0% found this document useful (0 votes)

150 views

Manual de Servicio

Uploaded by

Cristian Faundes

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

150 views

Manual de Servicio

Uploaded by

Cristian Faundes

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 568

Service Manual

EP14N2T
EP16(C)N2(T)
EP18(C)N2(T)
EP20N2(T)

Keep this manual in your forklift truck as a ready reference. 664200-EN A

Only adequately trained service persons are allowed to carry out service operations. The terms of the
warranty prescribe appropriate maintenance of the truck. Use original spare parts.

It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare
parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring
becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your
truck dealer for qualified, authorized and efficient maintenance service.

© 2023 MLE Oy. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos,
“Caterpillar Corporate Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and
product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Mitsubishi Logisnext Americas (Houston) Inc.

2121 W. Sam Houston Parkway N.

Houston, TX 77043-2305

APPROVALS AND VERSION HISTORY

REVISION DATE DESCRIPTION OF CHANGE APPROVED BY

A 06/15/2023 First issue R&D

These are the original instructions.

Service Manual

TABLE OF CONTENTS
1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Safety-related signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Interactive links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Safety requirements for industrial trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Repairs and structural modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 LOCKOUT and TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7 Service area safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.8 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.9 Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.10 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Truck models covered by this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Identification plates and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Operating direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.6 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6.1 Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.6.1.1 Jack points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.6.1.2 Hoist points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6.2 Towing connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6.3 Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.6.4 Brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.7 Assembly and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.8 Order spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5 MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1 Truck covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2 Overhead guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3 Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.1 Manual holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.2 Emergency exits (cabin truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3.2.1 Open the operator door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3.2.2 Open the rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.5 Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5.1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.5.2 Mini steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.5.3 Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5.3.1 Armrest with fingertip controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5.3.2 Ergologic armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.5.3.3 Dual joystick armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5.3.4 Control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.4 Manual levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5.5 Side control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6 Display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.6.1 Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.6.2 Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.6.3 Display control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.6.4 Truck display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.6.4.1 Main view of the truck display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.6.4.2 Hierarchy of the truck display menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.7 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.7.1 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.7.2 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.7.3 Electronic friction lock pedal (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.7.4 Dual pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.7.5 Pedal functionalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.8 Electric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.8.1 Electrical operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.8.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.8.1.2 How to use the schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.8.1.3 Power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.8.1.4 Safety circuit (emergency stop button) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.8.1.5 Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.8.1.6 Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.8.2 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.8.3 Vehicle master controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.8.3.1 Vehicle master controller connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.8.3.1.1 Vehicle Master Controller, Connector A . . . . . . . . . . . . . . . . . . . . . 81
5.8.3.1.2 Vehicle Master Controller, Connector B . . . . . . . . . . . . . . . . . . . . . 83
5.8.4 Traction controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.8.4.1 Traction controller connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.8.4.1.1 CNA external connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.8.4.1.2 Description of the power connections . . . . . . . . . . . . . . . . . . . . . . 89
5.8.5 Pump controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8.5.1 Pump controller connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.8.5.1.1 CNA external connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.8.5.1.2 Description of the power connections . . . . . . . . . . . . . . . . . . . . . . 93
5.8.6 Sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.8.6.1 Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.8.7 Option panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.8.8 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.8.8.1 Location of the fuses in the electric panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.8.8.2 Location of the fuses for optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.8.9 Relays and contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.8.9.1 Main relays and contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.8.9.2 Option panel relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.8.10 DC/DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.8.11 Armrest connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.8.12 Display connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.9 Hydraulic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.9.1 Hydraulic operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.9.2 Hydraulic operation lifting/lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.9.3 Hydraulic symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.9.4 Hydraulic valve unit with fingertip controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.9.4.1 Manual lowering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.9.5 Hydraulic valve unit with manual levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.9.5.1 Clamp release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.9.6 Hydraulic supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.9.7 Hydraulic flow distribution with additional hydraulic functions . . . . . . . . . . . . . . . . . . . . 120
5.9.7.1 Additional hydraulic functions in a truck with the armrest . . . . . . . . . . . . . . . 121
5.9.7.2 Additional hydraulic functions in a truck with the manual levers . . . . . . . . . . 122
5.10 Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.11 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.11.1 Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.11.2 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.12 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.13 Steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.14 Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.14.1 Lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.14.2 Integrated sideshift carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.14.3 Integrated fork positioner with sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.14.4 Load backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.15 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.15.1 Simplex mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.15.2 Duplex mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

5.15.3 Triplex mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

5.15.4 Mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.15.5 Main rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.15.6 Mast cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.15.6.1 Free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.15.6.2 Side cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.15.6.3 Tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.15.7 Automated performance reduction based on lift height . . . . . . . . . . . . . . . . . . . . . . . . 139
5.16 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.16.1 Solid rubber wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.16.2 Pneumatic wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.2 Truck covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.2.1 Remove the cover of the hydraulic valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.2.2 Remove the pedal plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.2.3 Open the battery door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.2.4 Open the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.2.5 Remove the back cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.2.6 Remove the steering wheel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.2.7 Remove the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.2.8 Remove the side control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.2.9 Remove the step cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.2.10 Remove the side plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.2.11 Remove the right side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.2.12 Open the roof cover (cabin trucks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.2.13 Remove the rear spoiler cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.3 Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.3.1 Windshield washer tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.3.2 Cabin seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.4 Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.4.1 Fastening of the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.4.2 Leakage check of the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.4.3 Lubricate the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.4.3.1 Oil volume measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.4.4 Test the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.4.5 Test the regenerative brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.4.6 Electromechanical parking brake maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.5 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.5.1 Hydraulic system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.5.2 Leakage check of the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6.5.3 Replace the hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
6.5.4 Replace the air breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
6.5.5 Cleaning of the hydraulic oil suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.5.5.1 Remove the hydraulic oil suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.5.6 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.5.7 Operation of the hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
6.5.8 Relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
6.5.9 Hydraulic oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.5.10 Hoses and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.5.11 Lubricate the pump axle splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.5.12 Clean the oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
6.6 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.6.1 Mounting of the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.6.2 Wear level of the mast rollers and contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
6.6.3 Chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.6.4 Chain lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.6.5 Chain wear measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.6.6 Check the chain anchors and locking pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
6.6.7 Check the cylinders and piston rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.6.8 Lifting and lowering speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.6.9 Lubrication of the mast channel surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.6.10 Lifting test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.6.11 Examine the welding in the mast for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

6.6.12 Mounting of any attachments and load-carrying components . . . . . . . . . . . . . . . . . . . 184

6.6.13 Examine the welding of the cylinders and masts for cracking . . . . . . . . . . . . . . . . . . . 184
6.6.14 Examine the rollers, pins and welds for cracking and damage . . . . . . . . . . . . . . . . . . 184
6.6.15 Apply grease to the lubrication points of the tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . 185
6.6.16 Additional mast attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.7 Lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.7.1 Examine the welding in lifting carriage for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.7.2 Examine the load backrest for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.7.3 Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.7.4 Maintenance of the integrated sideshift carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.7.4.1 Check the sliding blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6.7.4.2 Adjust the lower hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6.7.5 Maintenance of the integrated fork positioner with sideshift . . . . . . . . . . . . . . . . . . . . . 194
6.7.5.1 Check the sliding blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
6.7.5.2 Adjust the lower hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
6.8 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.8.1 Lubricate the rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.8.1.1 Oil volume measurement and oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.8.2 Lubricate the rear axle (4-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
6.8.3 Examine the operating condition of the bearings, check for looseness of the bearings 200
6.8.4 Examine the welds for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.8.5 Examine the mounting of the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.8.6 Examine the condition of the rubber spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.9 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.9.1 Damage and wear in the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.9.2 Before you replace the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6.9.3 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.9.3.1 Remove the front wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.9.3.2 Install the front wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.9.3.3 Replace the wheel shaft bolts of the front wheel . . . . . . . . . . . . . . . . . . . . . . 205
6.9.4 Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.9.4.1 Remove the rear wheels (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.9.4.2 Install the rear wheel (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6.9.4.3 Replace the wheel shaft bolts of the rear wheel (3-wheel) . . . . . . . . . . . . . . 209
6.9.4.4 Remove the rear wheels (4-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6.9.4.5 Install the rear wheel (4-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
6.9.4.6 Replace the wheel shaft bolts of the rear wheel (4-wheel) . . . . . . . . . . . . . . 213
6.10 Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6.10.1 Test the functionality of sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6.10.1.1 Traction motor sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6.10.1.2 Steering motor sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
6.10.1.3 Pump motor sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.10.1.4 Battery door sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
6.10.1.5 Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
6.10.1.6 Rear axle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
6.10.1.6.1 Rear axle sensor (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . 223
6.10.1.6.2 Rear axle sensor (4-wheel models) . . . . . . . . . . . . . . . . . . . . . . 226
6.10.1.7 Tilt angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6.10.1.8 Mast height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
6.10.1.9 Steering wheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
6.10.1.10 Mini steering wheel sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
6.10.1.10.1 Mini steering wheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
6.10.1.10.2 Mini steering wheel armrest sensor . . . . . . . . . . . . . . . . . . . . 235
6.10.1.11 Accelerator pedal sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
6.10.1.12 Brake pedal sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
6.10.1.13 Electronic friction lock pedal sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
6.10.1.14 Dual pedal sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6.10.1.14.1 Dual pedal direction sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6.10.1.14.2 Dual pedal angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
6.10.1.15 Manual lever sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
6.10.1.16 Seat belt switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
6.10.1.17 Seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
6.10.1.18 Side control panel switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
6.10.1.19 Steering column driving direction selection switch . . . . . . . . . . . . . . . . . . 248

6.10.1.20 Clamp release switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

6.10.1.21 Autolight sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
6.10.2 Steering wheel functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
6.10.3 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.10.4 Electrical connections tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.10.5 Cables and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.10.6 Examine and clear the alarm history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.10.7 Insulation resistance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.10.7.1 Test voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.10.7.2 Check the insulation tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6.10.7.3 Measure the insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6.10.7.3.1 Insulation resistance of the truck . . . . . . . . . . . . . . . . . . . . . . . . 253
6.10.7.3.2 Insulation resistance of the battery . . . . . . . . . . . . . . . . . . . . . . 254
6.10.8 Discharge the controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.10.9 Emergency stop button functionality check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
6.10.10 Key switch functionality check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6.11 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.11.1 Inspect the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.12 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.12.1 How to clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.12.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.12.3 Examine the welding in the truck frame for cracking . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.12.4 Examine the truck frame and the lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.12.5 Examine the overhead guard for deformation, cracking and damage . . . . . . . . . . . . . 259
6.12.6 Examine the gas springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.12.7 Examine the condition and position of the identification plates . . . . . . . . . . . . . . . . . . 260
6.12.8 Examine the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.12.9 Safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.12.10 Examine the fastening of the steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
7 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
7.1 Lead-acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
7.1.1 Safety with lead-acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
7.1.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1.3 Requirements for battery charging areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1.4 Charge the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
7.1.4.1 After the battery is charged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.1.5 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
7.1.5.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.1.5.2 How to clean the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7.1.5.3 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.1.5.4 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
7.1.5.5 Monthly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
7.1.5.5.1 Measure the specific gravity of the battery . . . . . . . . . . . . . . . . . 270
7.1.5.6 Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.1.6 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.1.7 Acquire a new battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.1.8 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.2 Lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.2.2 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.2.3 Requirements for battery charging areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
7.2.4 Charge the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
7.2.4.1 Recharging a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.2.4.2 Before charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
7.2.4.3 After charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
7.2.4.4 Opportunity charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
7.2.4.5 Battery balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
7.2.5 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
7.2.5.1 Examine the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.2.5.2 How to clean the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.2.5.3 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.2.5.4 Service and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.2.6 Acquire a new battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
7.2.7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

7.3 Replace the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

7.3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
7.3.2 Replace the battery with a lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.3.3 Remove the battery with the battery sideway exchange tools . . . . . . . . . . . . . . . . . . . . 285
7.3.4 Install a battery with the battery sideway exchange tools . . . . . . . . . . . . . . . . . . . . . . . 288
8 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.1 Repair drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.1.1 Drive axle lifting and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
8.1.2 Remove the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
8.1.3 Disassemble the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.1.4 Assemble the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
8.1.5 Install the electromechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
8.1.6 Install the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
8.1.7 Test the drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
8.2 Repair rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.2.1 Rear axle lifting and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.2.2 Rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
8.2.2.1 Remove the rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
8.2.2.2 Disassemble the rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . 315
8.2.2.3 Assemble the rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
8.2.2.4 Install the rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
8.2.2.5 Test the rear axle (3-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
8.2.3 Remove and install the rear axle (4-wheel models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
8.3 Repair hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
8.3.1 Remove the pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
8.3.2 Disassemble the steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
8.3.3 Set the lifting pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
8.3.4 Disassemble the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
8.3.5 Disassemble the M1, M2 and M9 valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
8.3.6 Remove the clamp release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.4 Repair mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.4.1 Remove the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
8.4.2 Disassemble the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
8.4.2.1 Disassemble the simplex mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
8.4.2.2 Disassemble the duplex mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
8.4.2.3 Disassemble the triplex mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8.4.3 Repair mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
8.4.3.1 Adjust the mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
8.4.3.2 Replace the mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
8.4.4 Repair free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.4.4.1 Replace the free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
8.4.4.2 Sealing housing of the free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
8.4.5 Repair side cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.4.5.1 Replace the side cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
8.4.5.2 Sealing housing of the side cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
8.4.6 Repair tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
8.4.6.1 Remove the tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
8.4.6.2 Disassemble the tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
8.4.7 Replace the main rollers of the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
8.5 Repair lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
8.5.1 Remove the lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
8.5.2 Adjust the rollers of the lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
8.5.3 Replace the guidance rollers of the lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
8.5.4 Replace the main rollers of the lifting carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
8.5.5 Replace the load backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
8.5.6 Repair integrated sideshift carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
8.5.6.1 Troubleshooting integrated sideshift carriage . . . . . . . . . . . . . . . . . . . . . . . . 390
8.5.6.2 Disassemble the mobile frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
8.5.6.3 Replace the sliding blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
8.5.6.4 Remove the piston of the integrated sideshift cylinder . . . . . . . . . . . . . . . . . 392
8.5.6.5 Sealing housing of the integrated sideshift cylinder . . . . . . . . . . . . . . . . . . . . 392
8.5.6.6 Disassemble the upper sliding blocks and lower rollers . . . . . . . . . . . . . . . . 394
8.5.6.7 Bleed the hydraulic circuit of the integrated sideshift carriage . . . . . . . . . . . . 395
8.5.7 Repair integrated fork positioner with sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

