 Step 3: 8Nm +- 1
Step 4: 8Nm +- 1 Step 5:
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?
Checking the ACT

Add the steps?
Fitting the floor


Fit the covers

CROSS REFERENCE
14.10.2 Replacing ACH.
Removing the floor

Removing the covers

CROSS REFERENCE
Removing the ACH.
Step 4 Step 5
Method
2: Disconnect the plastic yoke.
3: Disconnect the yokes to the ACT.

4: Turn the yokes over the ACT.

5: Remove the ACH.
Fitting the ACH.
Step 1 Step 2 Step 3: 8Nm +-1
Step 2 Step 5: 8Nm +-1
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.

Checking the ACH

How is that done?
Fitting the floor

Fit the covers

CROSS REFERENCE
14.11 Work function harnesses / fuse C5590
14.11.1 Fuse panel
Overview

Description
Fuses
F1 Main fuse for T1

F60 Fuse for relays
F61 Main fuse for A5
F62 Main fuse for A1
F64 Fuse for activation of A2
F66 Fuse for [T5] and T6
F71 Fuse for A5
F72 Fuse for A2
F73 Fuse for control voltage
14.11.2 Checking fuses
Method
Checking fuses; no indication = broken fuse

14.11.3 Roof wiring
Description
Overview
14.11.4 Replacing the roof wiring
14.11.5 Mast wiring
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
14.11.6 Replacing the mast harness
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

14.11.7 Check and adjust the mast wiring
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

14.11.8 Reach carriage wiring
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
Replacing the reach carriage wiring harness
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

3: Connect the connector X13 to the main valve unit

4: Disconnect the connector X14 for the mast functions ans connector X15
if the truck is equipped with height indicator
5: Fix the wiring to the hydraulic hoses using 2 cable clips.
14.12 Main processor MCU C5710
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 flashes 2Hz No program or error in program

LED is unlit The MCU is defective or has no power
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:
Pin Function Active In/Out

1 Power source +5 V 5V Out:
2
3 Hydraulic air pressure [B4] 0.5 4.5 V In
4 Brake pedal, signal 1 0.5 4.5 V In
5 Voltage measurement, battery 48 V In
6 Ground, analogue 0V In
8 CAN2 low 0.5 2.5 V In/Out
Aisle sensor (north magnet), fork
10 48 V In
direction
End of aisle retardation 2, drive wheel
11 48 V In
direction
12 Height sensor, pulse A 48 V In
Aisle sensor (south magnet), drive
13 48 V In
wheel direction
16
17 Accelerator 0.5 4.5 V In
18 Brake pedal, signal 2 4.5 0.5 V In
19 Battery measurement 2 0V In
20 Ground, digital 0V Out:
22 CAN2 high 4.5 2.5 V In/Out
Power measurement +15 V, service
23 15 V Out:
key
Aisle sensor (north magnet), drive
24 48 V In
wheel direction
25
26 Height sensor, pulse B 48 V In
27 Mast lowering mode B 48 V In
29 Ground, analogue 0V
30 Hydraulic air pressure [B6] 0.5 4.5 V In
31 Safety pedal/safety switch, door 1.5 3.5 V In


32 Battery measurement 1 0V In
33 CAN2 ground 0V Out:
34 Ground, service key 0V
37 Power source +15 V 15 V Out:
38 End of aisle retardation 1, fork direction 48 V In
39
Aisle sensor (south magnet), fork
40 48 V In
direction
41 Seat switch 48 V In
X131:

1 Current source 48 V In
2 Mast lowering mode A 48 V In
3
4 Speed limitation 3 48 V In
5 Status, emergency switch 48 V In
6 Status, key relay 48 V In
7 Main relay 48 V Out:
8 Left-hand direction indicator 48 V Out:
9 Fan control 48 V Out:
Extra hydraulic valve 1B, battery
10 48 V
change
11
12 Support arm brakes, inner 0 48 V PWM Out:
13 Valve for fork unit activation [Q24] 0 24 V PWM Out:
14 Ground 0V
15 Charging capacitor 48 V In/Out
Travel direction pedal, drive wheel
16 48 V In
direction
18 End of aisle stop 1, fork direction 48 V In
19 Key (option) 48 V In
20 Parking brake 48 V Out:
21 Longitudinal positioning lamp 48 V Out:
22
23 Travel alarm 1, acoustic signal 48 V Out:
24 Camera change 48 V Out:
25 Horn 48 V Out:
26 Valve for main mast lift [Q2] 0 24 V PWM Out:
27 CAN1 high 4.5 2.5 V In/Out
30 Travel direction pedal, fork direction 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
14.12.1 Replacing the MCU
Replacing the MCU
Removing the floor

Removing the MCU
Step 1 Step 2
Method
1: Disconnect the connectors to the MCU.
2: Remove the MCU.

Fitting the MCU
Step 1 Step 2
Method
1: Fit the MCU
2: Disconnect the connectors.
Fitting the floor


14.13 Sending units and sensors C5800
14.13.1 Inductive sensors

Inductive sensors are affected by metallic objects that are moved into the
sensor's active area.
The sensors used in this truck have protection against incorrect polarity and
have short-circuit protected outlets.
When inductive sensors are energised, they have a short start-up time, 50
ms.
14.13.2 Position sensor
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
Pos. Description Min Nom. Max. Unit

a Active area 2525 mm
sa Detection guaranteed 3 5 mm
d1 37.5 mm
Free area
d2 24 mm

Steering reference sensor

Active area
The sensors have an active area, 12 x 12 mm, at the end of the cylindrical
body.
The sensitivity of the sensors is such that metallic objects within the area
0 1.6 mm are detected.
To avoid erroneous detection, there should be a free area around the
sensors active area:
d2
a sa
Pos. Description Min Nom. Max. Unit

a Active area 1212 mm
sa Detection guaranteed 0 1.65 mm
d2 Free area 6 mm

14.13.3 Pressure sensor

Properties
The output voltage range is 0.5 V 4.5 V in the pressure range 0 25 MPa
(250 bar).
14.13.4 Pulse transducer

The pulse transducers have two outputs, channels, where each channel
transmits a pulse train when the sensor shaft rotates.
Pulse ratio: During a period, the channel is high 50% 10% of the time:
Vout
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.

14.14 Safety sensor / - sensors C5830
14.14.1 Emergency switch off
14.14.2 Emergency switch off [S21]
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 on a login attempt with the

emergency switch off depressed.

Indication on the Central Information Display when the emergency switch off
is depressed and the truck is in logged-in mode.
Replacing the emergency switch off
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

14.14.3 Safety pedal [B31]
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.
ELECTRONIC CARD, MAIN CONTROL UNIT

A5
B31
1
X10
2 84
X130:31 INP. LEFT FOOT SWITCH
3
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%
0 1 2,5 1,5 4 5 (mm)

(activation)

Replacing the safety pedal
Step 1. Step 2.
n
s
Step 3. Step 4, S: T30, n: 2.
Step 5. Step 7.

Required tools
Torx key T30
Screwdriver or similar
Method
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.

14.15 Height measurement system
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
14.16.1 Calibration of the joystick
1: Start by selecting followed by

tf f followed by
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)

14.16.2 Height measurement/reach movement length calibration
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
14.16.3 Reference sensor, main lift. (Screen 1)

4: Calibration of the reference sensor is performed in screen 1. The actual
height is shown to the left, and the sensor signal is shown in the bottom
right box.
5: The mast must be lowered so that it is not separated, and the forks must
be horizontal, not tilted.