8.5.7.1 Troubleshooting the fork positioner with sideshift . . . . . . . . . . . . . . . . . . . . . 397

8.5.7.2 Hydraulic system (Fork positioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
8.5.7.3 Disassemble the fork shifting cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
8.5.7.4 Disassemble the mobile frame of the positioner . . . . . . . . . . . . . . . . . . . . . . 403
8.5.7.5 Disassemble the fork supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
8.5.7.6 Replace the seals of the fork shifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . 407
8.5.7.7 Install the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
8.5.7.8 Connect the hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
8.5.7.9 Assemble the integrated fork positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
8.5.7.10 Reset the equipment and bleed the hydraulic circuit . . . . . . . . . . . . . . . . . . 409
8.5.8 Repair hook-on sideshift carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8.5.8.1 Remove the hook-on sideshift frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8.5.8.2 Remove the hook-on sideshift cylinder piston . . . . . . . . . . . . . . . . . . . . . . . . 412
8.6 Repair pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
8.6.1 Remove the accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
8.6.2 Remove the brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
8.6.3 Remove the electronic friction lock pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
8.6.4 Remove the dual pedal plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
8.6.5 Remove the dual pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
8.6.6 Adjust the dual pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
8.6.7 Adjust the direction sensor of the dual pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
8.6.8 Adjust the dual pedal angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
8.7 Repair steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
8.7.1 Remove the steering wheel unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
8.7.2 Remove the steering wheel gas spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
8.7.3 Remove the lever unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
8.7.4 Remove the levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
8.8 Repair mini steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
8.8.1 Disassemble the mini steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
8.8.2 Disassemble the mini steering wheel holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
8.9 Repair armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
8.9.1 Remove the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
8.9.2 Remove the armrest base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
8.9.3 Replace the armrest padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
8.9.4 Fingertip control armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
8.9.4.1 Remove the armrest levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
8.9.4.2 Remove the thumb plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
8.9.5 Ergologic armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
8.9.5.1 Remove the joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
8.9.5.2 Replace the switches and horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
8.9.6 Dual joystick armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
8.9.6.1 Remove the dual joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
8.9.6.2 Remove the operating direction selection switch . . . . . . . . . . . . . . . . . . . . . . 433
8.9.7 Calibrate the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
8.10 Repair operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
8.10.1 Remove the operator's seat from the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
8.10.2 Replace the seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
8.10.3 MSG65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
8.10.3.1 Replace the seat padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
8.10.3.2 Replace the seat base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
8.10.3.2.1 Remove the seat base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
8.10.3.2.2 Install the seat base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
8.10.3.3 Replace the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
8.10.3.4 Replace the weight adjustment handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
8.10.3.5 Replace the seat rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
8.10.3.6 Replace the gas spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
8.10.3.7 Ground the operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
8.11 Repair electric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
8.11.1 Remove the electric panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
8.11.2 Replace the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
8.12 Repair sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
8.12.1 Replace the rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
8.12.2 Replace the battery door sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
8.12.3 Replace the rear axle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

8.12.4 Replace the tilt angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453

8.12.5 Replace the mast height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
8.12.5.1 Adjust the mast height sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
8.12.6 Replace the sensors of the hydraulic valve unit with manual levers . . . . . . . . . . . . . . 456
8.12.7 Replace the manual lever switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
8.12.8 Replace the steering wheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
8.12.9 Replace the mini steering wheel sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
8.12.9.1 Replace the mini steering wheel sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
8.12.9.2 Replace the mini steering wheel armrest sensor . . . . . . . . . . . . . . . . . . . . . 459
8.12.10 Replace the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
8.12.11 Replace the horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
8.12.12 Replace the side control panel switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
8.12.13 Replace the autolight sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
8.13 Repair cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
8.13.1 Operator door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
8.13.1.1 Remove the opening handle of the operator door . . . . . . . . . . . . . . . . . . . . 464
8.13.1.2 Remove the cover plate of the operator door . . . . . . . . . . . . . . . . . . . . . . . 465
8.13.1.3 Replace the lock of the operator door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
8.13.1.4 Replace the gas spring of the operator door . . . . . . . . . . . . . . . . . . . . . . . . 467
8.13.1.5 Adjust the operator door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
8.13.1.6 Adjust the operator door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
8.13.2 Side door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
8.13.2.1 Replace the opening lever of the side door . . . . . . . . . . . . . . . . . . . . . . . . . 469
8.13.2.2 Replace the gas spring of the side door . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
8.13.3 Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
8.13.3.1 Replace the gas spring of the rear window . . . . . . . . . . . . . . . . . . . . . . . . . 471
8.13.3.2 Remove the rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
8.13.4 Manual holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
8.13.4.1 Replace the manual holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
8.13.5 Windshield washer (cabin truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
8.13.5.1 Replace the windshield wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
8.13.5.2 Remove the motor of the windshield wipers . . . . . . . . . . . . . . . . . . . . . . . . 475
8.13.6 Sun guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
8.13.6.1 Remove the sun guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
9 TRUCKTOOL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
9.2 Location of the service socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
10 PARAMETER DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
11 SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
11.1 Special tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
11.2 Tightening torques for standard bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
11.3 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
11.3.1 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
11.3.2 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
11.3.3 Mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
11.3.4 Mast channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
11.3.5 Pump axle splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
11.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
11.4.1 Troubleshooting case examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
11.4.2 Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
11.4.3 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
11.4.4 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
11.4.5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
11.4.6 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
12 OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
12.1 Options overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
12.2 Accessory rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
12.3 A4 paper holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
12.4 Computer holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
12.5 Scanner holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
12.6 Holder arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
12.7 Reverse drive handle with horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
12.8 Smart backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
12.9 Rear combination and tail lights kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

12.9.1 Turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

12.9.2 Brake lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
12.9.3 Front lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
12.10 Amber strobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
12.10.1 Install the amber strobe under the overhead guard . . . . . . . . . . . . . . . . . . . . . . . . . . 510
12.11 Autolight sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
12.11.1 Install the autolight sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
12.12 Blue point light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
12.12.1 Blue point front light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
12.12.1.1 Install the blue point front light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
12.12.2 Blue point rear light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
12.12.2.1 Install the blue point rear light under the overhead guard . . . . . . . . . . . . . 515
12.12.3 Remove the blue point lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
12.13 Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
12.13.1 Install the working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
12.14 Red stripe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
12.14.1 Install the red stripe safety lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
12.15 USB connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
12.16 Plastic storage locker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
12.16.1 Install the plastic storage locker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
12.17 Load weight indicator and overload notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
12.18 Operator's seat options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
12.18.1 Seat armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
12.18.1.1 Install the seat armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
12.18.1.2 Adjust the height of the seat armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
12.18.2 Backrest extension (MSG65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
12.18.2.1 Install the mounting bracket of the backrest extension . . . . . . . . . . . . . . . 529
12.18.2.2 Adjust the backrest extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
12.18.3 Swivel seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
12.19 Battery sideway exchange system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
12.19.1 Requirements for power pallet trucks used to move batteries of counterbalance
trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
12.19.2 Battery sideway exchange tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
12.19.2.1 Install the battery sideway exchange tool . . . . . . . . . . . . . . . . . . . . . . . . . 533
12.19.2.2 Disassemble the battery locking mechanism . . . . . . . . . . . . . . . . . . . . . . . 533
12.20 Wide view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
12.20.1 Install the wide view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
12.21 Rear view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
12.21.1 Install the rear view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
12.22 Side-view mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
12.22.1 Install the side-view mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
12.23 Hydraulic accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
12.23.1 Install the hydraulic accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
12.23.2 Adjust the hydraulic accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
12.24 Front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
12.24.1 Install the rubber front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
12.25 Sun guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
12.26 Reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
12.26.1 Install the reading light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
12.27 Cabin fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
12.27.1 Install the cabin fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
12.28 Fender extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
12.29 Tilt angle sensor / display status indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
12.29.1 Install the tilt angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
12.30 Hook-on sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
13 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
14 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
15 TRUCK DISPLAY LANGUAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560

1 FOREWORD

READ THE INSTRUCTIONS

Read this manual before you operate or do maintenance on the truck. After reading this
manual, store it in a safe, dry place for later use.

A truck can cause serious accidents unless you are sufficiently familiar with its
operation and unless you know its operating and maintenance instructions.

To get more copies of this manual, contact your dealer.

DANGER
Personnel could be exposed to death or serious injury if LOCKOUT/TAGOUT procedure
is not performed prior to servicing the lift truck.

Only the trained technician who performs the LOCKOUT/TAGOUT procedure must
release the lift truck back into service.

Only proper LOCKOUT/TAGOUT devices must be used.

This service manual is a guide for servicing lift trucks.

The long productive life of your lift truck depends on regular and proper servicing, consistent
with the instructions provided in this service manual.

Before you start to test, repair or rebuild a lift truck, read the respective sections of this manual
carefully and make sure that you know all of the components.

The descriptions, illustrations and specifications contained in this manual are for lift trucks with
serial numbers in effect at the time of printing.

Trucks are constantly being developed. The graphic illustrations in this manual may differ
slightly from the actual design of the truck. The manufacturer reserves the right to modify the
design, equipment and technical features without prior notice and without any obligations.

For your convenience, the instructions are grouped by systems as an easy reference.

Unauthorized copying and lending of this material is strictly prohibited.

2 HOW TO READ THIS MANUAL

2.1 Safety-related signs

These are the safety-related signs used in this document.

DANGER
DANGER indicates a hazard with a high level of risk which, if not avoided, will result in
serious injury or death.

WARNING
WARNING indicates a hazard with a medium level of risk which, if not avoided, could
result in serious injury or death, or damage to the machine.

CAUTION
CAUTION indicates a hazard with a low level of risk which, if not avoided, could result
in minor or moderate injury, or damage to the machine.

NOTICE
NOTICE indicates a hazard with a risk of damage to equipment or property.

NOTE: Notes are used to indicate important information and useful tips.

2.2 Safety symbols

Hazard symbols
These symbols indicate a hazardous situation or action. Symbols are used to warn of situations,
which can cause environmental damage and personal injury.

Table 1: Hazard symbols

General warning sign Electrical hazard

Fire hazard Explosion hazard

Battery hazard Corrosive hazard

Hand crushing hazard Laser beam hazard

Prohibited action symbols

These symbols are used in warnings and notifications to indicate an action that should not be
taken. The prohibited action symbols are shown below.

Table 2: Prohibited action symbols

Prohibited action Restricted access

No smoking Do not touch

Mandatory action symbols

These symbols are used in warnings and notifications to indicate an action that must be taken.
The mandatory action symbols are shown below.

Table 3: Mandatory action symbols

General symbol for mandatory Read the manual or

action instructions

Wear head protection Wear hearing protection

Wear eye protection Wear hand protection

Wear foot protection First aid

Batteries marked with this sign must be recycled

2.3 Units

SI units are used in this manual.

The following table shows the conversion of SI units to customary units.

Table 4: Units of measurement

ITEM SI UNIT METRIC UNIT YARD-POUND UNIT

Force 1N 0.102 kgf 0.225 lbf

Pressure 1 MPa 10.1972 kgf/cm2 145.038 psi

Torque 1Nm 0.102 kgf m 0.7376 lbf ft

1 mm - 0.039 inch
Length
1m - 3.281 feet

Weight 1 kg - 2.205 lb

Temperature 1 °C - °F=1.8 x °C+32

Volume 1l - 0.264 US.gal.

2.4 Interactive links

References to chapters, figures and tables are implemented as interactive links in the digital
version of this manual. Clicking a link takes you to the corresponding section within the manual.
For example, clicking 3 Safety instructions automatically takes you to the section that contains
information about operational safety.

3 SAFETY INSTRUCTIONS

3.1 General safety instructions

WARNING
Risk of injury

Incorrect performance of lubrication or maintenance operations is dangerous and can

cause injury or death. The correct and safe lubrication and maintenance of these lift
trucks as recommended by the manufacturer is given in this document.

Read this manual before you do lubrication or maintenance on these trucks.

Do not make changes or repairs that can make the structure of the truck weaker or
put safety at risk.

READ THE INSTRUCTIONS

Incorrect truck operation is dangerous and can result in injury or death. Do not operate
the truck unless you have read and understood the instructions in the operation
manual.

Knowledge of the system and its components is important before you remove or disassemble
the components. The next sections describe some basic precautions that you must always
follow.

3.2 Safety requirements for industrial trucks

The lift truck was manufactured in accordance with the American National Standards Institute,
Inc. / Industrial Truck Standards Development Foundation (ANSI/ITSDF) B56.1, Safety
Standard for Low and High Lift Trucks. Operate this lift truck in accordance with Local, State,
Federal (e.g., OSHA) regulations, B56.1, UL 583 and NFPA 505 standards.

Manufacturer cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are therefore not all inclusive.

If you use a tool, procedure, work method or operating technique not specifically recommended
by the manufacturer, you must make sure that it does not pose a safety hazard to yourself or
others. You must also make sure that the product is not damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.

See www.itsdf.org web site for more information on the B56.1 Safety Standards for Low Lift and
High Lift Trucks. For further information on trucks and/or training, contact the sales organization.

3.3 Repairs and structural modifications

NOTE: After making this product available for the market, the manufacturer cannot be held
responsible for modifications made by the end user and the consequences thereof, which
can alter the conformity of the product.

To ensure that the truck continues to conform with all national and local standards and
regulations, no modifications or alterations to a powered industrial truck, which could affect, for
example, capacity, stability or safety requirements of the truck, must be made without the prior
written approval of the original truck manufacturer, its authorized representative, or a successor
thereof. This includes the changes affecting, for example, braking, steering, visibility and the
addition of removable attachments. When the manufacturer or his successor approves a
modification or alteration, the manufacturer or his successor must also make and approve the
appropriate changes to the plates, decals, tags and manuals of the truck.

If the end user arranges a modification or alteration without the prior written approval of the
original truck manufacturer, its authorized representative, or a successor, the end user must:

Arrange for the modification or alteration to be designed, tested and implemented by an

engineer with experience in industrial trucks and their safety

Maintain a permanent record of the risk assessment, design, tests and implementation of the
modification or alteration

Approve and make appropriate changes to the plates, decals, tags and manuals of the truck

Put a permanent and readily visible label to the truck stating how the truck has been
modified or altered, together with the date of the modification or alteration and the name and
address of the organization that accomplished those tasks, and

3.4 Seat belt

WARNING
Risk of injury

Using a defective seat belt can result in injury. Replace the seat belt if it is damaged or
defective.

If there is a collision, you must replace the seat belt before the truck can be operated
again.

Do not modify the seat belt.

Only operate the truck with an intact seat belt.

MANDATORY ACTION
Only trained personnel are allowed to replace the seat belt. Use original spare parts.

Inspect the seat belt regularly for any damage or defects.

3.5 Wheels

CAUTION
Risk of accident

The size, quality and possible wear of the wheels can affect the stability and
performance of the truck.

Only use wheels that correspond to the original factory delivery. Make sure that the
wheels are the same size and brand as indicated on the type plate and in the
specifications of the manufacturer. The use of other types of wheels can reduce the
safety and performance of the truck.