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)
14.16.4 Pulse length for main lift sensor bearing (Screen 2)

In order to get an exact measurement it is necessary to know how long a
pulse on the bearing is. To get the best resolution possible it is necessary to
measure two heights as far distant as possible, and to count the number of
pulses in between.
1: Go to screen 2. If you are in screen 1, go to the top right-hand box and
press "+"
2: Lift the forks a couple of meters above the reference height in the main lift
area.
3: Measure the height to the upper side of the forks manually as close as
possible to the mast.
4: Enter the measured value (in mm) in the bottom right-hand box and
press the green button.
5: The pulse length value is displayed and adjusted to the top left position.
14.16.5 Max. lift height. (Screen 3)

1: Move on to screen 3. If you are in screen 2, go to the top right-hand box
and press "+"
2: Lift the forks to their maximum possible.
3: Select the lower box and press the green button to save the value. The
saved value will be 4mm lower that the measured value. This is to stop
the mast from being extended maximally in operations.
Warning: This height is a calibrated height. If you want to limit the maximum
lift height to a lower height, you must use the height limitation parameters
instead of adjusting this value. In this way the height limit does not need to be
re-entered in case of recalibrating the truck.
14.16.6 Calibration of the reach carriage extension

1: Move on to screen 4. If you are in screen 3, go to the top right-hand box
and press "+".
2: Run out the reach carriage to the outer limit. Push against the
mechanical stop a few seconds.
3: Retract the reach carriage to the inner limit. Push against the mechanical
stop until you hear the beep.

4: The calibration is done, and the screen displays 0
14.16.7 Valve calibration
1: Start by selecting followed by

tf f use the up and down arrows
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.
14.16.8 Lowering valve, starting value. (Screen 1-S)

1: Highlight the box "S" and enter the value 200 mA.
2: Lift the forks up to ~ 1 meter.
3: Use the control to lower the forks, and the forks will slowly descend.
4: Reduce the value in the box "S" with intervals of 0.5 - 1 second until the
forks stop moving.
5: Save the value by pressing the green button.
14.16.9 Lowering valve, final value. (Screen 1-E)

1: Highlight the box "E"
2: Lift the forks high on the main lift.
3: Measure the lowering speed as the main lift lowers.
4: Adjust the value E in the box (+ if it is too slow, - if it is too fast) Repete
items 2 - 4 until the lowering speed is about 0.5 m/s.
5: Save the value by pressing the green button.

14.16.10 Lifting height limiting.

When you are lifting, the speed will be reduced incrementally as the forks are
approaching a pre-defined height. These reductions can be adjusted with
parameters.
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


Repair manual: Hydraulic system C6000 Model(s): R112, R114, R116
15. Hydraulic system C6000

15.1 General
The hydraulics on the truck consist of a pump that takes oil by suction from
the tank and pumps it to the main valve located in the reach carriage.
The main valve distributes the oil to the reach cylinder and the mast.
The return oil from the reach cylinder and mast is pumped via the main valve
through the filter to the tank.
Always take the following safety precautions prior to commencing work on
the truck's hydraulic systems:
Slowly depressurise system pressure.
Use some paper or a stiff piece of cardboard when checking for possible
oil leaks. Do not use your hand.
Be careful since the oil in the transmission and hydraulic systems can be
scalding hot.
WARNING!
Risk of burns if hot transmission oil or hydraulic oil gets onto the skin.
15.2 Hydraulic hygiene

Note:
Risk of malfunction.
If impurities get into the hydraulic system, there is a risk of malfunctions in
part or all of the hydraulic system. There is also a risk of severe damage to
components.
For all work on the hydraulic system, the following instructions must be
followed.
Note:
Use only new and clean oil when refilling the hydraulic oil system. If the oil
is contaminated, the hydraulic components will suffer damage.
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
15.2.5 Work procedures

When working on the hydraulic system, great cleanliness must be observed
so that no impurities can enter the system.
No work that generates particles may be carried out in the same workplace
or close to where work is being carried out on the hydraulic system.
The service technician must ensure that the components to be used are
carefully deburred and cleaned.
Couplings for pipe ends or other openings must never be removed until the
part is to be fitted to the receiving component.
Note:
All hydraulic components that have not been cleaned, e.g. pipe couplings and
nipples, must be blown clean before fitting.

15.3 Bleeding the air from the hydraulic system

Method
1. Put the truck program in service mode and activate the service mode for
bleeding. The bleeding mode initiates pump motor start-up and
simultaneous opening of both the lifting and the lowering valves. The
pressure in the valve unit will reach around 1 MPa (10 bar).
2. Open the bleed nipple on the main lift cylinder approx. 2 turns. If the
bleed nipple cannot be reached from the operator compartment, use a
ladder or similar item leant up against the mast.
3. Once all the air has been removed from the cylinder, oil begins to drip out.
After four or five drops, the bleed nipple must be closed.
4. Repeat bleeding on the other main lift cylinder.
5. Quit the truck program's service mode for bleeding.
6. Activate the service mode for separate operation of free lift and main lift.
7. Run the free lift (NOTE! NOT the main lift) between maximum height and
the fully lowered position 3 4 times to vent the air from the free lift
cylinder into the tank. End with the mast in its fully lowered position.
8. Quit the truck program's service mode.
9. Check the oil level in the tank and top up as necessary to the right level.
15.4 Hose inspection

Hydraulic hoses must be checked regularly for leaks and wear and tear
according to the service schedule.
The hydraulic hose must be replaced if:
It is leaking
The cord is visible
There are cuts visible on the hose
The hose looks like it has been "broken"
15.5 Hydraulic couplings C6230
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.

15.5.1 Quick change connectors
b
a
Pos. Description
a Disassembly ring
b Assembly stop
Assembling the quick change connector
Step 1. Step 2.
Step 3.
1: Fit the assembly stop to the hose couplings male fitting.

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

Disassembly of the quick change connector
Required tool Step 1.
Step 2. Step 3.
Step 4. Step 5.
1: Use a screwdriver or similar to remove the assembly stop.

2: Push the male fitting all the way into the female fitting.
3: Pull the male fitting out of the female fitting.
4: Refit the assembly stop to the male fitting.
5: Fit the protective plugs on the connection and hose to prevent oil
spillage.

15.5.2 Tightening torques for hydraulic connections
Tapered coupling with O-ring

Tighten the nut by hand against the stop and then tighten to the torques or the
degrees presented in the table below. Common connection type on most
hydraulic hoses on the trucks.
Dimension Tightening torque Tightening angle []

[mm] [Nm]
6 23 30-45
10 30 30-45
12 50 30-45
15 60 30-45
18 70 30-45
20 80 30-45
Tredo seal
The nut/connection should be tightened by hand against the stop and then
tightened to the torque indicated in the table below.
Dimension Tightening torque [Nm]

R 1/8 12-18
R 1/4 25-45
R 3/8 50-70
R 1/2 70-100
R 5/8 100-140
R 3/4 150-200
R1 195-250
R 1 1/4 250-310
R 1 1/2 310-400
M 18 50-70
M 22 100-140
M 26 150-200

Pipe coupling
Tighten the coupling by hand and then turn it another half turn to obtain the
correct tightening torque.
Coupling set in aluminium
Designation with Dimension Torque [Nm]

cutting edge
G 1/8 R 1/8 ~7
G 1/4 R 1/4 ~12
G 3/8 R 3/8 ~20
G 1/2 R 1/2 ~30
G 3/4 R 3/4 ~80
G1 R1 ~100

Coupling set in steel

Pressure class L
Designation with Dimensio Torque Designation with Dimension Torque

cutting edge n [Nm] ELASTIC [Nm]
sealing ring
GE 6-LM M 10x1 ~20 GE 6-LM-ed M 10x1 ~10
GE 6-LR R 1/8 ~20 GE 6-LR-ed R 1/8 ~10
GE 8-LM M 12x1.5 ~29 GE 8-LM-ed M 12x1.5 ~20
GE 8-LR R 1/4 ~39 GE 8-LR-ed R 1/4 ~20
GE 10-LM M 14x1.5 ~39 GE 10-LM-ed M 14x1.5 ~29
GE 10-LR R 1/4 ~39 GE 10-LR-ed R 1/4 ~20
GE 12-LM M 16x1.5 ~59 GE 12-LM-ed M 16x1.5 ~29
GE 12-LR R 3/8 ~59 GE 12-LR-ed R 3/8 ~39
GE 15-LM M 18x1.5 ~69 GE 15-LM-ed M 18x1.5 ~39
GE 15-LR R 1/2 ~108 GE 15-LR-ed R 1/2 ~59
GE 18-LM M 22x1.5 ~108 GE 18-LM-ed M 18x1.5 ~59
GE 18-LR R 1/2 ~108 GE 18-LR-ed R 1/2 ~59
GE 22-LM M 26x1.5 ~128 GE 22-LM-ed M 22x1.5 ~69
GE 22-LR R 3/4 ~157 GE 22-LR-ed R 3/4 ~88
GE 28-LM M 33x2 ~216 GE 28-LM-ed M 33x2 ~118
GE 28-LR R1 ~265 GE 28-LR-ed M 33x2 ~137
GE 35-LM M 42x2 ~353 GE 35-LM-ed M 42x2 ~196
GE 35-LR R 1 1/4 ~392 GE 35-LR-ed R 1 1/4 ~235
GE 42-LM M 48x2 ~491 GE 42-LM-ed M 48x2 ~294
GE 42-LR R 1 1/2 ~491 GE 42-LR-ed R 1 1/2 ~294

15.6 Hydraulic unit C6100
15.6.1 Hydraulic oil tank C6110
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.
Checking the oil level
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.

Filling the tank
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.

Replacing the tank
Removing the tank
Step 4 Step 5
1: Remove the tank from outside the chassis, 3 screws.

2: Remove the hose clamp to the pump.
3: Pull the hose from the tank.
4: Lift out the tank.
5: Mop up any spillage.

Fitting the tank
Step 4
1: Put back the tank

2: Connect the hose, and fit a hose clamp to the pump side of the hose.
3: Attach the tank from the rear side of the battery wall.
4: Connect the return hose to the tank.

15.6.2 Hydraulic hoses C6120
Replacing the suction hose
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.

15.6.3 Filter C6130
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.

Filter replacement (for air and oil)
Steps 4 and 5. Step 6. Step 7.
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.

5: Refit the cover over the air filter.

6: Detach the filter holder from the filter bridge.
7: Remove oil filter from the filter holder.
8: Insert a new oil filter in the filter holder.
9: Secure the filter holder in the filter bridge.
10: Fit the filter in place and screw on the cap by hand.
15.7 Hydraulic pump C6140
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.

15.7.1 Replacing the hydraulic pump

Note: In cases of leaks between the pump and the motor, check if
the O-ring is not damaged, replace it if needed!
1. Undo the suction connection (b) from the pump.
2. Remove the screws (a).
3. Separate the hydraulic pump (c) from the motor (d).
a b d
4. Place the suction connection on the new pump unit.

5. Install a new O-ring between the pump and pump motor. (See figure for
replacement of O-ring)
Note: do not pinch the O-ring
6. Place the pump unit on the pump motor.
7. Tighten the screws.

15.7.2 Replacing the driver
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
Note: take care to place the O-rings correctly.
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

15.8 Main valve unit C6210
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
Inserts for quick change connectors

The main valve has six quick change connectors for hydraulic hoses. These
connectors consist of replaceable inserts:
Connection Type
P DN12
T DN12
H1 DN12
H2 DN10
H3 DN10
A1 DN10
B1 DN10
A DN06
B DN06

The inserts are made up of sealings and a lock in a single unit:
a
b
c
d
e
f
Pos. Description Material

a O-ring NBR Nitrile rubber
b Support ring Hytrel
c Washer Hardened steel
d O-ring NBR Nitrile rubber
e Catches Hardened steel
Steel coated with
f Front section microencapsulated thread
locking
Polyethylene LD (Low
g Dust guard
Density)
The dust guard g is removed when the corresponding hose is connected.

The complete insert is sorted as iron/steel when scrapped.
Specifications:
Min. Nom. Max. Unit
Working pressure 350 bar
Burst pressure 1400 bar
Temperature range -30 +100 C

Tightening torques for valve components
Tightening torque
Q2 32.5-35.3Nm Q19 25.8-28.5Nm

Q4 44.9-50.3Nm RV1 25.8-28.5Nm
Q6 25.8-28.5Nm RV2 44.7-50.2Nm
Q7 25.8-28.5Nm MP 30 Nm
Q18 25.8-28.5Nm EC1 45-50Nm
Nuts for the valve and the coil must be tightened to 6.8-9.5Nm
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

15.8.2 Replacing a complete valve unit
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.
NOTE! A new valve unit assembly is preset to 215 Bars.
15.8.3 Replacing a valve
Disassembly
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)
Replacing the lowering valve

See Replacing valves

Adjusting the lowering valve

The adjusting screw has a little mark to help perform the adjustment. It is suitable
to make a rough setting of the valve before installing it in the valve block.
If an adjustment is all that is needed, it is not necessary to remove the valve.

All that is needed to adjust this valve is a 2mm Allen key and a 3/8" (9.5mm) key.
The torque too tighten the counter-nut is 0.85Nm +- 0.17Nm.
If the valve has been "adjusted" out of all proportions, the DX 3000-5000 and the
TX 4400-7000 are to open about 4.7 turns from the fully screwed in position, and
the TX 7500-8500 is to open about 5.7 turns from the fully screwed in position.
Calibrating the lowering valve

One method of testing that the maximum flow is set to the correct level is:
1: Start by setting the maximum current in the coil calibration menu 1 to 150%.
2: Exercise the system in order to fill the valve with oil. The lowering speed may
be quite low initially. Proceed all the way up on the main lift. The hose breaking
safety feature may be triggered.
3: When the valve is properly adjusted,and the lowering speed is high enough,
measure the lowering speed, and adjust the stroke limiter so that the maximum
lowering speed is approximately 0.55 m/s.
4: When the lowering speed is correct, tighten the counter-nut if the adjustment is
finished. Verify the lowering speed one final time.
Calibrate the valve. Start by calibrating the position for actuation, and then reduce
the value of parameter 1 until you have a measured lowering speed of 0.5 m/s.
The valve is fully adjusted when the maximum possible speed is approx. 0.55 m/s
and the software is set to 0.5 m/s and the position for actuation is calibrated.

Examples of aids for calibration of lowering valve.

1: Place a cord with weights at both ends over a fork. The distance between
the ends of the cord must be 1.06 m and it should be sufficiently long for
the longest end not to touch the floor when the mast is raised 2 m within
the free lift range and the main lift range respectively. Attach the cord to
the fork with a piece of tape.
2: Raise the forks so that longest end is >0.5 m above the floor within the
main lift (Q4) working range
3: To ensure that the lowering valve is fully open during the measuring
interval, the lowering movement must be started with an acceleration
distance of approx. 0.5 m before measuring is started and the measuring
must be concluded before the forks are 0.5 m above the floor
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.

Replacing the pressure limiting valve
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
Mast type R112 R114 R116
DX 3000-5000 (180 Bar) (200 Bar) (228 Bar)

(-60 minutes) (-25 minutes) (+22 minutes)
TX 4400-7000 (200 Bar) (228 Bar) (250Bar)
(-25 minutes) (+22 minutes) (+60 minutes)
TX 7000-8500 (185 Bar)

(-50 minutes)
Note: Important information: Every turn equals 36 Bars, this may be used to
adjust the valve correctly.

15.9 Control valve C6220
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

15.10 Chassis-mounted hydraulic hoses C6230
15.10.1 Replacing the supply hose
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.
15.10.2 Replacing the return 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
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.