Do not mix different sizes or types of wheels because it can affect the stability of the
truck.

CAUTION
Risk of accident

A flat wheel tilts the truck, which makes it difficult to turn the steering wheel. If you
operate a truck with a flat wheel, you can cause an accident. Do not operate a truck that
has a flat wheel.

MANDATORY ACTION
Uneven wear on the wheels can affect the stability of the truck and increase the braking
distance. Replace the front and rear wheels in pairs. Make sure that the truck is not
skewed after you have replaced the wheels.

MANDATORY ACTION

Changing the wheel type affects the weight and the maximum lifting capacity of the
truck. If you change the wheel type, you must acquire an updated type plate and
capacity plate. Only use wheels approved by the manufacturer.

3.6 LOCKOUT and TAGOUT

DANGER
Risk of injury

Personnel could be exposed to death or serious injury if LOCKOUT/TAGOUT procedure

is not performed prior to servicing the lift truck.

Only the trained technician who performs the LOCKOUT/TAGOUT procedure must
release the lift truck back into service.

Only proper LOCKOUT/TAGOUT devices must be used.

WARNING
Risk of injury

Doing maintenance work on the forklift truck can create hazardous situations with risk
on injury. Wear appropriate personal protective equipment. Do service work on the
forklift truck only in a secure maintenance area.

LOCKOUT is not only used to disconnect a power supply, but also to physically isolate power
sources from supplying power to the lift truck. This is achieved with a lockout device, which
essentially disables the lift truck.

TAGOUT also reduces the risk of operating the machine during LOCKOUT with the use of a
"DO NOT OPERATE" or similar warning tag. Warning tags are ideally placed on the lockout
device to indicate the lift truck must not be operated until the tag is removed. Combined use of
LOCKOUT/TAGOUT reduces the risk of accidental or inadvertent operation. A lift truck that has
been LOCKED OUT and TAGGED OUT must not be operated until the required service has
been completed and the lift truck is no longer LOCKED OUT and TAGGED OUT.

NOTE: In the United States, employers have a responsibility to provide a safe workplace
under the regulations of the Occupational Safety and Health Administration (OSHA). For
more information on OSHA LOCKOUT/TAGOUT see the 29 CFR 1910.147 and Appendix A
to 29 CFR 1910.147 (available at www.osha.gov).

Basic requirements before servicing equipment:

Wear appropriate personal protective equipment.

Do service work on the forklift truck only in a secure maintenance area.

Park the lift on hard surface and make sure that the forks of the forklift truck are on the
ground.

Apply the parking brake.

Set the direction switch in NEUTRAL position.

Block the wheels. Make sure that the engine is stopped.

Turn the key switch to the OFF position.

Remove the key from the key switch.

To lock the truck:

1. Remove the key to the lift truck from the key switch and access the battery compartment.

2. Disconnect the battery plug/connector and their connections from the lift truck and attach the
lockout device.

3. Lock the lockout device.

4. TAGOUT the lift truck by placing a “DO NOT OPERATE” or similar warning tag where it can
be visibly seen.

5. After the work is finished, the technician with the key to the lift truck must unlock the lockout
device and remove the tag.

3.7 Service area safety

Keep the servicing area clean. Oil, grease, and water make the floor slippery.

If possible, make all repairs with the truck parked on a level, hard surface.

Before you start to do repairs on the truck, hang a Do not Operate sign in the operator
compartment.

The truck must always be supported on jacks if someone works under it.

Do not work on any truck that is supported only by lift jacks or a hoist. Always use jack
stands or other supports to support the truck before doing any disassembly.

Lower the forks or other implements to the ground before performing any work on the truck.
If this cannot be done, make sure the forks or other implements are blocked correctly to
make sure that they do not fall unexpectedly.

Use steps and grab handles (if applicable) when you mount or dismount a truck. Clean mud
or debris from the steps, walkways or work platforms before use. Always face the truck when
you use steps, ladders and walkways. When it is not possible to use the designed access
system, use ladders, scaffolds, or work platforms to perform safe repair operations.

To avoid back injury, use a hoist when you lift components that weigh 23 kg (51 lb) or more.
Make sure that all chains, hooks, slings, etc., are in good condition and of the correct
capacity. Make sure that all hooks are positioned correctly. Lifting eyes are not to be side-
loaded during a lifting operation.

Make sure that all protective devices including guards and shields are properly installed and
functioning correctly before you start a repair. If a guard or shield must be removed to
perform the repair work, be even more careful than usually.

Always support the mast and carriage to keep the carriage or attachments raised when you
perform maintenance or repair work that requires the mast to be in the lifted position.

3.8 Personal safety

DANGER
Risk of injury

The forklift truck is intended only for handling and transporting loads. Always exercise
special caution when handling loads and be aware of the people working around the
truck. The immediate vicinity of the truck must always be considered a hazardous zone.
To avoid fatal injuries resulting from improper use:

Do not lift or transport anyone on the forks or a load pallet that is on the forks.

Do not let anyone, under any circumstances, walk or stand under the forks.

Do not place any part of your body between the mast structures or any moving parts
of the truck such as the lifting carriage and attachments.

WARNING

Electric hazard
Burn hazard

Note that there is DC voltage (48V) in the connectors under the truck covers. There can
be voltage in the electric system during maintenance or repair work. If a metal object
gets into contact with an electrically conductive part, it can cause a short circuit or a
burn.

Remove all rings, watches and other metal jewelry before performing maintenance
on the electric system.

Turn the key switch/start of the truck to OFF position and disconnect the battery
connector before you open the cover of the motor or the electrical system.

After opening the covers, wait for 15 to 30 seconds for the voltage to discharge
before performing maintenance on the electric system.

MANDATORY ACTION
Always wear appropriate personal protective equipment when servicing the truck.

Wear protective glasses and protective shoes when working around trucks.

Wear protective glasses when you use a hammer or sledge on any part of the truck
or its attachments.

Wear welding gloves, hood, apron and other appropriate protective equipment when
performing welding jobs.

Do not wear loose fitting or torn clothing.

3.9 Work safety

Set the power of the truck to OFF and disconnect the battery connector before you open the
cover of the motor compartment or the electrical system.

Release all pressure in the air, oil or water systems before you disconnect or remove lines,
fittings or related items. Release the residual pressure when you remove a pressurized
device.

If it is necessary to work at height during maintenance work, make sure that you use
applicable access equipment and follow the safety instructions of the equipment
manufacturer.

With sit-on trucks, remove the seat when you do servicing to the truck.

Before you operate, lubricate or repair the truck, read all warning plates and stickers on the
truck.

Do not use your hands to search for oil leaks.

To prevent burns, be careful of the hot sections and hot fluids in lines, tubes and
compartments, also when the truck is idle or OFF.

Only use clean oil in the hydraulic system. Always fill the oil through the oil filter.

Do not mix different lubricants. It is possible that different brands of lubricants are not be
compatible with each other. Only use lubricants recommended by the manufacturer.

Repairs that need welding must be done only with the applicable reference information and
by personnel trained in welding procedures. Determine the type of metal and select the
correct welding procedure and electrodes, rods or wire to provide a weld metal strength
equivalent at least to that of the parent metal.

When you weld, always disconnect the battery and electronic devices. Remove all paint from
a 10 cm radius from the welding point to avoid creating toxic gases during welding.

Use the correct lifting procedures when you remove components.

Be careful when you remove cover plates. Gradually, remove the last 2 bolts or nuts at the
opposite ends of the cover or device. Before you remove the last 2 bolts or nuts, turn the
cover loose to release springs or other pressures.

Be careful when you remove filler caps, breathers and plugs on the truck. Put a cloth around
the cap or plug to make sure that you are not sprayed or splashed by liquids under pressure.
Be aware that the liquids spray and splash more easily immediately after you have stopped
the truck, because the fluids are very hot.

Only use well-maintained tools. Also, make sure that you use the tools in a correct way.

Reinstall all fasteners with the same part number. If a replacement is necessary, do not use
a fastener of lesser quality.

Do not cause damage to the wiring during the removal process. Do not use damaged wiring.
When you install the wiring back, make sure the wiring does not touch sharp corners or hot
parts. Put all wiring away from the oil pipe.

Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do
not bend or hit high pressure lines or install ones that are bent or damaged. Examine all
lines, tubes and hoses carefully. Pin hole (very small) leaks can cause a high velocity oil
stream that cannot be seen near the hose. This oil can go through skin and cause personal
injury. Use a cardboard or paper to find pin hole leaks.

Tighten connections to the correct tightening torque. Make sure that all heat shields, clamps
and guards are installed correctly to prevent excessive heat, vibration or rubbing against
other parts during operation. Protective shields against oil sprays onto hot exhaust
components in the event of a line, tube or seal failure must be installed correctly.

Do not operate the truck if a rotating part is damaged or touches another part during
operation. All high speed rotating components that are damaged or altered must be
examined for balance before you use them again.

3.10 Operating temperature

NOTICE
If you frequently move the truck between a freezer storage and a storage area that is in
room temperature, moisture can condense on the surfaces of the truck. If a damp truck
is operated in a freezer storage, there is a risk of ice accumulation. A frozen sensor or
switch can result in equipment malfunction. The truck must be dry before moving it into
a freezer storage.

The truck can be continuously operated at a temperature of -20...+40 °C (-4...+104 °F). The
recommended humidity is 30...95% (non-condensing). It is recommended to use low-
temperature hydraulic oil below -10 °C (14 °F) to ensure performance. The recommended
humidity is 30...95% (non-condensing).

Performance can be reduced due to high operating temperatures.

If you have to operate the truck in a cold environment, warm up the truck at the beginning of
the shift by lifting and lowering the empty forks a few times before you start working.

If the truck is specified for use in very cold operating conditions, it can be used at temperatures
down to -35°C. Charging, maintenance and long-term parking must always be done at or above
+1°C.

Each work cycle can involve driving in and out of the cold storage. In these
conditions condensation will form on the truck. The truck must not remain in the cold storage
for longer than 10 minutes to prevent the condensation from freezing.

The truck can be used continuously inside the cold storage for long periods and be then
driven out to normal temperature. In this case, the truck must be completely free of moisture
and condensation before the shift inside the cold storage starts. The truck must be parked
inside the cold storage during short breaks that are less than 30 minutes. The truck must not
be kept in the cold storage area unused for longer than 30 minutes.

4 GENERAL INFORMATION

4.1 Truck models covered by this manual

This service manual contains the service instructions for 48-volt electric counterbalance lift
trucks with the capacity of 1400–2000 kg. The manual describes the models listed in the
following table.
MODEL SERIAL NUMBER

EP14N2T ETB21B 00011 → ETB21B 49999

EP16CN2T ETB22B 00011 → ETB22B 49999
EP18CN2T ETB22B 50011 → ETB22B 99999
EP16N2T ETB23B 00011 → ETB23B 49999
EP18N2T ETB23B 50011 → ETB23B 99999
EP20N2T ETB24B 00011 → ETB24B 49999
EP16CN2 ETB27B 00011 → ETB27B 49999
EP18CN2 ETB27B 50011 → ETB27B 99999
EP16N2 ETB28B 00011 → ETB28B 49999
EP18N2 ETB28B 50011 → ETB28B 99999
EP20N2 ETB29B 00011 → ETB29B 49999

4.2 Identification plates and decals

NOTE: Make sure that all the plates and decals on the truck are legible and securely
attached.

NOTE: If a plate or decal is damaged, replace it with a new identical plate or decal. When
you send an order for a new plate or decal, include the serial number of the truck in your
order.

Figure 1, Figure 2, Figure 3, Figure 4 and Figure 5 show the plates and stickers of the truck and
their locations. For more details on the plates and stickers of the truck, see 14 Labels.

Figure 1: Plates and decals of the truck

1. Type plate 12. Overhead guard decal

2. Capacity plate 13. Operator restraint system decal
3. Manufacturer authorized tires decal 14. Safe operation decal
4. Blue light radiance decal 15. UL Classified aluminium plate
5. No passengers warning decal 16. UL EE classified decal
6. High voltage decal 17. Oil cap decal
7. Open battery cover decal 18. Quality check label
8. Safety notice decal 19. Manual pocket decal
9. In case of tipover warning decal 20. Presence system decal
10. Back-up alarm decal 21. Lithium-ion battery decal
11. In case of tipover warning decal

Figure 2: Plates and decals of the mast

1. Crush point decal 3. Load backrest decal

2. Mast warning decal 4. Mast lifting decal

Figure 3: Emergency exit decal (cabin truck)

Figure 4: Type plate

1. Truck model 6. Lithium-ion battery inormation

2. Serial number 7. Battery minimum and maximum mass (kg
3. Year of manufacture / lbs))
4. Rated capacity (kg / lbs) 8. Battery terminal voltage (V)
5. Tire information (type, dimensions, 9. Maximum ampere hours
inflation pressure) 10. Manufacturer name and address

Figure 5: Capacity plate

1. Truck model 6. Machine mass without removable

2. Serial number attachments and battery (kg / lbs)
3. Mast model 7. Actual capacity (kg / lbs)
4. Back tilt degree (if applicable) 8. Maximum fork height (mm / inch)
5. Attachment manufacturer and type (if 9. Load centre (mm / inch)
applicable) 10. Allowable working capacity (kg / lbs)

The type plate of the attachment (if applicable) includes this information:
Manufacturer name and address

Model

Serial number

Year of manufacture

Mass of attachment (kg / lbs)

Rated capacity (kg / lbs)

Load centre (if applicable) (mm / inch)

Lost load centre distance (mm / inch)

The instruction The capacity of the truck and attachment combination is complied with.

MANDATORY ACTION

Make sure that the type plate and capacity plate have corresponding information.

Make sure that the capacity plate and the type plate of the attachment have
corresponding information.

When you operate a truck that has attachments, you must always make sure that the
capacity of the truck is sufficient and that the truck is not overloaded.

NOTE: If a plate or decal is damaged, replace it with a new identical plate or decal. When
you send an order for a new plate or decal, include the serial number of the truck in your
order.

4.3 Special tools

Table 5: Special tools

PART
FIGURE DESCRIPTION
NUMBER

Extraction tools

Extraction tool for main connectors

RL622096
(SUPERSEAL)

Extraction tool for main connectors (Junior

RL655766
Power Timer)

Extraction tool for main connectors (HDSCS) RL622094

Yazaki connector tool RL623467

Extraction tool for the key switch RL360402

Crimp tools

Crimp tool for main connectors (Junior Power

RL655770
Timer)

Crimp tool for the key switch connector RL360401

Hand tool frame (Ergocrimp) RL622090

Die set for female pin (HDSCS) RL622091

Die set for male pin (HDSCS) RL622092

Complete tool (SUPERSEAL) RL622095

Complete tool (AMPSEAL) RL622097

Other tools

Hook spanner, 52-55 mm (Duplex mast, side

RL478045
cylinders)

Hook spanner with a stud, 50-80 mm

RL662188
(Simplex and Triplex mast, side cylinders)

Hook spanner, 65-70 mm (Duplex and Triplex

RL662189
mast, free lift cylinder)

Pump RL623970

Pressure cylinder RL623968

Wheel bolt tool RL623971

Motor shaft rotation tool RL623972

Brake release plug RL644700

4.4 Operating position

WARNING
Risk of injury

Operating the truck without a seat belt can result in injury. The seat belt decreases the
risk of injury in case of a collision or if the truck stops suddenly. It decreases the risk of
falling and being trapped between the truck and the ground if the truck tips over.