15.11 Mast hydraulic conduits C6320
Replacing the supply hose to the free lift cylinder
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
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

15.11.1 Fork carriage
Overview
a Hydraulic hose sideshift

b Hydraulic pipe tilting cylinder

Replacing the hose to the sideshift
Disassembly
1: Remove the hose from the cylinder
2: Plug the connection to the cylinder
3: Remove the hose to the valve unit
Assembly
3: Remove the plug from the cylinder
4: Connect the hose to the cylinder
5: Wipe clean and test the functions.

Replacing the pipe in the fork carriage
Disassembly
1: Check that the tilt is in the lowered position
2: Remove the hydraulic pipe at the tilt cylinder
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.

15.12 Main lift cylinder C6610
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

Nomenclature for cylinder head
d
e
Pos. Description
a Wiper
b Piston rod seal
c Guide belt
d O-ring and stay ring
Nomenclature for piston
Pos. Description
a Guide belt

15.12.1 Removing the air cylinder from the mast

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 mast and support the intermediate guide using blocks.
2. Loosen the lifting chain at the cylinder to be removed, and place it on the
floor over the reach carriage.
3. Remove the lift chain wheel.
4. Loosen the cylinder rod from the top member (b).
5. Lower the lift cylinder to the bottom.
6. Remove the hydraulic hose from the lift cylinder and valve block and plug
the valve block.
7. Check that the lift chain that still remains is not damaged.
8. Check that the lift chain does not get damaged nor damage anything
while you raise the mast to the top.
9. Undo the lift cylinder at its bottom stud (d).
10. Undo the cylinder support at the top (e or f).
11. Remove the cylinder from the mast.
g
b
a
f
i
c
d
h

15.12.2 Replacing the hose rupture valve

The hose rupture valve is integrated in the quick change connector for the
hydraulic hose.
Note:
When fitting these components, it is very important that no dirt etc. enters
the hydraulic system.
1. Remove the hydraulic hose from the quick change connector and plug it.
2. Unscrew the quick change connector from the cylinder.
3. The new quick change connector should be torque tightened to 60 +10
Nm.

15.12.3 Dismantling the cylinder
Tools required Step 1.
Step 2. Step 3, KM 8/ = 58 mm.
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:
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.
15.12.4 Dismantling the piston.
Method
1. The plunge piston has slits and can be removed by hand.

15.12.5 Dismantling the cylinder head
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.

15.12.6 Fitting the cylinder head seals.
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:
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.
15.12.7 Fitting the piston guide belt
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:
3. The guide band has slits and is easy to fit by hand.

15.12.8 Assembling the cylinder
Step 2.
Step 3. Step 4.
Step 5, Loctite 243 Step 6, KM 8/ = 58 mm, T = 150 Nm

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.

15.12.9 Assembling a mast cylinder

Note:
1: Lift the cylinder into the mast. Check that the tension pin (g) is fitted to the
cylinder rod and that any shims (h) are refitted when assembling the
repaired cylinder.
2: Mount the cylinder on the bottom stud with screw (d) and washer. Tighten
according to the torque in the table.
3: Mount the cylinder support (e or f) with screw (a or c) and washer.
Tighten according to the torque in the table.
Note:
If the shims are not applied properly to center the cylinder, the cylinder may
bend or the bracket may come loose.
4: Using blocks, chock up the inner guide approximately 50 cm above the
floor.
5: Lower the mast.
9. Remove the plugs from the hydraulic hose and valve block and connect
the hose.
6: Raise the forks until the lift cylinder makes contact with the top beam.
7: If a new cylinder has been fitted, check whether shims (h) need to be
fitted. If shims are necessary, back off the bottom stud and fit the required
number of shims (h).
8: Screw the cylinder into position in the top beam with screw (b) and
washer. Tighten according to the torque in the table.
9: Lower the forks to the bottom.
10. Fit the chain wheel and lift chain.
11. Adjust the chain so that the top of the mast is not pulled sideways

g
b
a
f
i
c
d
h
Pos. Description Note

a Screw Tightening torque: 45 +11/-5Nm
b Screw Tightening torque:
110Nm (for 2.5-ton masts)
65Nm (for 1.6 and 2.0-ton masts)
c Screw Tightening torque: Se avsnitt 22.1 Generella
tdragningsmoment.
d Screw Tightening torque:
47Nm (for 1.6 and 2.0-ton masts)

15.13 Free lift cylinder C6620
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
Pos. Description
a Piston seal
b Guide belt
c Circlip
d Piston

15.13.1 Removing the free lift cylinder from the truck

Note:
Note:
1: Remove the cable sheathing to the hose reel
2: Start by lifting the mast so that you can reach the screw that locks the
cylinder to the mast guide
3: Place a wooden block under the fork carriage, and lower the fork
carriage so that it rests on the block. This way the hoses and the wiring
will hang slack for easy removal.
4: Undo the nuts of the free lift chain to slacken the chain.
5: Remove the cross beam so that it is possible to lower the mast.
6: Undo the nuts to the chain bolt in the fork carriage.
7: Remove the chain from the chain bolt at the hose reel, and lift out the
chain.
8: Undo the 2 screws to remove the chain wheel, then pull out the shaft to
remove the chain wheel.
9: Remove the hose and plug the connection and the hose.
10: Remove the cylinder from the cross bracket between the beams on the
inner guide.
11: Lift out the cylinder
15.13.2 Replacing the hose rupture valve, free lift cylinder

The hose rupture valve (lowering brake valve) is fitted in the hydraulic
cylinder's WEO connection and can be replaced using standard tools.
Note:
the hydraulic system

15.13.3 Dismantling the cylinder
Tools required
Step 1.
Step 3, KM 8/ = 58 mm.
Step 2.
Step 4.
Step 5.

Tools required
hook spanner
Method
1. Clean the cylinder from dirt, etc.
Note:
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.
15.13.4 Dismantling the piston
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.
.

15.13.5 Dismantling the cylinder head
Step 1. Step 2.
Method
Note:
Be careful not to scratch the cylinder head.

Step 2. Step 3.
Step 4.

Method
Note:
Note:
Note:
with soft bends.
4. Fit the wiper. Make sure it locates correctly in its groove.

15.13.7 Fitting the piston seals
Step 2.
Step 3.
Step 4.

Method
Note:
Note:
3. Fit the piston seal, make sure it is fitted the correct way round.

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
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.
15.13.9 Assembling the free lift cylinder in the mast

Note:
1: Lift the cylinder into place in the mast
2: Fit the cylinder in the cross bracket between the beams of the inner
guide.
3: Remove the plug from the supply hose and connect the hose to the
cylinder
4: Fit the chain wheel by installing the shaft and locking it with 2 screws
5: Pull the free lift chain through the chain roller.
6: Fit the chain to the chain bolt
7: Fit the chain with two nuts in order to lock it to the chain bracket.
8: Fit the chain in the fork carriage
9: Lift the mast slowly to place a wooden block under the fork carriage.
Then it is possible to fit hoses and wiring over the roller.
10: Lift the mast to install the bolt that locks the cylinder at the bottom of the
mast.
11: Fit the cable sheathing on the roller
12: Adjust the free lift chain

15.14 Reach/telescopic cylinder C6650
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.

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

15.14.1 Removing the reach cylinder from the truck

Note:
Note:
1. Fully extend the mast.
2. Remove the battery cut out connector from the truck.
3. Remove the hoses from the reach cylinder and plug them.
4. Remove the locking rings from the cylinder pins.
5. Remove the reach cylinder.

15.15 Dismantling the cylinder
Step 3. Step 4.
Step 5.
Tools required
Small screwdriver

Method
1. Empty the cylinder of oil and clean off any contaminants, etc .
Note:
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.
15.15.1 Fitting the reach cylinder in the truck

Note:
1. Fit the reach cylinder to the pins.
2. Put the locking rings in position on the pins.
3. Fit the hoses to the cylinder.

15.16 Tilting cylinder C6660
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.

15.16.1 Remove the tilt cylinder from the truck
Mast with valve on the fork carriage.
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:
Note:
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).
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)

15.16.2 Fit the tilt cylinder in the truck
Mast with valve on the fork carriage.
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:
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.
15.17 Sideshift cylinder C6670
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
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

15.17.2 Dismantling the cylinder from the truck

Note:
During servicing, the truck must be switched off and the battery
disconnected.
During maintenance, the hydraulic system must be depressurised.
The couplings must be sealed so that no dirt can enter the hydraulic system.
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.
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

15.18 Dismantling the cylinder
Step 3. Step 4.
Step 5.
Tools required
Small screwdriver

Method
1. Empty the cylinder of oil and clean off any contaminants, etc .
Note:
not jammed.
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:
Carefully pull out the cylinder head, piston rod and piston.

15.18.1 Removing the piston rod
Step 1.
Tools required
Step 2. Step 3.
n
s mm
Step 4. Step 5: s = 19, n = 1
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.

Dismantling the cylinder head
Step 1.
Step 2. Step 3.
Step 4.

Method
2. Remove the piston rod seal.
4. Remove the last seal.
Note:

Step 2.
Step 3. Step 4.
Step 5. Step 6.

Method
Note:
Note:
Note:
with soft bends.
3. Fit the seal.
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.

15.18.3 Mounting the piston rod
Tools required Step 1. Step 2.
n
s mm
Step 3: S = 19, N = 1, Mv = 150 Nm
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.
Check if there is any damage on the surfaces. Minor damage can be
removed by polishing with fine sandpaper.
Note:
Note:
Note:
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
2. Fit the piston rod in the cylinder pipe.
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.
15.18.5 Refitting the cylinder in the truck

Note:
1. Assemble the cylinder on the studs.
2. Fit the circlips to the studs.
3. Fit the hoses to the cylinder

Repair manual: Mast C7000 Model(s): R112, R114, R116
16. Mast C7000
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.

16.1.1 The available combinations of truck and mast.
R112 R114 R116
Battery type Battery type Battery type

310Ah and 465Ah and 620Ah
465Ah 620Ah
DX Tele 3000 DX Tele 3000 DX Tele 3000
TX Tele 4400 TX Tele 4400 TX Tele 4400
TX Tele 7500 TX Tele 7500
16.1.2 Ordering replacement masts

When ordering a replacement mast, contact TMHE Technical Support
for identification of the mast.
16.1.3 Mast type and weight

See technical data
16.2 Installing a mast in a newly delivered truck

See chapter Installation

16.2.1 Adjusting/setting mast inclination

Remember to park the truck on a level surface when you are checking the
mast inclination, proceed as follows:
1: Use a clinometer, and attach it to the outside of the mast as per the
figure. Tolerance 10 min front/rear
2: Attach the clinometer to the side of the mast and measure. Tolerance 6
min lateral inclination as per the figure

16.3 Main mast C7100
16.4 Main lifting chain system C7120
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.
If it is not possible to pull out the chain to its

Replace the
Stiff links normal position this can be because of link
chain.
rust or seizing.

Inspection
point
Bolt rotation can be a phenomenon of stiff

links. Replace the
Bolt rotation
The fault is easy to see when comparing chain.
with a new chain.
If a bolt is loose it will protrude from the

Replace the
Loose bolts side of the chain, and this is due to a stiff
chain.
link or bolt rotation.
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
point
The amount of stretch on a lifting chain is

measured on the part of the chain that runs
over the chain roller. The amount of stretch
may, at the most, be 2% on the most worn
section of the chain. The measurement is
The chain should
best made over 300 1000 mm of the
be replaced if
Stretching chain.
stretching is more
The nominal and
than 2 %.
maximum permitted chain lengths for lifting
chains are stated in the table below.
Wear to the bolts and around the holes on
the discs is one reason why the chain
stretches.

Nominal disc Nominal chain length Maximum permitted chain

Minimum disc Pitch P
Type of chain height H2 for 20/30/50 discs length for 20/30/50 discs
height H3 (mm) (mm)
(mm) (mm) (mm)
3/4", 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4", 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4", 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1", 4x4 23.6 22.4 25.4 508/762/1270 518/777/1295
1", 6x6 23.6 22.4 25.4 508/762/1270 518/777/1295
Inspection
point
The chain must be

replaced if
Other damage
damaged in any
way.
If a plate has broken on the chain, this Replace the

Damaged plates
may be due to overloading or corrosion. chain.
It can be difficult to determine whether a

Damaged bolts bolt has broken. It can appear as bolt Replace the
rotation and/or that the outer plate is chain.
loose.
If a chain is very dirty replacement is recommended first and

Dirty chain foremost. It can also be removed and cleaned. See section
"7.3.5 Cleaning the chain".

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
* Similar products from other manufacturers may be used.

16.4.3 Replacing the free lift chain
Removing the free lift chain
Method
1:

Fitting the free lift chain
Method
1:

16.4.4 Replacing the mast chain
Removing the mast chain
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.

Fitting the mast chain
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.
Adjusting the mast chain

16.4.5 Replacing the mast harness
Removing the mast cables
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.

Fitting the mast 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.

16.5 Fork carriage C7130
16.5.1 Checking the fork carriages wear strip

a The wear strip (a) between the yoke and ball beam on the fork carriage is
subject to wear and must be checked annually.
1. Measure the gap (b) between the yoke and the ball beam. When the wear
b strip is new, the gap is 2 mm. If the gap is 4 mm or more, the wear strip
must be replaced.
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)
a Max tilt angle
a: Maximum tilt angle

16.5.2 Lubricating the fork carriage

The following locations should be lubricated once a year:
Between the ball beam and the wear strip of the side shift unit (a)
Between the yoke and the friction plate (b)

16.5.3 Replacing the fork yoke
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.
16.6 Main mast suspension C7190
16.7 Forks C7410
16.7.1 Overview
a
b
d
L
e
c
a = fork, b = clamp, c = spring pin, d = washer, e = spring, f = catch
16.7.2 Inspection procedures

References:
ISO 5057:1(E), 1993-12-15
ISO 2330:2002(E), 2002-09-27

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
If surface cracks are detected on a fork, crack detection must also be

performed on the welds around the bearing plate.
Crack detection on the welds around the bearing plate

Difference in height between the fork tips

Check a set of forks to see if there is any difference in height once they are
installed in the fork holder. If the difference in tip height exceeds 3% of the
blade length or the limit value recommended by the truck manufacturer, the
set of forks in question must be taken out of service and a crack detection
check must be performed on the welds around the bearing plate.
Such a set of forks must not be taken into service again until they are rectified
and tested. See section "16.7.3 Repairs and testing".
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.