Always fasten the seat belt before you operate the truck. Do no open the seat belt while
driving.

To operate the truck:

Sit in the operator’s seat.

Stay under the overhead guard. Do not hold on to the overhead guard.

Fasten the seat belt.

If the operator's seat has an armrest, fold it down.

Hold the steering wheel with both hands.

Use the controls on the armrest or the manual levers with your right hand. When you do not
use them, return your right hand back to the steering wheel.

How you operate the pedals depends on the pedal combination you have on your truck.

Accelerator pedal and brake pedal:

Use the accelerator pedal and the brake pedal with your right foot.

The truck can be set to decelerate automatically when you release the accelerator pedal.
Contact service personnel to change the settings.

Accelerator pedal, brake pedal and electronic friction lock pedal:

Use the electronic friction lock pedal with your left foot. Press the pedal down to lock the
front wheels to obtain simultaneous traction.

Use the accelerator pedal and the brake pedal with your right foot.

You can release the electronic friction lock by releasing the pedal and doing one of the
following:

Press the brake pedal

Turn the steering over 45 degrees

Accelerate the truck over 10km/h (6.2 mph)

The truck can be set to decelerate automatically when you release the accelerator pedal.
Contact service personnel to change the settings.

NOTE: If your truck has an electronic friction lock pedal, you must push the pedal down to
activate the friction lock.

Dual pedal and brake pedal:

Use the forward accelerator pedal with your right foot.

Use the reverse accelerator pedal with your left foot.

To decelerate:

Lift your foot off the accelerator pedals.

Push the brake pedal.

Push the accelerator pedal of the opposite direction while the truck moves (inverse braking).

NOTE: The right and left accelerator pedals are mechanically linked. When you push one
pedal down, the other pedal is lifted up.

When you operate the truck, always keep your body completely within the outlines of the truck.
Adjust the steering wheel and operator’s seat correctly to make sure that the operating position
is ergonomic, see Figure 6.

Figure 6: Ergonomic operating position

4.5 Operating direction

The operating direction is as follows:

To go forward, operate the truck in the direction of the forks.

To go backward, operate the truck in the direction of the counterweight.

NOTE: The forward-driving direction is determined in EN ISO 3691-1 Annex A.

4.6 Transportation

CAUTION
Risk of accident
Risk of equipment damage

It is important to secure the truck properly for transportation. Improperly secured truck
can move during transportation and cause accidents. To ensure maximum safety
during transportation:

Do not secure the truck from the top beam of the mast. The ropes can break and
cause an accident.

Do not secure the truck from the overhead guard. The ropes can break and cause an
accident or the surface of the overhead guard can become damaged.

Make sure that the ropes do not go across sharp edges. The ropes can break and
cause an accident.

Do not secure the truck by attaching the ropes across the truck floor. The mat can
become damaged.

During transportation, it is important that you secure the truck so that it does not move. You can
use ropes or chains to secure the truck.

The transportation of the truck can be done in 2 ways:

Mast installed to the truck.

Mast removed from the truck.

Figure 7 shows how to secure the truck safely for transportation with the mast installed to the
truck.

Figure 7: Securing the truck for transportation with the mast attached to the
truck

Figure 8 and Figure 9 show how to secure the truck safely for transportation with the mast
removed from the truck.

Figure 8: Securing the truck for transportation with the mast removed from
the truck

Figure 9: Securing the truck for transportation with the mast removed from
the truck

4.6.1 Lifting the truck

DANGER
Risk of injury

The truck is heavy. If the truck tips over or falls on a person, it will result in a serious
injury or death.

When lifting the truck, make sure that the capacity of the lifting equipment is
sufficient.

Always put support below the truck if anyone must do any work under it. Support the
truck with safety blocks or rigid stands.

4.6.1.1 Jack points

Figure 10 indicates the correct jack points for lifting the truck up for maintenance.

Figure 10: Jack points

NOTE: Truck models with battery sideways exchange option have decals that indicate the
correct jack points. Other truck models can be lifted up from elsewhere, too.

4.6.1.2 Hoist points

NOTICE
The truck configuration does not allow truck hoisting with a crane. If possible, the lift
truck can be driven into the trailer of a cargo truck for transportation.

4.6.2 Towing connection

CAUTION
Risk of accident
Risk of equipment damage

The truck is not rated for towing trailers. Towing a trailer can cause damage to the
truck. If a trailer comes loose during towing, it can cause an accident. Do not use the
towing connection to tow trailers.

Figure 11: Towing connection

The truck has a towing connection that can be used to tow the truck temporarily or tie the truck
to a vehicle for transportation.

4.6.3 Towing the truck

CAUTION
Risk of accident
Risk of equipment damage

The towing connection is not rated for towing a trailer. Towing a trailer can result in an
accident if the towing connection breaks and the trailer is let loose.

Do not use the towing connection to tow trailers.

Use the towing connection only to tow the truck.

NOTE: The parking brake must be released before you can tow the truck. For information
on releasing the parking brake, see 4.6.4 Brake release.

To tow the truck:

Insert a cable to the towing connection. Make sure that the tow pin is securely attached.

Have someone watch the tow pin during towing from a safe distance. Stop towing
immediately if the tow pin moves from the correct position.

Tow the truck slowly. Do not pull the truck with sudden movements, because it can cause the
cable to break.

4.6.4 Brake release

WARNING
Risk of injury

After the parking brake is released, the truck can start moving uncontrollably. This can
result in injury or equipment damage. Use wheel chocks or other suitable method to
prevent unintentional movement.

The parking brake can be released with a brake release plug. See sections 4.3 Special
tools and 9 TruckTool Diagnostics.

Figure 12: Location of X4/ connector

1. Secure the truck.

2. Remove the pedal plate. See 6.2.2 Remove the pedal plate.

3. Locate the X4/ connector on the right front edge of the truck. See Figure 12.

4. Remove the empty plug and attach the brake release plug.

5. Activate Towing mode with Trucktool. After the system is booted, activate the towing mode
by pushing the display browse up button for 5 seconds. The magnetic brakes are
energized, and the truck can be towed with an external device. All the other functions are
disabled, except you can still steer the truck.

You can disable Towing mode by switching the truck OFF.

6. See 4.6.2 Towing connection for instructions on how to tow the truck.

7. Tow the truck carefully.

8. After towing is finished, deactivate Towing mode with TruckTool.

9. Remove the brake release plug and attach the empty plug.

10. Install the pedal plate.

4.7 Assembly and commissioning

MANDATORY ACTION

The assembly of the mast, commissioning of the truck and guidance of the operator
must be done by personnel trained and authorized by the manufacturer.

For instructions on how to assemble the mast, see the relevant section in 8.4 Repair mast.

4.8 Order spare parts

When you order spare parts, always contact your maintenance center. Only use original spare
parts. To make sure that you receive the correct parts, include the following information in your
order:

Truck type

Serial number of the truck

Order number of the part

Name of the part

Number of parts ordered

5 MAIN COMPONENTS

5.1 Truck covers

Figure 13: Truck covers

1. Pedal plate 6. Dashboard (lower part)

2. Side plate 7. Battery cover
3. Step cover 8. Battery door
4. Steering column covers 9. Covers of the hydraulic valve block
5. Dashboard (upper part) 10. Right-side cover

5.2 Overhead guard

WARNING
Risk of injury

The overhead guard is a safety device. Do not make any modifications to it that can
make the structure of the overhead guard weaker. Do not cut, bend, drill or weld. There
is a risk of loss of the protection function.

The overhead guard is intended to protect the operator from the impact of small
objects, for example packages, boxes or bagged material. It is not designed to
withstand the impact of a falling load.

If it is possible for objects to fall through the openings in the overhead guard, use
plexi roof, mesh guard or other equivalent additional protection.

WARNING
If the overhead guard is damaged, do not attempt to repair it. It is a safety device and
must be replaced in accordance with the instructions of the manufacturer. If the
overhead guard is damaged, contact your dealer for instructions on how to proceed.

Trucks that can lift a load higher than 1.8 m (5.9 ft) must have an overhead guard. The
overhead guard protects the operator from falling objects. The overhead guard can be equipped
with the following options:

Plexi roof to increase the protection of the operator against falling small objects.

Plexi roof and windscreen without washer and wiper (for indoor use only) for additional
protection.

Figure 14: Overhead guard

5.3 Cabin

Figure 15: Cabin doors

1. Operator door 2. Side door

5.3.1 Manual holder

The manual holder can be used to keep the manual safe and available for the truck operator at
all times. The manual holder is equipped with a locking mechanism that prevents it from
opening unintentionally during operation.

Figure 16: Manual holder

5.3.2 Emergency exits (cabin truck)

In an emergency, exit the truck through the operator door. If you cannot use the operator door,
exit the truck through the rear window or the side door. See the emergency exits in Figure 17.

For instructions on how to open the rear window, see 5.3.2.2 Open the rear window.

The rear window is marked with an Emergency exit sign. See 14 Labels and Figure 3 in 4.2
Identification plates and decals.

Figure 17: Emergency exits

5.3.2.1 Open the operator door

1. Hold the handle of the operator door and open the operator door.

2. Pull the door opening handle to the open position.

5.3.2.2 Open the rear window

Figure 18: Rear window

To open the rear window:

1. Turn the handle.

2. Lift the window up.

With the gas springs, you can also lock the rear window open:

Figure 19: Rear window locked open

5.4 Operator's seat

The operator's seat is a MSG65 performance seat. It has a flat mechanical scissor suspension
and weight adjustment with 45% vibration reduction.

Figure 20: Operator’s seat

5.5 Operating devices

Figure 21: Operating devices

1. Armrest with fingertip controls / Ergologic 3. Side control panel

armrest / Dual joystick armrest 4. Steering wheel
2. Operating direction selection switch 5. Truck display
(option) 6. Pedals

NOTE: As an alternative to the armrest with fingertip controls, you can select the manual
levers, Ergologic armrest or dual joystick armrest for the truck. See 5.5.4 Manual levers,
5.5.3.2 Ergologic armrest and 5.5.3.3 Dual joystick armrest.

NOTE: The operating direction selection switch is a standard feature in a truck with the
manual levers, but an optional feature in a truck with the armrest. If the truck has an armrest,
the operating direction is selected using the switch on the armrest. See 5.5.3 Armrest.

If the truck has a dual pedal, the operating direction is selected using that. There are
three alternative pedal combinations available for the truck. See 5.7 Pedals.

NOTE: The operator’s seat has a seat belt and seat switch. The seat switch monitors if the
operator is sitting on the seat and prevents the truck from operating if the operator is not
sitting on the seat.

5.5.1 Steering wheel

Figure 22: Steering wheel

1. Steering wheel 3. Turn signal / light switch (option)

2. Operating direction selection switch

NOTE: The operating direction selection switch is a standard feature in a truck with the
manual levers. If the truck has an armrest or a dual pedal system, those are used to select
the operating direction instead.

The 3-wheel truck models have an electric steering system. The 4-wheel truck has an
electrohydraulic steering system. In either case, the steering wheel has no direct mechanical
connection to the wheels of the truck.

Steering direction

When you operate the truck forward (to the direction of the forks), turn the steering wheel
clockwise to steer the truck right. Turn the steering wheel counterclockwise to steer the truck
left.

Curve cutback speed

Truck maximum operational speed is limited by steering angle of the rear wheel. Full operational
speed is allowed only when steering is straight.

5.5.2 Mini steering wheel

As an option to the traditional steering wheel, the truck can be equipped with a mini steering
wheel. The mini steering wheel provides the operator with better posture as the operator does
not have to reach for the steering wheel and the operator can rest their left hand on the armrest
of the mini steering wheel. The mini steering wheel also lets the operator to use their right hand
solely to operate the control and operating devices on the right-hand side.

Figure 23: Mini steering wheel and handlebar

1. Mini steering wheel 2. Handlebar

NOTE: Lift the mini steering wheel in the upright position to make entering and exiting the
operator's compartment easier.

Figure 24: Mini steering wheel lifted in the upright position

Steering direction
When you operate the truck forward (to the direction of the forks), turn the mini steering wheel
clockwise to steer the truck right. Turn the mini steering wheel counterclockwise to steer the
truck left.

NOTE: Use calm movements when you turn the mini steering wheel. The mini steering
wheel is less than half the size of a traditional steering wheel and does not require large
operating movements. Also note that the armrest of the mini steering wheel moves slightly
back and forth when you turn the mini steering wheel.

5.5.3 Armrest

5.5.3.1 Armrest with fingertip controls

NOTE: The armrest does not have an operating direction selection switch if the truck has
dual pedal. In this case the operating direction is selected using the pedals.

Figure 25: Armrest with fingertip controls

1. Lift lever 5. (Optional lever) Optional function / Attach

2. Tilt lever 3
3. Sideshift lever / Attach 1 6. F2 button
4. (Optional lever) Fork positioner lever / 7. Operating direction selection switch
Attach 2 8. Horn

NOTE: A standard armrest has three fingertip control levers. The armrest can have up to
five levers in total. Up to three levers can be assigned to additional control functions like
sideshift, fork positioner, clamp and rotation.

Always operate the armrest using your right hand. The levers and switches automatically
return to the center position when released.

5.5.3.2 Ergologic armrest

NOTE: The armrest does not have an operating direction selection switch if the truck has
dual pedal. In this case the operating direction is selected using the pedals.

Figure 26: Ergologic armrest

1. Joystick 4. Thumb wheel

2. Operating direction selection switch 5. Slider wheel
3. Horn 6. F2 button

All auxiliary functions that are available for the thumb wheel and slider wheel can be configured
for either one. Both the thumb wheel and slider wheel have two positions. They return
automatically to the center when released.

The joystick is configurable in TruckTool. See Figure 27 for details about the different
configurations.

Figure 27: Joystick functionalities

5.5.3.3 Dual joystick armrest

NOTE: The armrest does not have an operating direction selection switch if the truck has
dual pedal. In this case the operating direction is selected using the pedals.

Figure 28: Dual joystick armrest

1. Left joystick 4. Horn

2. Right Joystick 5. F2 button
3. Operating direction selection 6. Clamp release

The dual joystick is configurable in TruckTool. See Figure 29 for the control functions in different
configurations.

Figure 29: Joystick functionalities

5.5.3.4 Control functions

NOTE: This section describes the factory defaults for all control functions. The control
functions can be configured via TruckTool.

Always operate the armrest using your right hand.