Wear fork blade and fork face

The fork blade (a) and face (b) must be carefully checked for wear. Pay
particular attention to the area around the tilt stop. If the thickness of the blade
or face has been reduced to 90% of the original thickness or to the minimum
thickness specified by the fork or truck manufacturer, the fork must be taken
out of service.
c
b
Wear fork mounting fixtures

Check the upper hook's support surface and the attachment surfaces of both
hooks for wear, crushing or other local deformations. If the defects are so
obvious that play between the fork and fork holder becomes excessive, the
fork must be taken out of service. Perform similar checks on other types of
mounting fixtures.
16.7.3 Repairs and testing
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.
Testing the yield point

A repaired fork (except for repairs to or replacement of position locks and/or
markings) may only be used again if it has undergone a yield point test as
described in ISO 2330 and been approved. However, the test load must
conform with the table.
Specified fork capacity, m Test load Ft

m 5000 2.5 m
m > 5000 2.1 m

Repair manual: Wiring diagram Model(s): R112, R114, R116
17. Wiring diagram

17.1 Component list
Des. Function Component type Other Picture Schematic

chart
(7531025)
A1 Central Information Electronic card 3,8,9.15
Display (CID) with display
A2 Power steering Electronic circuit 6
(EPS) board
A5 Main micro- Electronic circuit 1,4,7,10,11
controller (MCU) board ,12,15
A6 Sensor control Electronic circuit 9
board
A9 Power distribution Fuse box 1
A60 Electronic card 9
A82* Data management Electronic circuit T.W.I.S. unit in the 14
unit board truck
B1 Temperature sensor Temperature 2 4
in [M1] sensor
B2 Temperature sensor Temperature 2 5
in [M3] sensor
B11 Speed Pulse transducer 2 4
measurement [M1]
B12 Speed Pulse transducer 2 5
measurement [M3]
B13 Pulse sensor, Twin sensor 5V 8
steering wheel bearing
B17 Reference for Inductive sensor 12V 2.9 6
steering angle 180-
360
B19 Height sensor main Sensor 15V 14 11
lift
B20 Raise/lower forks Hall sensor Nominal output 9
B21 Fork carriage in/out Hall sensor voltage: 9
0.5 V (min)
B22 Fork tilt up/down Hall sensor 2.5 V (neutral 9
B23* Side-shift right/left Hall sensor position) 9
4.5 V (max)
B31 Safety pedal Inductive sensor 5V 6 7


chart
(7531025)
B32 Pedals (acceleration Hall sensor 5V 6 7
and brake)
B35 Horn Horn 5V 9
B36 Travel direction Hall sensor 5V 9
selector
B39* Height limit Hall sensor 5V 15
B40 Working lights Hall sensor 5V 15
B41 Extra Hall sensor 5V 15
B49 Seat switch Inductive sensor 48V Distance: 7 12
0-6.5 mm
B58 Height reference, Inductive sensor 48V 14 11
forks below 1 m
B59* Steering angle Inductive sensor Distance:
sensor 0-1.6 mm
B90* Shock sensor Shock sensor 9 14
E3* Working lights Lamp 48V 12 15
E4* Working lights Lamp 48V 12 15
F1 Fuse for [T1] Fuse 250 A 1.5 1
F60 Fuse for relays Fuse 3A 1 1
F61 Main fuse for [A5] Fuse 7.5 A 1 1
F62 Main fuse for [A1] Fuse 7.5 A 1 3
F64 Fuse for activation Fuse 3A 1 6
of [A2]
F66* Fuse for [T5] and Fuse 7.5 A 1 2
[T6]
F71 Fuse for [A5] Fuse 7.5 A 1 1
F72 Fuse for [A2] Fuse 30 A 1 6
F73 Fuse for control Fuse 7.5 A 1 2
voltage
G1 Truck battery Battery 48V 5 1
G3 Cooling of [T1] and Fan motor 48V 2.4 4
[T2]
G4 Cooling of [M3] Fan motor 48V 3 4
K20 Key relay Key relay 460-330 Ohms at 1 2
48V
K64 Working lights Power relay 12 15


chart
(7531025)
M1 Truck traction 3-phase AC motor 2.4 4
M3 Pump motor 3-phase AC motor 4 5
M6 Steering servo Stepping motor 2 6
motor
P4 Horn Horn 48V 3 12
P5* Warning lamp LEDs 48V 10 15
P7* Travel alarm Horn 12
Q1 Parking brake Electromagnetic 32 Ohm 2.4 10
brake
Q2 Valve for main mast Electromagnetic 22 Ohm 10
lift valve
Q4 Valve for main mast Electromagnetic 5
lowering valve
Q6 Valve for reach Electromagnetic 25 Ohm 10
carriage in valve
Q7 Valve for reach Electromagnetic 10
carriage out valve
Q9 Valve for extra Electromagnetic 15.16 10
hydraulic function, valve
direction B
Q10 Main relay Contactor 48V 1.5 1
Q18 Valve for fork tilt/ Electromagnetic 10
side-shift valve
Q19 10
R101 Damping resistance Resistor 120 Ohm 1
for CAN1
for CAN1
for CAN2
S21 Emergency stop Switch 0-48V 1 1
S89 Seat switch Switch 48V 7 12
T1 Control of drive Frequency DC to 3-phase AC 2.4 4
motor [M1] converter
T2 Control of pump Frequency DC to 3-phase AC 2.4 5
motor [M3] converter
T5* Voltage converter DC/DC From +48 V DC to 13
Transformer +12 V DC


chart
(7531025)
T6* Voltage converter DC/DC From +48 VDC to 13
Transformer +24 V DC
T20* Antenna Antenna T.W.I.S. 14
X1* Connection for Connector (battery 5 1
battery connector)
X10 Connector 4 7
X11 Connector 3.13 5,10,11
X12 Connector 3.13 11
X13 Connector 13 5.10
X14 Connector 15.16 10
X15 Connector 13 11
X20 Connector 1 15
X21 Connection for roof Connector 2,8,9.11 6.13
wiring harness
X22 Connector 9 14
X24 Connection for Connector 3 12
travel alarm [P7]
X26 Connection for Connector 7 12
basic seat
X27 Connection for Connector 8
pulse sensor,
steering arm
X41 Connection for CAN contact 3
service key
X43* Socket 12 V DC Connector 13
X44* Socket 24 V DC Connector 13
X45* Connection for DC/ Connector 13
DC transformer
X47 Connection for seat Connector 7 12
X50 Connection for extra Connector 11
power connector
X500 Connection for Connector 1 3.8
control panel

17.2 Component location
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
17.3.1 ACT [T1]
Connection Cable Function Active In/Out

84 27 Off/On 48V In
85 10 Sensor + 12V, 1 kOhms Out:
92 14 In
98 220 CAN2 L 0-5V In/Out
99 219 CAN2 H 0-5V In/Out
100 218 CAN 2 GND 0V In
103 12 Pulse sensor, phase 1 12V, 1 kOhms In
105 11 In
106 219
17.3.2 ACH [T2]
Connection Cable Function Active In/Out

84 27 Off/On 48V In
85 15
88 41
89 41
92 19
98 220 CAN2 L 0-5V In/Out
99 219 CAN2 H 0-5V In/Out
100 218 CAN 2 GND 0V In
105 16
108 35
115 27 Off/On 48V In

17.3.3 CID [A1]
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

17.3.4 MCU [A5]
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)
X130:17 87 Accelerator 0.5-4.5 V In

X130:18 86 Brake pedal, reference 2 (min.max.) 4.5-0.5 V In
X130:20 30 Ground, digital 0V Out:
X130:22 219 CAN2 high 4.5-2.5 V In/Out
X130:23 117 Current measurement +15 V, service key 15 V Out:
X130:26 76 Height sensor - forks, upper free lift, pulse B 48 V In
X130:31 84 Safety pedal 48 V In
X130:33 218 CAN2 ground 0V Out:
X130:37 29 Current source +15 V 15 V Out:
X130:41 83 Seat switch 48 V In
X131:1 22 Current source 48 V In
X131:2 141 Height reference forks 48 V In
X131:5 21 Status, emergency switch In
X131:6 28 Status, key relay 48 V In
X131:7 31 Main relay 48 V Out:
X131:8 Out, working light
X131:9 33 Fan control 0-48 V Out:
X131:10 67 Valve for reach movement in 0-48 V Out:
X131:11 63 Valve for fork tilt/fork reach carriage/AUX. 0-48 V Out:
X131:12 97 Brake 048 V PWM Out:
X131:14 40 Ground 0V
X131:15 23 Charging capacitor 48 V In/Out
X131:21 Output, mast lift
X131:23 Output, drive alarm

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.
17.3.5 Fuse panel [A9]
Description Protects (Function) I (A)

F60 +48 VDC Emergency stop circuit 3
F61 +48 VDC, MCU supply 7.5
F62 +48 VDC, CID supply 7.5
+48 VDC, Steering servo supply
F64 3
(electronic)
+48 VDC, DC/DC transformer and DHU
F66 7.5
supply (Option)
F71 +48 VDC, Capacitor charging 7.5
+48 VDC, Steering servo supply (high
F72 30
current)
F73 Supply 48 VDC / Key relay status 7.5
17.3.6 Steering motor [ [A2]
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

17.4 General wiring diagram

24
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
CAN 2 GND 98 218 Q19

1 2
27 84 +48DC LOGIC SUPPLY
Q18
106 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
84 +48DC LOGIC SUPPLY

B32
CAN 2 H
219
115 OUT. +48DC (HIGH SIDE OUT) 6 2
85/WH
Q4 CAN 2 GND 218
1 2 35 108 OUT. (PWM) MAST LOWER
3
86/BK
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
1 2 211 (X901:11) INP. STEERING WHEEL REFERENCE CAN 2 219

POSITION H (X901:2)
3
212 (X901:12) OUT. GND FOR REF, SENSOR R202 120?

L (X901:10) 220
G3 CAN 2
27 1 2
M
G4
27 +
M -

7,5A
F62
40
32
21
MCU A5
40 (X131:14) GND, POWER
22 (X130:5) INP. BATT. VOLTAGE STATUS
40
22 (X131:1) INP.+48VDC POWER MCU
21E.S.O. STATUS (X131:5)
32
PTC
31 OUT.MAIN CONTACTOR (X131:7)
24
(X504:9) +48VDC POWER
23 (X131:15) MAIN CONT./CAP CH.
32 (X504:18) OUT. KEY POWER RELAY

27 INP.KEY POWER RELAY. STATUS (X131:6)
21
(X504:17) EMERGENCY
SWITCH OFF STATUS
40
(X504:2) INP.GND
B49
95 (X131:12) INP.SEAT SWITCH (X130:41) 83 2 1 27
OUT.PARKING BRAKE
3
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
76 (X130:26) INP.HEIGHT SENSOR Main Lift B

5 7 47 (X504:14) STEER SENSOR 2 PULSE A
+ A
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.
84 INP.AUX 1 / SIDESHIFT (X505:6) 6 OUT.B23 -

(X130:31) INP.LEFT FOOT SWITCH
B23
OUT.GND (X505:7) INP.GND
90/BU (X130:6) GND. ANALOG 7 +
SIG.
-
OUT.+5V (X505:8) 8 INP.+5V
85/WH (X130:4) INP.BRAKE REF. 1
86/BK (X130:18) INP.BRAKE REF. 2

GND. ANALOG (X503:8)
87/GY (X130:17) INP.ACCELERATOR SIGNAL
55/RD (X130:1) OUT.+5VDC +5VDC SOFTWARE CONTROLLER (X503:7) WH/OR
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

17.5 Detailed diagrams















Repair manual: Hydraulics schematics Model(s): R112, R114, R116
18. Hydraulics schematics

18.1 Component list
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

18.2 Component location

4.
3.
9.
10.
2.
8.
5.
6.
7.
1.

18.3 Valve unit
18.3.1 Main valve unit
Cv1
A1
Cv2 B1
B
H3
H1 Q6
Q7 H2
T
P
Q19
Q18 Rv2
Q4 Q2 A
Rv1
Pos. Description Pos. Description

A1 Reach function Cv1 Non-return valve
B1 Reach function Cv2 Non-return valve
H1 Free lift Rv1 Reach pressure limiter
H2 Main lift Rv2 Main pressure limiter
H3 Main lift Q2 Lift valve main lift
Adjustable main lift lowering
A Extra function Q4
valve
B Extra function Q6 Reach movement in
Nipple for pressure
M Q7 Reach movement out
gauge
P Pump connection Q18 Extra function for A1
T Tnk connection Q19 Extra function for B1

18.3.2 Fork carriage valve
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 Hydraulics schematics
18.4.1


Repair manual: Tools Model(s): R112, R114, R116
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)
Tool Number Usage

213296 (JPT, PT) Pin/sleeve removal tool
213298 (MPT) Pin/sleeve removal tool
1=163787 (JPT) Tool for crimping sleeves

2=163788 (JPT)
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

19.2 MQS contacts
Tools Number Usage

257841 MQS Basic toolbox.
The box contains:

1 pair crimping pliers
1 pair stripping pliers
25 x splice sleeves 0.5-1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
connectors (male and female) with
prewired cables and splicing sleeves.
Please use to replace damaged connectors
on the truck.

Tools Number Usage

257842 MQS refill box.
Use to refill the MQS 257843 Complete
toolbox.
The refill box contains:

200 x sleeves 0.2-0.5 mm2
200 x SWS sleeves 0.2-0.5 mm2
400 x SWS sleeves 0.5-0.75 mm2
100 x Clean body sleeves 0.5-0.75 mm2
200 x SWS pins 0.2-0.5 mm2
400 x SWS pins 0.5-0.75 mm2
1200 x seals
200 x blind plugs
and connectors
257843 MQS Complete toolbox.
Contains 4 pliers with tools:

MQS SWS 0.25-0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&Clean body 0.25-0.5 mm2
MQS Std&Clean body 0.50.75 mm2
Puller for 2, 3, 4, 6, 8 and 12-pin male and

female connectors.

19.3 CPC contacts
Tool Number Usage

1=213336 (CPC) Crimping tool (sleeves only)
2=213338 (CPC)
1
2
183593 Pin/sleeve removal tool

19.4 Other tools
Tool Usage
7513225 Service instrument (CAN)
1=7521083 1, 2 are Service instruments

1 2=163793 (CASTOR USB)
for programming
3 CPC
3 is a service instrument (CPC-USB for PC)
2
Anti-static mat for electronic work
219730 Hydraulic pressure gauge

Tool Usage
651154 Support block
7504474 Adjustment of mast angle
1/4" 254526 Plugs (male part) for valves with WEO type
3/8" 254527 quick change connector
1/2" 254528
1/4" 254529 Plugs (female part) for hydraulic hoses with

3/8" 254530 WEO type quick change connector
1/2" 254531
08-17526 Oil dipstick

Tool Usage
7509180 Door latch
SMA-1000PAA Measuring hose. Length 1000 mm.
11-1310 Lifting tool for batteries

Max. 1,500 kg
11-1091 Lifting tool for mast 1.4 - 2.0 t

Tool Usage
651217 Inclinometer for mast tilt
08-13585 Wheel shaft tool
11-1020 Lifting tool for mast guide

7
41

Tool Usage
11-1021 Lifting tool for mast guide
0
38
Slut p avsnittet


Repair manual: Service data and grease specifications Model(s): R112, R114, R116
20. Service data and grease specifications

20.1 General tightening torques
Millimetre threads M3 to M24.
The tables apply under good conditions, e.g. steel against steel.
20.1.1 Galvanised, non-oiled screws
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
Tightening torque T (Nm)
20.1.2 Untreated, oiled screws
Strength class:
8.8 10.9 12.9
M3 1.2 1.7 2.1
M4 2.9 4.0 4.9
M5 5.7 8.1 9.7
M6 9.8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
Tightening torque T (Nm)

NOTE:
Experience has shown that if the torque wrench is adjusted to the values for
untreated screws, the correct torque value for galvanised screws will also be
obtained. Do not tighten more than the values indicated in the table,

Repair manual: Service data and grease specifications Model(s): R112, R114, R116
otherwise the screws can be destroyed.
20.2 Oil and grease specification

Ref: 236021 Rev. 5 (2008-05-21)
Specification
Lubricant type Usage
> -15C < -15C
S213366 S213366
Grease Bearings and bushings
Q8 Rubens WB Q8 Rubens WB
Synthetic hypoid oil
Transmission oil SAE 75W-90 Gears
Class API-GL5
Grease See table below See table below Chains
Grafloscon Grafloscon
Grease Gear ring (drive gear)
A-G1 (Klber) A-G1 (Klber)
S213366 S213366
Grease Mast
Q8 Rubens WB Q8 Rubens WB
Ambient temperature Viscosity class Usage