Standard functions

Table 6: Armrest controls

DESCRIPTION

ARMREST WITH FINGERTIP

CONTROL ERGOLOGIC ARMREST DUAL JOYSTICK ARMREST
CONTROLS

Pull the lever to lift the forks. The further Move the joystick along the Y-axis to lift Move the left joystick along the Y-axis to
you pull the lever, the faster the lifting and lower the forks. lift and lower the forks.
Lift speed. The further you move the joystick, the The further you move the joystick, the
/ lower Push the lever to lower the forks. The faster the lifting or lowering speed. faster the lifting or lowering speed.
further you push the lever, the faster the
lowering speed.

Pull the lever to tilt the mast or the forks

Move the joystick along the X-axis to tilt Move the left joystick along the X-axis to
Tilt up. Push the lever to tilt the mast or
the mast forward and backward. tilt the mast forward and backward.
forks down.

Press the horn button to give a warning Press the horn button to give a warning Press the horn button to give a warning
Horn
sound. sound. sound.

Operating Use the switch to select the operating Use the switch to select the operating Use the switch to select the operating
direction direction. Hold the switch down in the direction. Hold the switch down in the direction. Hold the switch down in the
selection correct direction to enable the slow correct direction to enable the slow correct direction to enable the slow
switch speed mode. speed mode. speed mode.

Additional functions and attachments

The following controls are related to optional functions and attachments that can be selected for
the truck. The number of available additional functions depends on the armrest type.

Table 7: Controls for additional functions and attachments

DESCRIPTION

ARMREST WITH FINGERTIP

CONTROL ERGOLOGIC ARMREST DUAL JOYSTICK ARMREST
CONTROLS

Push the lever forward to shift the

Use the thumb wheel or slider wheel to Use the right joystick to shift the forks right
Sideshift forks to the left. Pull the lever to
shift the forks right or left. or left.
shift the forks to the right.

Push the lever to move the forks

Use the thumb wheel or slider wheel to
Fork further apart from each other. Pull Use the right joystick to move the forks
move the forks further apart or closer
positioner the lever to move the forks closer further apart or closer together.
together.
together.

Push the lever to rotate the clamp Use the thumb wheel or slider wheel to
Use the right joystick to rotate the clamp
Rotation counterclockwise. Pull the lever to rotate the clamp counterclockwise or
counterclockwise or clockwise.
rotate the clamp clockwise. clockwise.

Push the lever to extend the forks. Use the thumb wheel or slider wheel to Use the right joystick to extend or retract
Extension
Pull the lever to retract the forks. extend or retract the forks. the forks.

Use the lever to close the clamp. Use the thumb wheel or slider wheel to Use the the right joystick to close the
Press the F2 button and move the close the clamp. Press the F2 button and clamp. Press the clamp release button and
lever to the opposite direction to rotate the wheel to the opposite direction use the joystick to the opposite direction to
Clamp
release the clamp. The lever must to release the clamp. The wheel must be release the clamp. The joystick must be in
be in the neutral position when you in the neutral position when you press the the neutral position when you press the
press the F2 button. F2 button. clamp release button.

The F2 button can be used to give The F2 button can be used to give an The F2 button can be used to enable
an additional feature to the additional feature to the thumb wheel and additional features on the left joystick:
following levers: slider wheel:
F2 button + Tilt: Tilt auto centering
F2 button + Tilt lever: Tilt auto F2 button + Tilt: Tilt auto centering
F2 button + Tilt: Tilt shake
centering
F2 button + Tilt: Tilt shake (configurable via TruckTool)
F2 button + Tilt lever: Tilt (configurable via TruckTool)
shake (configurable via
F2 button + Clamp: Clamp release
TruckTool)
F2 button + Clamp lever: If your truck has both the tilt auto
F2 button
Clamp release centering and the clamp release function,
clamp release requires F2 button +
If your truck has both the tilt auto double command from the clamp release.
centering and the clamp release NOTE: You must activate the clamp
function, clamp release requires F2 function within 2 second after you press
button + double command from the the F2 button.
clamp release lever.
NOTE: You must activate the clamp
function within 2 second after you
press the F2 button.

Clamp Clamp release button can be used to enable

release n/a n/a the clamp release function on the right
button joystick.

5.5.4 Manual levers

Figure 30: Manual levers

1. Lift lever 5. Horn button

2. Tilt lever 6. Tilt centering button (option)
3. Sideshift lever (option) / Attach 1 7. Clamp release button (option)
4. Optional lever (option) / Attach 2

NOTE: The truck can be equipped with three or four manual levers. If your truck has the
reel clamp option, the reel clamp release button is installed either on the third or fourth lever.

Always operate the manual levers using your right hand. The levers automatically return to the
center position when released.

Table 8: Control functionalities

CONTROL FUNCTIONALITY DESCRIPTION

Pull the lever to lift the forks. The further you pull the lever, the faster the
lifting speed.
Lift lever
Push the lever to lower the forks. The further you push the lever, the faster
the lowering speed.

Pull the lever to tilt the mast or the forks up. Push the lever to tilt the mast or
Tilt lever
the forks up

Tilt
Press the tilt centering button and hold it down. Then move the tilt lever
centering
forward or backward to activate the centering function. The centering function
button
stops when you release the button or lever.
(option)

Horn Press the button to give a warning sound.

Sideshift
Push the lever forward to shift the forks to the left. Pull the lever to shift the
lever
forks to the right.
(option)

Fork
positioner Push the lever to move the forks further apart from each other. Pull the lever
lever to move the forks closer together.
(option)

Clamp
Pull the lever backward to close the clamp. Press the clamp release
lever
button and push the lever to release the clamp.
(option)

Clamp
Use the button to enable clamp release on the clamp lever.
release
The clamp release button is located on the tip of the clamp lever handle.
button
The lever must be in the neutral position when you press the button.
(option)

5.5.5 Side control panel

Five control switches can be installed on the side control panel.

Figure 31: Side control panel

1. Manual working lights 4. Rear window wiper (option)

2. Automatic working lights (option) 5. Rear window heater (option)
3. Windshield wiper and washer (option)

Table 9: Control functionalities

CONTROL FUNCTIONALITY DESCRIPTION

Use the switch to control the working lights. The switch has three positions:
Manual OFF
working Forward lights are ON and rear lights turn ON automatically when
lights reversing
Forward and rear lights are ON

Automatic When you set the working lights on automatic mode, the lights turn ON
working automatically when the lighting of the working environment is inadequate.
lights When you use the working lights on automatic mode, you must also set the
(option) manual working lights switch to the ON position.

Use the switch to control the windshield wiper. The switch has three
Windshield positions:
wiper and OFF
washer ON
(option) ON + Washer fluid spray

Rear
window
Use the switch to set the rear window wiper ON and OFF.
wiper
(option)

Use the rear window heater switch to control the rear window heater. Switch
has an indicator light to indicate heater status. Heater switches off
Rear automatically after 10 minutes. The switch has three positions (two static
window and one returning):
heater OFF
(option) OFF / stay ON 10 minutes after toggle command
(Returning state) Toggle rear window heater ON

5.6 Display panel

Figure 32: Display panel

1. Key switch / start switch 3. Display control buttons

2. Truck display 4. Emergency stop button

5.6.1 Emergency stop button

Figure 33: Emergency stop button

5.6.2 Key switch

Figure 34: Key switch

5.6.3 Display control buttons

Figure 35: Display control buttons

1. Browse up / PIN code 1 button 4. Browse left / PIN code 4 button

2. Browse right / PIN code 2 button 5. Exit / Esc button
3. Browse down / PIN code 3 button 6. Enter button

5.6.4 Truck display

Figure 36: Truck display

1. Truck display 2. Display control buttons

NOTE: After you have set the power of the truck to ON, but before you start to operate the
truck, wait until the main view is shown on the truck display.

5.6.4.1 Main view of the truck display

Figure 37: Main view of the truck display

1. Battery discharge indicator 3. Date and time or messages

2. Center information area

In normal operating situations, the main view of the truck display shows

The battery discharge indicator

The center information area with speed and direction indication.

Date and time

NOTE: The truck display looks different if you have the load weight indicator option installed
to your truck.

NOTE: The display images in this manual have English messages as examples. The
display language can be changed via TruckTool. Contact the service personnel. See 15 Truck
display languages.

5.6.4.2 Hierarchy of the truck display menus

Figure 38: Hierarchy of the truck display menus

5.7 Pedals

There are 3 different pedal combination alternatives for the truck:

Accelerator pedal and brake pedal

Accelerator pedal, electronic friction lock pedal and brake pedal

Dual pedal and brake pedal

5.7.1 Accelerator pedal

Use the accelerator pedal with your right foot. The more you push the accelerator pedal, the
higher the speed. The accelerator pedal returns to the neutral position automatically when it is
released. For instructions on how to calibrate the accelerator pedal, see the instructions of
TruckTool.

Figure 39: Accelerator pedal

5.7.2 Brake pedal

Use the brake pedal with your right foot. The more you push the brake pedal, the stronger the
braking is. The brake pedal returns to the neutral position automatically when it is released. For
instructions on how to calibrate the brake pedal, see the instructions of the TruckTool.

NOTE: To reduce the wear of the mechanical brakes, adjust the electric brake pedal sensor
so that the electric brake produces full braking power when the brake pedal is pushed half-
way down.

Figure 40: Brake pedal

5.7.3 Electronic friction lock pedal (option)

Figure 41: Electronic friction lock pedal overview

5.7.4 Dual pedal

Figure 42: Dual pedal

1. Accelerator pedal forward 3. Accelerator pedal reverse

2. Brake pedal

Figure 43: Lubrication points of the dual pedal

Table 10: Lubricant of the dual pedal

Lubricant VASELINE Molykote BR2 Plus (NLGI. No. 2 grade)

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are
not compatible with each other. Only use lubricants recommended by the manufacturer.

5.7.5 Pedal functionalities

Table 11: Pedal functionalities

CONTROL FUNCTIONALITY DESCRIPTION

Accelerator
Use the accelerator pedal with your right foot. The more you push the
pedal
accelerator pedal, the higher the operating speed.
(single
NOTE: Handle the accelerator pedal gently.
pedal)

The truck has an electric service brake for reducing the operating speed.
Push the brake pedal gently to slow the speed.
The service brake decelerates the truck and charges the battery in the
following cases:
When the brake pedal is pushed.
Brake pedal When the operating direction changes.
When the accelerator pedal is released.

If the brake pedal is pressed all the way down, a panic braking function is
activated which stops the truck using a combination of electric service
brake and mechanical magnetic brake.
NOTE: Practice braking with and without a load.
The truck may be equipped with an electronic friction lock function. This
function is useful especially in slippery conditions when starting off with the
steering not straight. The front wheels provide maximum traction and one
Electronic wheel cannot slip alone. Use the electronic friction lock pedal with your left
friction lock foot. Press the pedal down to lock the front wheels to obtain simultaneous
pedal traction. You can release the electronic friction lock by releasing the pedal
(option) and doing one of the following:
Press the brake pedal
Turn the steering over 45 degrees
Accelerate the truck over 10km/h (6.2 mph)

Accelerator
pedal Use the accelerator pedal forward with your right foot. The more you push
forward the accelerator pedal, the higher the operating speed.
(dual pedal The accelerator pedals forward and reverse are mechanically linked, so
systems that when you push one pedal down the other pedal is lifted up.
only)

Accelerator
pedal Use the accelerator pedal reverse with your left foot. The more you push
reverse the accelerator pedal, the higher the operating speed.
(dual pedal The accelerator pedals forward and reverse are mechanically linked, so
systems that when you push one pedal down the other pedal is lifted up.
only)

The boost function is activated when you press the accelerator pedal
quickly or completely. The maximum boost duration has a maximum time
limit. If one boost sequence doesn’t use the whole time limit, the remaining
Acceleration
time is stored for the next boost. The boost function cannot be activated
boost
repeatedly if the duration of the boost is long. The software monitors the
system temperatures and can prevent the boost if excessive temperatures
are detected.

The software monitors the torque demand at different driving speeds. The
torque boost is activated automatically when the normal torque of the truck
Torque is not able to maintain the constant travel speed. For example, when the
boost truck speed drops on a ramp, the torque boost activates automatically. The
torque boost is also controlled based on the duration and repetition of the
boost and the detected system temperatures.

A fully automatic parking brake stops the truck on the ramp when the
operator's foot is lifted off the accelerator pedal. The parking brake
prevents the truck from running down the ramp. If the passive sway control
Hill hold is enabled, then the parking brake is not activated immediately after the
truck stops, but the truck is kept at its place by the torque at the traction
motors. If the operator leaves the truck, the parking brake activates
immediately.

The advanced functionalities of the truck allow fast steering response. This
enhances the stability of the truck. The truck travel speed is reduced
Curve based on the actual steering angle of the truck. In addition, the stability of
control the truck is enhanced by reducing the maximum steering speed based on
the travel speed. Full travel speed is allowed only when the steering is
close to straight.

5.8 Electric system

WARNING
Electric hazard

Note that there is DC voltage (48V) in the connectors under the truck covers. There can
be voltage in the electric system when you open the covers which causes a risk of
electric shock.

Set the power of the truck to OFF and disconnect the battery connector before you
open the covers of the truck.

Do not operate the truck with the electric panel uncovered.

After opening the covers, wait for 15 to 30 seconds for the voltage to discharge.

WARNING
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before you
inspect and replace the fuses, set the power of the truck to OFF and disconnect the
battery connector.

Figure 44: Electric system overview

1. Vehicle master controller 8. Frontlight relay

2. Key contactor 9. Traction controller
3. Secondary service connector 10. Pump controller
4. Fuse box 11. Traction controller
5. Truck/battery connector 12. Controller fan
6. Main contactor for motor controllers 13. Steering controller
7. Horn relay

5.8.1 Electrical operation

5.8.1.1 Overview

This chapter describes the electrical operating principles of the power counterbalance truck.
The standard model and its electrical schematic diagram are used as an example.

MANDATORY ACTION
Always use the correct schematic diagram for the specific model you are servicing. The
latest schematic diagrams are available from the website of the manufacturer.

To troubleshoot a particular component, locate the component on the appropriate page

of the schematic diagram and check the circuitry associated with it. Keep the
schematic diagram at hand for reference while reading the explanation. Make sure that
you have the correct schematic diagram with regard to the truck model and its age.

5.8.1.2 How to use the schematic diagram

NOTE: The figures provided in this section are provided as examples only. Therefore the
information in the actual schematic diagram of the truck model you are servicing can differ
from the figures.

The electrical operating principles of the power counterbalance truck are described here. The
standard model and its electrical schematic diagram are used as an example.

As an example, Figure 45 shows a part of a schematic diagram.

Figure 45: Page 1/8, zone 13, wiring reference J14

Note the numbers above the wiring reference J14. These numbers (8/16) direct you to the page
and zone where the wire is connected. The page numbers also act as active links in the
schematic diagram. You can also search the pdf with text.

This procedure is used to follow the circuits throughout the schematic diagram. If the numbers
are given without the slash (/), the connection is on the same page of the schematics.

Table 12 explains the different identifiers used in the schematic diagram. # stands for a number.

Table 12: Schematic diagram identifiers

IDENTIFIER DESCRIPTION

S# Switches and other state changing devices (for example, most sensors).

#F# Fuse

Reference.
J# All references marked with an even ”J” (e.g. J2) are positive (+). All
references marked with an odd “J” (e.g. J3) are negative (-).

M# Motor

V# Diode

A# Controllers and displays

K# Contactors and relays

X# Connector. Contact numbers are marked on individual wires.

XX# Splice. Multiple wires are connected together at this point.

Figure 46 shows the reference to which Figure 45 referred.

Figure 46: Page 8, zone 16, wiring reference J14

Once again, note the numbers below the wiring reference J14. These numbers (1/13) direct you
back to the page (and zone) shown in Figure 45.

Figure 47: Page numbers (4/9), circuit diagram number (3-7109) and
revision letter (H)

Page numbers, the circuit diagram number and the revision letter can be found in the bottom
right corner of the page.

Figure 48: Page modification history

On the left side of the circuit diagram, you can see the modification history of the page.

5.8.1.3 Power source

This truck uses a wet lead-acid battery, which consist of 24 cells and supplies a nominal voltage
of 48 volts. The battery has the maximum capacity of 750 Ah, depending on the truck
model. The battery resides in a separate compartment and is connected to the system via the
X1 battery connector.

Lithium-ion battery with the maximum capacity of 444 Ah is available as an option.

5.8.1.4 Safety circuit (emergency stop button)

NOTE: The following description applies to truck models supplied with a lead-acid battery.

If the emergency stop button (S2) is in its normal closed position, B+ continues to flow to the
key switch (S1). B+ also flows to the coil of the key switch contactor (K2) though the battery
polarity protection diode V2. The operator can shut down the system power at any time by
pushing the emergency stop button. When the button is pushed, the connection opens and
removes B+ from the coil of the key switch contactor (K2). At the same time, the software
monitors the emergency stop switch contact position, and if it is pushed, but the power is not
lost from the controllers, alarm is given and the truck is stopped safely.

5.8.1.5 Key switch

NOTE: The following description applies to truck models supplied with a lead-acid battery.

The main key switch (S1) controls the electrical power supply to the entire system with the help
of the key switch contactor (K2) and the main contactor (K1). The key switch is activated by
turning it to the ON position. When the key switch closes, B+ flows to the coil of contactor K2,
and the negative is connected straight to the battery. After this, the contactor K2 closes the
contacts, which energizes the control system of the truck. Coil of the contactor K1 has a positive
supply after contactor K2. K1 is controlled by PWM with the right traction controller.

Positive electrical power is supplied to the system through the main fuses 11F1, 12F1,
14F1 and 9F1.

The truck has individual left (M1) and right (M2) traction motors that each have a dedicated left
(A1) and right (A2) traction controller. After the main fuses 11F1 and 14F1, the B+ supply is fed
to controllers A1 and A2. The main voltage is supplied to the +BF terminals on the traction
controllers.

The truck has a pump motor (M3) that is controller by the pump contoller (A3). After the main
fuse 12F1, B+ supply is fed to the contacts of the controller A3. The main voltage is supplied to
the terminal +BF on the pump controller.

The truck as a steering motor (M4) that is controlled by a steering controller (A6). After the main
fuse 9F1, B+ supply is fed to the contacts of the controller A6. The main voltage is supplied to
the terminal B+ on the the steering controller.

NOTE: The contactor coils, location of the fuses, and the connections for all motors and
their controllers are presented in the schematic diagram.

5.8.1.6 Traction

The movement of the truck is controlled by the left and right traction controllers. Before the truck
can be operated, the battery must be connected, the main key switch must be in the ON
position and the system must have passed the self-test procedure. Additionally, the seat switch
must indicate that the operator is sitting on the seat, and the seat belt must be fastened.

When the truck is powered on and in the standby mode, the operating direction can be selected
using an FNR control switch on the armrest or on the left-hand side of the steering wheel. If the
truck has the dual pedal, the driving direction is selected by pushing down the correct
accelerator pedal. The method for selecting the operating direction depends on the
configuration of the truck.

The accelerator pedal is connected to the right traction controller. The integrity of the
accelerator pedal signal is continuously monitored. When the accelerator pedal is pushed down,
it provides a varying voltage to the traction controller based on the position of the pedal.

5.8.2 Controllers

Figure 49: Location of controllers

1. Left traction controller 4. Vehicle master controller

2. Right traction controller 5. Steering controller
3. Pump controller

5.8.3 Vehicle master controller

This forklift truck has a VCM Vehicle Master Controller, which performs all the electric functions
that are usually present in reach trucks, high level order pickers and counterweight lift trucks.

The controller performs these functions:

Drivers for several ON/OFF and proportional solenoid valves

2 CAN bus interfaces

Interface for 2 encoders

11 digital inputs

10 analog inputs

Flash memory

Double microcontroller

5.8.3.1 Vehicle master controller connectors

WARNING
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before any
inspection or repair work:

Set the key switch to the OFF position

Disconnect the battery connector

Discharge all controllers

Record the places of the harness connections before disassembly.

NOTICE
When disconnecting the connector, hold the connector housing and plug, and unlock
the connector. Holding the case can cause damage to the inside card, while holding the
cable can cause the wires to break.

Figure 50: Vehicle master controller connectors

The vehicle master controller uses 2 connectors:

CNA 35 poles connector

CNB 23 poles connector

Contact 0.5-1.25 mm2 for CNA and CNB connectors.

5.8.3.1.1 Vehicle Master Controller, Connector A

Vehicle master controller is labeled as A4 in the circuit diagrams.

Table 13: Vehicle Master Controller, Connector A

CIRCUIT PHYSICAL
SOFTWARE PHYSICAL
DIAGRAM PIN FUNCTION
IDENTIFIER RANGE
IDENTIFIER NUMBER

POWER
+48V 1 +BATT +BATT for the valve supplies
IN1

Tilt forward valve,

Tilt Forward NEVP3 2 0-1000 mA
proportional

Tilt backward valve,

Tilt Backward NEVP4 3 0-1000 mA
proportional

Attach 2 function,
ATTACH2 A NEVP7 4 0-1000 mA
proportional

Attach 2 function,
ATTACH2 B NEVP8 5 0-1000 mA
proportional

ATTACH3 A NEV1 6 0/48V VDC Attach 3 function, on/off

ATTACH3 B NEV2 7 0/48V VDC Attach 3 function, on/off

Multipurpose Generic input which can be

DI1 8 0/12V
in 3 configured in various ways.

Battery lock input. Stop the

Battery lock DI2 9 0/12V
truck if open.

Clamp release switch for the

Clamp
DI3 10 0/12V reel-clamp attachment
release
(option)

CAN1L CANL1 11 CAN-bus 1

CAN1H CANH1 12 CAN-bus 1

Positive supply for lift/lower

+ PEVP1 13 48V
valves

+ PEVP2 14 48V Positive supply for tilt valves

Positive supply for ATTACH1

+ PEVP3 15 48V
valves

Positive supply for ATTACH2

+ PEVP4 16 48V
valves

Positive supply for ATTACH3

+ PEV1 17 48V
valves

EPS all ok DI4 18 0/48 V EPS all ok hardwired signal

Mast height sensor,

Mast height
DI5 19 0/12V continuously active when
sensor
mast is below free lift area

Automated
working Automated working lights
DI6 20 0/12V
lights switch in the dashboard
ON/OFF

Seat belt
DI7 21 0/48V Seat belt switch
switch

0V sensor
NPOT 22 GND 0V sensor for the sensors
supply

General input which can be

Multipurpose
CPOT1 23 0/5V configured in various ways
in 4
(Multipurpose input 4)

Lift NEVP1 24 0-700 mA Lift valve, proportional

Lower NEVP2 25 0-700 mA Lower valve, proportional

ATTACH1 function,
ATTACH1 A NEVP5 26 0-1000 mA
proportional

ATTACH1 function,
ATTACH1 B NEVP6 27 0-1000 mA
proportional

KEY KEY 28 48V KEY input for the VCM

0V supply for VCM and valve

0V -BATT 29 -BATT
drives

CAN2L CANL2 30 CAN-bus 2

CAN2H CANH2 31 CAN-bus 2

32 Not used

+12V / +12V supply, 500mA total

+12V PPOT1 33
500 mA together with +5V supply

+5V sensor +5V /

PPOT2 34 +5V supply for the sensors
supply 500 mA

MC lift lever CPOT2 35 MC valves lift lever

5.8.3.1.2 Vehicle Master Controller, Connector B

Table 14: Vehicle Master Controller, Connector B

CIRCUIT PHYSICAL
SOFTWARE PHYSICAL
DIAGRAM PIN FUNCTION
IDENTIFIER RANGE
IDENTIFIER NUMBER

Main
CPOT3 1 0/48V Main contactor status
contactor

MC valves
CPOT4 2 0/5V MC valves tilt sensor
tilt

Tilt B CPOT5 3 0.5-4.5V Mast tilt angle sensor

Light
CPOT6 4 0-5V Measure ambient light amount
sensor

Tilt A CPOT7 5 0.5-4.5V Mast tilt angle sensor

Pressure sensor to measure

Pressure
CPOT8 6 0-10 V hydraulic pressure at the free-lift
sensor
area for load weight scale

POWER
+48V 7 48V +BATT input for the valves
IN2

48V PEV2 8 48V FREE

Encoder2 ENCB
9 encoder FREE
Ch A CHA

Encoder2 ENCB
10 encoder FREE
Ch B CHB

MC valves
CPOT9 11 0/5V MC valves attach 1 input
Attach 1

MC valves
CPOT10 12 0/5V MC valves attach 2 input
Attach 2

Seat
DI8 13 0/48V Seat switch
switch

Forward DI9 14 0/12V F-N-R switch forward

Lowering lock valve to add

redundancy to lowering (FC) or
Lift lock NEV3 15 0/48V
disable the lowering when no
power present (MC)

+5V / +5V supply for multipurpose

+5V PPOT3 16
500 mA input 4

ENCA
A 17 0/12V Mast height sensor channel A
CHA

ECNA
B 18 0/12V Mast height sensor channel B
CHB

0V NENC 19 GND 0V supply for sensors

0V -BATT 20 -BATT 0V supply for VCM and valves

Neutral DI10 21 0/12V F-N-R switch neutral

Backward DI11 22 0/12V F-N-R switch backward

Magnetic
NEVP9 23 0/48V Multipurpose output 1
brakes

5.8.4 Traction controller

This forklift truck has two ACE-2 Controllers, which are designed to control 4.0 kW to 9.0 kW
motors.

The controller performs these functions:

Controller for AC asynchronous 3-phase motors

Regenerative braking functions

2 CAN bus interfaces

Flash memory (128 Kbytes on-chip program memory)

Digital control based upon a microcontroller

Voltage: 36–48 V

Maximum current 350 A (RMS) for 3 minutes

1 hour current rating 170 A (RMS)

Operating frequency: 8 kHz

External temperature range: -30°C…40°C

Maximum controller temperature (at full power): 85°C

5.8.4.1 Traction controller connectors

WARNING
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before any
inspection or repair work:

Set the key switch to the OFF position

Disconnect the battery connector

Discharge all controllers

Record the places of the harness connections before disassembly.

WARNING
Burn hazard
Fire hazard

If the high-power cable terminals of the battery-operated vehicle are not tightened
properly, the increased contact resistance causes excessive heat generation. This can
even result in a fire.

To prevent accidents and equipment problems, examine the tightening torque of the
high-power cable terminals regularly.

Do not pull the cables to check connections or during adjustment.

If the cable terminal sections are moved, re-tighten the connections.

Figure 51: Traction controller CNA external connector and power terminals

The traction controller uses one connector:

CNA 23 poles connector

Contact 0.5-1.25 mm2 for the CNA connector.

5.8.4.1.1 CNA external connector

Traction controller (left) is labeled as A1 in the circuit diagrams.

Traction controller (right) is labeled as A2 in the circuit diagrams.

Table 15: Traction controller left

CIRCUIT PHYSICAL
SOFTWARE PHYSICAL
DIAGRAM PIN DESCRIPTION
IDENTIFIER RANGE
IDENTIFIER NUMBER

KEY KEY 1 48 V Key supply

+5V +5V 2 +5 V Sensor supply

Working lights 0.5…4.5 Working lights on/off

CPOT1 3
on/off V switch input

Electronic Friction Lock

OPP FWD 4 0/5 V
Switch input

CAN Identifier CAN ID 5 0/5 V CAN identifier jumper

Speed
CBRK2 6 0/5 V Speed cutback 2 input
cutback 2

Motor rotation speed

A ENCA 7 0/12 V
encoder channel A

Positive supply for

+12 V +12 8 +12 V
encoder

Multipurpose
NAUX1 9 0/48 V Multipurpose output 4
output 4

0.5…4.5
Input N/A 10 FREE INPUT
V

CAN2L CANL2 11 CAN-bus 2 low

CAN2H CANH2 12 CAN-bus 2 high

Speed
CPOT2 13 5V Speed cutback 1 input
cutback 1

Motor rotation speed

B ENCB 14 0/12 V
encoder channel B

0V sensor supply (encoder

0V GND 15 0V
ground)

0/48 V Traction controllers cooling

Fan speed NMC 16
PWM fan speed control

+48V free wheeling diode

+48V PCOM 17 +48 V point for the traction
controller outputs (N/A)

Electric brake Traction motor electric

EBRAKE 18 0/48 V
output (magnetic) brake output

Performance mode
Perf. mode PRESS_MAN 19 0/48 V
selection input

CAN1L CANL1 20 CAN-bus 1 low

CAN1H CANH2 21 CAN-bus 1 high

Motor thermal sensor

Temp. sensor THMOT 22 0-5 V
value

Temp. sensor THMOT 23 0V Motor thermal sensor 0V

Table 16: Traction controller right

CIRCUIT PHYSICAL
SOFTWARE PHYSICAL
DIAGRAM PIN DESCRIPTION
IDENTIFIER RANGE
IDENTIFIER NUMBER

KEY KEY 1 48 V Key supply

+5V +5V 2 +5 V Sensor supply

0.5…4.5
Throttle 2 CPOT1 3 Throttle sensor signal A2
V

Dual pedal Dual throttle pedal center

FWD 4 0/12 V
center position

CAN-ID jumper
CAN-ID BWD 5 5V
(connected)

0.5…4.5
Brake 1 CBRK2 6 Brake sensor signal A1
V

Motor rotation speed

B ENCA 7 0/12 V
encoder channel B

Positive supply for

+12 V +12 8 +12 V
encoder

Multipurpose
NAUX1 9 0/48 V Multipurpose output 2
output 2

0.5…4.5
Brake CBRK1 10 Brake sensor signal A2
V

CAN2L CANL2 11 CAN-bus 2 low

CAN2H CANH2 12 CAN-bus 2 high

0.5...4.5
Throttle 1 CPOT2 13 Throttle sensor signal A1
V

Motor rotation speed

A ENCB 14 0/12 V
encoder channel A

0V GND 15 0V 0V sensor supply

Main
NMC 16 0/48 V Main contactor control
cont.control

+48V free wheeling diode

+48V PCOM 17 +48 V point for the traction
controller outputs

Traction motor magnetic

Electric brake EBRAKE 18 0/48 V
brake control

EMS status PRESS_MAN 19 0/48 V EMS switch status

CAN1L CANL1 20 CAN-bus 1 low

CAN1H CANH2 21 CAN-bus 1 high

Motor thermal sensor

Temp. sensor THMOT 22 0-5 V
value

Temp. sensor THMOT 23 0V Motor thermal sensor 0V

5.8.4.1.2 Description of the power connections

Table 17: Description of the power connections

CONNECTION DESCRIPTION

-B Negative of the battery.