ISO VG32
0C +45C ISO 6743-4 category HM Hydraulic system
DIN 51524 part 2 = HLP
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
* Equivalent products from another manufacturer may be used.
Slut p avsnittet

Repair manual: Technical data Model(s): R112, R114, R116
21. Technical data
Model R112 R114 R116

Truck traction
Type 14110-0AG69-71
Output, kW S2 60 min 5.0
Transmission/gear mechanism
Designation GK25
Gear ratio 20.2:1
Oil volume, litres 3.3
Oil type Fully-synthetic hypoid oil
Viscosity class, ambient temperature + 40 SAE 75W-90 API GL 5
to -35C
Wheel and brakes
Parking brake, nominal braking torque 41 Nm
nominal play 0.3 0.1 mm
maximum play 0.50 mm
minimum thickness for the friction disc 10.5 mm
coil resistance 44 Ohms at 20C
Drive wheel, diameter x width, mm 330x140
Support arm wheel, diameter x width, mm 280x106
Maximum weight on support arms 1497/3432
without load/with load (kg)
Maximum weight on drive wheel 2047/1722
without load/with load (kg)
Maximum wheel pressure, support arm
(MPa)
Maximum wheel pressure, drive (MPa)

Model R112 R114 R116

Hydraulic system
Pump motor, type 14310-0AG69-71
Output, kW S3 15% 10
Pump displacement 7.9 cc DX, TX 1,6
10.9 cc TX 2,0
Tank volume, litres 25
Oil type:
0C +45C ISO VG32

ISO 6743-4 category HM
DIN 51524 part 2 = HLP
Hydraulic pressure
Overflow pressure, bar 228 DX mast
250 TX 1.6 mast
208 TX 2.0 mast
Pressure limiting valve, reach out, bar 100
Steering motor
Output, continuous, max. W 300
Fuses
F1, Drive motor 250 A
F60, ESO circuit 3A
F61, Main fuse MCU [A5] 7.5 A
F62, Main fuse CID [A1] 7.5 A
F64, Steering servo EPS [A2] 3A
F66, Converter [T5], [T6] (option) 7.5 A
F69, Extra equipment 10 A
F71, MCU [A5] 7.5 A
F72, Steering motor EPS [A2] 30 A
F73, Controls 48 V 7.5 A
Batteries
Capacity 310 620
Ah
Travel speed, km/h
Drive wheel direction, laden/unladen (km/ 10/10
h)
Fork direction, laden/unladen (km/h) 9/9

21.1 Mast type and weight (kg)
R112/ R114/ R116
Duplex Tele mast Triplex Tele mast
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)
3000 361 463 4400 490 610
3500 398 500 4800 519 639
4000 434 536 5400 561 681
4500 471 573 5700 583 703
5000 508 610 6300 688 808
6750 738 858
7000 759 879
7500 ,991 1113
8000 1038 1160
8500 1085 1207
21.2 IP classes on components and units
Components Unit IP class

Truck traction
IP 20
Pump motor
Motors IP 20
Steering servo
IP 54
motor
MCU IP 54
FCU IP 54
FCM IP 54
Electronic cards
CID Incl. in controls
LID IP 34
DHU IP 54
Motor controller: <TBD> <TBD>
Inductive IP 67
Sensor
Sensor bearing IP 65
Multi-function
control IP 34
Operating controls
Single-function IP 65
control
Contactor
0
Emergency switch
Other components IP 66
off
IP 34
Pedals

21.3 Battery sizes
Battery size 310 Ah 465 Ah 620 Ah

Battery dimensions LxHxW
1212x780x275 1212x780x275 1212x780x347
(mm)
Weight min/max (kg) 485-590 660-785 845-995
Fork pockets Yes Yes Yes

21.4 Truck dimensions
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
Dimensions, mm R112 R114-R116

b1 Chassis width 1270 1270
b3 Fork carriage width 850 850
b5 Width across forks 250-738 250-738
b11 Track width 1134 1134
s/e/l Fork dimensions 40/100/1150 40/100/1150
h6 Height over overhead guard 2153 2153
h7 Seat height
h13 Fork height, forks down 40 40
I1 Total length 2364 2436
I2 Length to fork back 1214 1214/1286
m1 Ground clearance, with load, under mast 70 70
m2 Ground clearance, wheel base centre 70 70
Wa Turning radius 1668 1668

Lift height dependant dimensions Duplex Tele mast, mm

h23 3000 3500 4000 4500 5000
h1 2050 2300 2550 2800 3050
h4 3550 4050 4550 5050 5550
Lift height dependant dimensions Triplex Tele mast, mm

h23 4400 4800 5400 5700 6300 6750 7000 7500 8000 8500
h1 2049 2182 2382 2482 2682 2932 3015 3223 3390 3556
h2 1416 1550 1750 1850 2050 2300 2384 2590 2756 2924
h4 5033 5432 6032 6332 6932 7382 7631 8133 8634 9132

Cesab Carelli Elevatori Spa Bologna, Italy

R112 114 116 - 7575392 040

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Repair manual 7575392-040

R112, R114, R116.

Issue date Order Changes

This manual contains information on the following trucks:

Model T-Code Valid from serial number

Cesab T Codes(s): 1006

Cesab 1 1 T Code(s): 1006

Cesab 1 2 T Code(s): 1006

9.6 Operator's seat C0620............................................................................... 917

Cesab 1 3 T Code(s): 1006

11. Mechanical Drive Gear Unit C2000 .......................................................... 111

Cesab 1 4 T Code(s): 1006

14. Electrical system C5000 ............................................................................ 141

Cesab 1 5 T Code(s): 1006

14.12 Main processor MCU C5710 ............................................................ 1442

Cesab 1 6 T Code(s): 1006

15.12 Main lift cylinder C6610 ....................................................................... 1539

Cesab 1 7 T Code(s): 1006

16.5 Fork carriage C7130 .............................................................................. 1615

Cesab 1 8 T Code(s): 1006

Cesab 2 1 T Code(s): 1006

Abbreviation Meaning Des. Explanation

Cesab 2 2 T Code(s): 1006

2.3 Warning symbols

Cesab 2 3 T Code(s): 1006

Identification of tools for screws and nuts

Cesab 2 4 T Code(s): 1006

Unit may be repaired without any

Unit has limited ability to be repaired.

Repair of the unit requires specialist

Cesab 2 5 T Code(s): 1006

2.4.3 Other pictograms

Symbol Procedure Symbol Procedure

Check of fluid level and Check that bolts, nuts, etc.

Listening for noise. Lubrication, application.

Check of functions. Calibration

Cesab 2 6 T Code(s): 1006

An example of another type of pictogram is Cut cable ties:

Cesab 2 7 T Code(s): 1006

Cesab 2 8 T Code(s): 1006

3. General safety rules

3.1 Work safety

Cesab 3 1 T Code(s): 1006

Cesab 3 2 T Code(s): 1006

3.2 Electrical system

Cesab 3 3 T Code(s): 1006

3.3 Safe lifting

Cesab 3 4 T Code(s): 1006

3.4 Truck modifications

Cesab 3 5 T Code(s): 1006

Cesab 3 6 T Code(s): 1006

4. Operation and connection sequences

Event: 1. Battery is connected

Cesab 4 1 T Code(s): 1006

Event: 2a. Login via keypad

Resulting conditions Login approved:

Main contactor [Q10] on

Main contactor [Q10] off

Cesab 4 2 T Code(s): 1006

Event: 2b. Login to emergency driving mode

and then press the green button

Main contactor [Q10] on

Event: 3. Driving in fork direction