+B Positive of the battery.

Terminal of the main fuse. The battery is connected to the +BF

+BF
connection. The fuse connects the +BF and +B terminals.

U; V; W Connection terminals of the three motor phases.

NOTE: The correct tightening torque for the traction controller terminal bolts is 13 – 15 Nm.

5.8.5 Pump controller

This forklift truck has an ACE-3 Controller, which is designed to control 20.8 kW to 25.5 kW
motors.

The controller performs these functions:

Controller for AC asynchronous 3-phase motors

CAN bus interface

Flash memory (128 Kbytes on-chip program memory)

Digital control based upon a microcontroller

Voltage: 36–48V

Maximum current ACE2 48 V / 450 A (RMS) for 3'

1 hour current rating ACE 48 V / 225 A (RMS)

Operating frequency: 8 kHz

External temperature range: -30°C…40°C

Maximum controller temperature (at full power): 85°C

Dual microcontroller

5.8.5.1 Pump controller connectors

WARNING
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before any
inspection or repair work:

Set the key switch to the OFF position

Disconnect the battery connector

Discharge all controllers

Record the places of the harness connections before disassembly.

WARNING
Burn hazard
Fire hazard

If the high-power cable terminals of the battery-operated vehicle are not tightened
properly, the increased contact resistance causes excessive heat generation. This can
even result in a fire.

To prevent accidents and equipment problems, examine the tightening torque of the
high-power cable terminals regularly.

Do not pull the cables to check connections or during adjustment.

If the cable terminal sections are moved, re-tighten the connections.

Figure 52: Pump controller CNA external connector

The pump controller uses one connector:

CNA 23 poles connector

Contact 0.5 – 1.25 mm2 for the CNA connector.

5.8.5.1.1 CNA external connector

Pump controller is labeled as A3 in the circuit diagrams.

Table 18: Pump controller connections

PHYSICAL
SOFTWARE PHYSICAL
CONNECTION PIN DESCRIPTION
IDENTIFIER RANGE
NUMBER

KEY KEY 1 48V Key supply

+5V sensor supply voltage

+5V +5V 2 +5V
(not used)

0,5…
Free input CPOT1 3 FREE
4,5 V

Free input FWD 4 0/12 V FREE

Release brakes for tow

tow mode BWD 5
mode jumper

0,5…
Free input CBRK2 6 FREE INPUT
4,5 V

Motor rotation speed

A ENCA 7 0/12 V
encoder channel A

Positive supply for

+ 12V +12 8 +12 V
encoder

Multipurpose NPN 48V

MIP4 9 Multipurpose output 4
input 4 (PWM)

0,5 V…
Free input CBRK1 10
4,5 V

CANL2 CANL2 11 CAN-bus 2 low

CANH2 CANH2 12 CAN-bus 2 high

0,5 V…
Free input CPOT2 13 FREE INPUT
4,5 V

Motor rotation speed

B ENCB 14 0/12 V
encoder channel B

0V GND 15 0V 0V sensor supply

Reverse light NMC 16 0/12 V Reverse light output

+48V free wheeling diode

+48V PCOM 17 +48 V point for the pump
controller outputs

Reverse Reverse alarm output

NEB 18 0/48 V
alarm (multipurpose output 3)

Free input PRESS_MAN 19 PNP 48 V FREE INPUT

CAN1L CANL1 20 CAN-bus 1 low

CAN1H CANH2 21 CAN-bus 1 high

Motor thermal sensor

Temp. sensor THMOT 22
value

23 Not used

5.8.5.1.2 Description of the power connections

Table 19: Description of the power connections

CONNECTION DESCRIPTION

-B Negative of the battery.

+B Positive of the battery.

This terminal is not used. The + pole of the battery is connected directly
+BF
to the +B terminal.

U; V; W Connection terminals of the three motor phases.

NOTE: The correct tightening torque for the pump controller terminal bolts is 13-15 Nm.

5.8.6 Sensors and switches

An inductive sensor is an electronic proximity sensor, which detects metallic objects without
touching them. The sensor consists of an induction loop. Electric current generates a magnetic
field that collapses, thus generating a current that falls asymptotically toward zero from its initial
level when the electricity input ceases. The inductance of the loop changes according to the
material in it and, since metals are much more effective inductors than other materials, the
presence of metal increases the current flowing through the loop. This change can be detected
by sensing circuitry, which can signal to some other device whenever metal is detected.

The magnetic reed switch is an electrical switch operated by an applied magnetic field. It
consists of a pair of contacts on ferrous metal reeds in a hermetically-sealed glass envelope.
The contacts can be normally open, closing when a magnetic field is present, or normally closed
and opening when a magnetic field is applied. The switch can be actuated by a coil, making a
reed relay or by bringing a magnet near to the switch. Once the magnet is pulled away from the
switch, the reed switch goes back to its original position.

HALL sensor measures the magnitude of a magnetic field. It generates an output voltage in
proportion to the strength of the magnetic field that comes into contact with the sensor. A HALL
sensor has an electric current directed through a conductor. When a magnetic field is introduced
near the sensor, the flowing electrons accumulate to the opposite sides of the conductor. This
produces a voltage gradient that can be measured. HALL sensors are commonly used as
proximity sensors, speed sensors and switches.

The following figures illustrate the locations of sensors and switches in the truck.

Figure 53: Location of sensors

Table 20: Location of sensors

# LOCATION DESCRIPTION

1 B20 Steering wheel sensor

2 B38 Rear axle sensor

3 Multiple Pedal sensors. See Figure 54.

4 S51 Battery door sensor

5 B42 Pressure sensor

6 B52 Tilt angle sensor (option)

7 S40 Mast height sensor

8 B43 Autolight sensor (option)

9 S29 Seat belt switch

10 S30 Seat switch

Figure 54: Pedal sensors

Table 21: Pedal sensors

# LOCATION DESCRIPTION

1 B21 Accelerator pedal

2 B22 Brake pedal

3 S5 Electronic friction lock pedal (option)

4 S34, S35 Dual pedal direction sensors (option)

5 B23 Dual pedal angle sensors (option)

Figure 55: Manual control switches

1. Horn switch 3. Clamp release switch

2. Tilt centering switch (option)

5.8.6.1 Horn switch

There are a total of three possible locations for horn switches in the truck. Up to two horn
switches can be installed at the same time.

Figure 56: Horn switches

1. Armrest 3. Reverse driving handle (option)

2. Manual control levers

5.8.7 Option panel

The option panel is located at the rear compartment. It contains the electric components for
optional features.

Figure 57: Option panel

1. DC-DC converters 3. Relay sockets

2. Fuses

For detailed information about fuses and relays, see 5.8.8 Fuses and 5.8.9 Relays and
contactors.

5.8.8 Fuses

WARNING
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before you
inspect and replace the fuses, set the power of the truck to OFF and disconnect the
battery connector.

NOTICE
When changing fuses, make sure that the replacement fuse is the correct type. See the
spare parts catalog for the correct fuse types. Use original spare parts.

Figure 58: Overview of fuse locations on the truck

1. Electric panel fuses 2. Option panel fuses

5.8.8.1 Location of the fuses in the electric panel

Location of the fuses in the electric panel (standard models)

Figure 59: Fuses overview

Table 22: Fuses

# LOCATION RATING DESCRIPTION

1 1F1 5A Key switch

2 2F1 5A Electromagnetic brakes

3 3F1 10 A Hydraulic valves

4 4F1 10 A Controllers (key)

5 6F1 10 A Optional outputs

6 7F1 10 A Horn

7 8F1 10 A Working lights

8 10F1 10 A DC/DC converter

9 9F1 50 A Steering controller

10 11F1 250 A Left traction controller

11 12F1 300 A Pump controller

12 14F1 250 A Right traction controller

Location of the fuses in the electric panel (UL E/EE-models)

Figure 60: Fuses overview

Table 23: Fuses

# LOCATION RATING DESCRIPTION

1 F10 2A Horn switch S6 at MC-lever

2 F9 2A Horn supply

3 F8 2A Controllers fan supply

4 F7 2A Display supply

5 F6 2A Multipurpose output 4 supply

6 F5 5A Controllers key

7 F4 2A Lower Enable

8 F3 5A VCM

9 F2 5A Electromagnetic brakes

10 F1 2A Key switch

11 A6F1 50 A Steering Contoller Supply

12 A3F1 300 A Pump controller supply

13 A1F1 250 A Left traction controller supply

14 F20 2A Aux device 3 left/right valves

15 F19 2A Aux device 2 left/right valves

16 F18 2A Aux device 1 left/right valves

17 F17 2A Tilt FW/BW valves

18 F16 2A Lift/lower valves

19 F15 2A Blue point front/rear

20 F14 2A Multipurpose output 1 supply

21 F13 2A Reverse alarm, Strobe

22 F12 2A Working lights

23 F11 10 A Cabin DC/DC converter

24 A2F1 250 A Right traction controller supply

5.8.8.2 Location of the fuses for optional equipment

Fuses for optional equipment are located in the rear compartment of the truck.

Location of the fuses for optional equipment (standard models)

Figure 61: Fuses for optional equipment

Table 24: Fuses for optional equipment

# LOCATION RATING DESCRIPTION

1 23F1 10 A Rear combination and tail lights kit

2 24F1 5A Rear combination and tail lights kit switches

3 25F1 20 A 12V supply

4 26F1 10 A Cabin heater

5 27F1 10 A Rear window heater

6 28F1 15 A Front screen wiper and washer

7 29F1 5A Rear screen wiper and washer

8 30F1 10 A Reading light, Cabin fan, USB power output on dashboard

Location of the fuses for optional equipment (UL E/EE models)

Figure 62: Fuses for optional equipment

Table 25: Fuses for optional equipment

# LOCATION RATING DESCRIPTION

1 F30 5A Option

2 F29 5A Option

3 F28 5A Rear window heater

4 F27 5A Rear screen wiper and washer

5 F26 5A Front screen wiper and washer

6 F25 5A Rear combination and tail lights

7 F24 5A Reading light

8 F23 5A USB power output and cabin fan

9 F22 5A 12 V socket supply

10 F21 5A 12 V supply

5.8.9 Relays and contactors

5.8.9.1 Main relays and contactors

Figure 63: Main relays and contactors

Table 26: Main relays and contactors

# COMPONENT DESCRIPTION

1 K2 Key contactor

2 K1 Main contactor for controllers

3 K32 Horn

4 K10 Woking lights

5 K17 Rear combination and tail lights kit power supply contactor

5.8.9.2 Option panel relays

Figure 64: Option panel relays

Table 27: Option panel relays

# COMPONENT DESCRIPTION

1 K7 Rear blue point

2 K6 Front blue point

3 K8 Reverse alarm

4 XK14/ Rear combination and tail lights kit reverse light

5 XK13/ Rear combination and tail lights kit brake light

6 XK12/ Rear combination and tail lights kit flasher

7 XK9/ Rear combination and taill lights kit low beam light

8 K15 Rear window heater time-delay

9 K11 Reverse working light

10 K18 Red line lights

Small relay bracket

If the truck has no DC/DC converters and the electric system contains few relays, a small relay
bracket is installed to the option panel.

Figure 65: Option panel relays on a small relay bracket

Table 28: Option panel relays on a small relay bracket

# COMPONENT DESCRIPTION

1 K7 Rear blue point

2 K6 Front blue point

3 K8 Reverse alarm

4 K11 Reverse working light

5.8.10 DC/DC converter

DC/DC converters allow multiple peripherals, such as terminals, barcode readers or label
printers to be connected to the electrical system of the truck.

Figure 66: DC/DC converters

Table 29: DC/DC converters

# LOCATION DESCRIPTION

Rear combination and tail lights kit / Power supply 12.4 V / 24 A / 300
1 G1
W (option)

2 G2 Cabin options

5.8.11 Armrest connector

The standard armrest with fingertip controls and the optional Ergologic armrest and dual joystick
armrest have identical pinout on the connector.

Figure 67: Armrest connector

Table 30: Armrest connector

CONNECTOR PIN FUNCTIONALITY

1 CAN high

2 FNR-N (low side switch)

3 Magic Button (low side switch)

4 LSS supply

5 Power supply horn

6 Power supply armrest (7-20V)

7 Not used

8 Not used

9 CAN low

10 FNR-R (low side switch)

11 FNR-F (low side switch)

12 LSS signal

13 Horn signal

14 GND

15 Not used

16 Not used

5.8.12 Display connector

Table 31: Display connector

CIRCUIT DIAGRAM SOFTWARE PHYSICAL PIN PHYSICAL

FUNCTION
IDENTIFIER IDENTIFIER NUMBER RANGE

XA5A/1 A1 +12V

XA5A/2 A2 0V

CAN 1
CAN1H = XA5A/3 A3
High

CAN 1
CAN1L = XA5A/4 A4
Low

5.9 Hydraulic operation

WARNING
Risk of injury

There is high pressure inside the hydraulic system. Opening the hydraulic connections
can cause hydraulic oil to spill from the system with high pressure. This can cause
injury and skin irritation. Release the hydraulic pressure by lowering the forks all the
way down before you open the system.

CAUTION
Burn hazard

Hydraulic system, oil and motors heat up during operation. Touching them can result in
a burn. Let the hydraulic system, oil and motors cool down before performing
maintenance.

CAUTION
Toxic hazard

Oils used in the truck and the hydraulic system are toxic substances. Oil can cause
skin irritation if it gets in contact with skin.

Always wear protective gloves when you handle hydraulic oil.

Use proper tools to find oil leaks. Do not use your hands.

NOTICE
The hydraulic system has extremely low tolerance for dirt. Even a small amount of dirt
or dust particles can cause malfunction in the hydraulic system. When performing
maintenance on the hydraulic system, take special precautions to make sure that your
hands, tools and working environment are clean. Use only clean oil in the hydraulic
system. Always fill the oil through the filter.

MANDATORY ACTION
Hydraulic oil is hazardous waste that must be disposed of accordingly.

NOTE: Use a clean cloth or other applicable plug to seal open connections.

5.9.1 Hydraulic operation overview

NOTE: Make sure that you have the appropriate version of the hydraulic schematics for the
truck model under maintenance. Contact your supplier or technical support for information on
obtaining up to date documentation for your truck model.

This section presents the hydraulic operation of the truck. The hydraulic schematic diagrams
shown in Figure 68 and illustrate the operation of the hydraulic system.

Figure 68: Hydraulic system overview on a truck equipped with an armrest

1. Suspension (option) 5. Auxiliary 2 (option)

2. Lift/lower 6. Aux2
3. Tilt 7. Aux3
4. Auxiliary 1

Figure 69: Hydraulic system overview on a truck equipped with manual

levers

1. Suspension (option) 4. Auxiliary 1

2. Lift/lower 5. Aux inhibit (option)
3. Tilt 6. Auxiliary 2 (option)

Table 32: Hydraulic system

1.4–TON AND 1.6–TON MODELS 1.8–TON AND 2.0–TON MODELS

Electric motor 10 kW (S3 10%) 10 kW (S3 10%)

Motor type 3-phase AC 3-phase AC

Pump size 16 cc 16 cc

Pump type External gear External gear

Tank volume 19.5 liters 19.5 liters

153 μ 153 μ
Suction filter Qmax: 70 lpm Qmax: 70 lpm

10 μ 10 μ
Return filter Qmax: 165 lpm Qmax: 165 lpm
Built in breather Built in breather

5.9.2 Hydraulic operation lifting/lowering

NOTE: Different truck models can have different hydraulic system configurations.

The principle of the hydraulic operation of the truck is as follows:

Lifting
Truck with manual levers

1. The electrical motor operates the hydraulic gear pump.

2. There is flow through LS-valve to tank.

3. Safety valve is energized.

4. Sensor detects lifting spool movement, and increases pump speed. Valve opens the channel
from load pressure to LS-line. LS-valve starts to close.

5. System pressure starts to increase due to LS-valve operation.

6. The lifting cylinder piston lifts the forks.

Truck with armrest controls

1. The electric motor operates the hydraulic gear pump.

2. There is flow through LS-valve to tank.

3. System starts to open the proportional lift valve. Lift pressure is connected to LS-line, and
LS-valve starts to close.

4. System pressure starts to increase due to LS-valve operation.

5. The lifting cylinder piston lifts the forks.

Figure 70: Hydraulic fluid flow during lifting

Lowering
1. Safety valve is energized.

2. The lifting/lowering valve (manual levers) or lowering valve (armrest fingertip controls) is
opened using the lowering lever.

3. Gravity pushes the lifting cylinder down as the hydraulic pressure reduces, and the hydraulic
fluid flows through the 300µ sieve and 10µ return filter back to the tank.

Figure 71: Hydraulic fluid flow during lowering

5.9.3 Hydraulic symbols

Table 33: Hydraulic symbols

SYMBOL DESCRIPTION

Cylinder

Plugged measuring point

Check valve

Return filter with a bypass valve

Solenoid valve

Electric motor and hydraulic pump

Suction filter

Adjustable pressure relief valve

Hydraulic oil flow control valve

Hydraulic oil tank filling plug

Hydraulic accumulator

Breather filter

Sieve

5.9.4 Hydraulic valve unit with fingertip controls

NOTICE
The hydraulic system has extremely low tolerance for dirt. Even a small amount of dirt
or dust particles can cause malfunction in the hydraulic system. When performing
maintenance on the hydraulic system, take special precautions to make sure that your
hands, tools and working environment are clean. When working on the hydraulic valves
and connectors, avoid getting any dirt into the connectors or valves.

Figure 72: Hydraulic valve unit with fingertip controls

1. H, Lift port 9. M3 Tilt (24,6 Ω)

2. P, Pressure port 10. M4 Tilt (24,6 Ω)
3. T, Tank port 11. M5 Aux 1A /Sideshift (24,6 Ω)
4. A1/B1 Tilt ports 12. M6 Aux 1B /Sideshift (24,6 Ω)
5. A2/B2 Aux 1A/B Sideshift 13. M7 Aux 2A (24,6 Ω)
6. A3/B3 Aux 2A/B ports 14. M8 Aux 2B (24,6 Ω)
7. M2 Lift valve (24,6 Ω) 15. M9 Lowering lock (90 Ω)
8. M1 Lowering valve (24,6 Ω) (400-1500 16. DV1 pressure adjustment
mA)

5.9.4.1 Manual lowering valve

The manual lowering valve is used to bypass the M1 valve and lower the mast manually in a
controlled manner.

Maximum opening 1.5 turns

Maximum torque MA = 2.5 +0.5 Nm

Figure 73: Manual lowering valve

1. M1 Lowering valve 3. Manual lowering screw

2. M2 Lift valve

NOTE: Coils are not shown in the picture.

5.9.5 Hydraulic valve unit with manual levers

NOTICE
The hydraulic system has extremely low tolerance for dirt. Even a small amount of dirt
or dust particles can cause malfunction in the hydraulic system. When performing
maintenance on the hydraulic system, take special precautions to make sure that your
hands, tools and working environment are clean. When working on the hydraulic valves
and connectors, avoid getting any dirt into the connectors or valves.

Figure 74: Hydraulic valve unit with manual levers

1. AUX 2 spool 6. Pressure relief valve

2. AUX 1 spool 7. Lowering enable valve
3. Tilt spool 8. Clamp lock valve (option)
4. Lift/lower spool 9. Manual lowering valve, max. opening 1.5
5. Lowering maximum speed setup turns
adjustment

5.9.5.1 Clamp release valve

Table 34: Clamp release valve

Type ON/OFF Valve

Coil nominal current 48 V (DC) / 100%

Electrical wiring 2-pole sealed connector

Valve functionality check

Measure the resistance between the solenoid terminals. The resistance should be ~274 Ω.

5.9.6 Hydraulic supply system

Figure 75: Hydraulic supply system overview

1. Return line 6. Pump motor

2. Hydraulic oil pressure line 7. Hydraulic oil return filter-element
3. Filling hole for hydraulic oil 8. Hydraulic oil suction line
4. Oil tank 9. Suction filter
5. Pump 10. Breather

Table 35: Pump motor specifications

Type 3-phase AC

Voltage 30 V

Output power 10 kW (S3 10%)

Electrical wiring M8 bolt terminals (max 8 Nm)

5.9.7 Hydraulic flow distribution with additional hydraulic functions

This section describes the additional hydraulic functions.

5.9.7.1 Additional hydraulic functions in a truck with the armrest

Hydraulics with 3 section control valve, FC

Figure 76: Hydraulics with 3 section control valve, FC

Hydraulics with 4 section control valve, FC

Figure 77: Hydraulics with 4 section control valve

5.9.7.2 Additional hydraulic functions in a truck with the manual levers

Hydraulics with the 3 section control valve

Figure 78: Hydraulics with the 3 section control valve

Hydraulics with 4 section control valve

Figure 79: Hydraulics with 4 section control valve

5.10 Drive axle

NOTICE
Before you do maintenance on the drive axle, clean the area with pressurized air.

Figure 80: Drive axle overview

1. Transmission gear left 5. Speed sensor

2. Transmission gear right 6. Electromechanical parking brake
3. Left traction motor 7. Thermal sensor
4. Right traction motor

The electric drive axle has 2 motors with transmission gears and an integrated parking brake.

Table 36: Drive axles

Motors 2 × 5.5 kW AC (S2 60 min)

Voltage 30 V (AC)

Maximum acceleration torque 1950 Nm

Maximum brake torque 1950 Nm

Gear ratio 1:42

Encoder 64 pulse per revolution

The drive axle has a warranty of 1 year.

5.11 Brakes

5.11.1 Service brake

MANDATORY ACTION
Practice steering, accelerating, braking and controlling the truck with and without a
load in a safe area before starting to operate the truck.

The truck has an electric service brake for reducing the operating speed. The service brake
decelerates the truck and charges the battery in the following cases:

When the accelerator pedal is released.

When the operating direction changes.

When the brake pedal is pushed.

If the brake pedal is pressed all the way down, a panic braking function is activated which stops
the truck using a combination of electric service brake and mechanical electromagnetic brake.

5.11.2 Parking brake

WARNING
Risk of injury

If the truck is parked on a ramp or operated on a ramp that is too steep, it can start
sliding uncontrollably. This can result in injury or equipment damage.

Do not park the truck on a ramp.

Do not operate the truck on slopes or ramps with a gradient of more than 15%.

The parking brake is a mechanical electromagnetic brake, which keeps the truck stationary after
the truck is stopped and left unattended.

To release the parking brake, push the accelerator pedal.

To engage the parking brake, release the accelerator pedal. When the truck is completely
stopped, the parking brake engages automatically.

To engage the parking brake immediately, press the brake pedal when the truck is
completely stopped.

The parking brake is also engaged in these cases:

When the brake pedal is pressed all the way down.

When the key switch/start switch is set to OFF.

When the emergency stop button is pushed.

When the control system does an emergency stop function.

When the mast is raised, the parking brake remains disengaged for 10 seconds (passive
sway control activated).

When the seat switch is de-activated.

CAUTION
Risk of injury

In all the situations listed above, the truck can stop abruptly. A sudden stop can cause
a hazardous situation that can result in injury, for example if the load slides off the
forks. Always wear a seat belt when operating the truck.

5.12 Rear axle

Figure 81: Rear axle, 3-wheel and 4-wheel models

Table 37: Rear axle

3-WHEEL MODEL 4-WHEEL MODEL

Steering angle 180° / 360° 103° / 78°

+3° / -3° with pneumatic tires

Maximum tilt angle -
+6° / -6° with solid tires

Turning speed 72°/s -

Speed 7min-1 -

Working pressure - 80-90 bar

Maximum working pressure - 120 bar

Maximum pressure - 150 bar (peak)

Torque 700 Nm -

5.13 Steering unit

3-wheel models
In 3-wheel models, an electric motor rotates the rear axle. The steering motor is located directly
on top of the axle.

Figure 82: Steering unit, 3-wheel models

4-wheel models
In 4-wheel models, the steering unit is a hydraulic power supply unit. Power unit generates
hydraulic pressure for the hydraulic cylinder in the rear axle. Hydraulic cylinder turns the rear
wheels.

NOTE: The unit uses hydraulic oil.

Figure 83: Steering unit, 4-wheel models

5.14 Load handling

5.14.1 Lifting carriage

Figure 84: Lifting carriage overview

1. Lifting carriage 4. Main roller

2. Fork 5. Load backrest
3. Sliding pad

5.14.2 Integrated sideshift carriage

Figure 85: Integrated sideshift carriage

1. Manufacturing date and identification 4. Load backrest

code 5. Cap for bleeding air from circuit
2. FEM mobile frame 6. Sideshifting cylinder
3. Fixed frame complete with sideshifting

5.14.3 Integrated fork positioner with sideshift

This equipment positions the loading forks of the truck.

Figure 86: Integrated fork positioner with sideshift

1. Manufacturing date and identification 4. Load backrest

code 5. Sideshifting cylinder
2. FEM mobile frame 6. Fork shifting cylinders
3. Lifting carriage chassis complete with 7. Fork supports
sideshifting

5.14.4 Load backrest

The load backrest provides the load with additional support and protects the truck operator and
people working around the truck from unexpected load movements.

Figure 87: Load backrest

If your truck does not have a load backrest, there is a stopper plate on each side of the lifting
carriage to prevent the fork arms from falling accidentally. See Figure 88.

Figure 88: Stopper plates

5.15 Mast

5.15.1 Simplex mast

Figure 89: Detailed construction of a simplex mast

1. Mast 8. Chain wheel

2. Internal mast 9. Sliding pad
3. Lifting carriage 10. Mast roller
4. Side cylinder 11. Hydraulic hose
5. Side cylinder collar 12. Hose fastener
6. Chain 13. Hydraulic pipe
7. Chain anchor 14. Load backrest

5.15.2 Duplex mast

Figure 90: Detailed construction of a duplex mast

1. Mast 9. Chain yoke

2. Internal mast 10. Sliding pad
3. Lifting carriage 11. Main roller
4. Side cylinder 12. Hydraulic hose
5. Side cylinder collar 13. Hose spout
6. Free lift cylinder 14. Hose guide
7. Chain 15. Hydraulic hose / pipe
8. Chain anchor 16. Load backrest

5.15.3 Triplex mast

Figure 91: Detailed construction of a triplex mast

1. Mast 11. Hose wheel

2. Second internal mast 12. Chain yoke
3. First internal mast 13. Main roller
4. Lifting carriage 14. Hydraulic hose
5. Side cylinder 15. Hose fastener
6. Side cylinder collar 16. Bracket
7. Free lift cylinder 17. Hydraulic pipe
8. Chain 18. Load backrest
9. Chain anchor 19. Sliding pad
10. Chain wheel

5.15.4 Mast chains

WARNING
Risk of accident

Mast chains are load-bearing components that affect the health and safety of the
operators. When replacing chains, always use the chain types specified by the truck
manufacturer. The minimum safety factor for mast chains is at least 5.

WARNING
Risk of accident

Removing or replacing chain link plates does not correct chain elongation. There is
increased risk of chain breaking and the load falling if you try to repair an elongated
mast chain. Do not lengthen or shorten mast chains. Replace the entire mast chain if
the chain is worn or elongated.

Figure 92: Mast chains overview

1. Chain 4. Locking nut

2. Chain anchor 5. Chain wheel
3. Tightening nut 6. Chain yoke

5.15.5 Main rollers

Figure 93: Main rollers

5.15.6 Mast cylinders

5.15.6.1 Free lift cylinder

Figure 94: Free lift cylinder overview

1. Free lift cylinder 4. Hydraulic pipe/hose

2. Chain 5. Hydraulic connector
3. Chain yoke 6. Sealing housing

5.15.6.2 Side cylinders

Figure 95: Side cylinders overview

1. Side cylinder piston 3. Sealing housing

2. Hydraulic connector / hose break valve

5.15.6.3 Tilt cylinders

Figure 96: Tilt cylinders

5.15.7 Automated performance reduction based on lift height

The performance of the truck can be automatically reduced based on how high the load is lifted.
The hydraulics and operating speed of the truck are automatically slowed down when the load
is lifted above the height of the mast height sensor. If the truck has free lift, the mast height
sensor is usually installed at the highest point of the free lift area. The performance reduction is
configured via TruckTool.

The lifting height is monitored with a mast height sensor. See 5.8.6 Sensors and switches.

Figure 97: Automated performance reduction based on lift height

1. Mast height sensor of the simplex mast 2. Mast height sensor of the duplex and
unit triplex mast units

5.16 Wheels

There are 2 types of wheels available for the truck:

Solid rubber wheels

Pneumatic wheels

5.16.1 Solid rubber wheels

For the correct size of the wheel, see the type plate of the truck.

The solid rubber wheels have a wear indicator, which is also known as the 60 J line. When the
wheels are worn to this line, they must be replaced immediately.

NOTE: Depending on the working environment, it is possible that you must replace the
wheels before they are worn to the 60 J line.

Figure 98: Wear indicator of a solid rubber wheel

5.16.2 Pneumatic wheels

As an alternative for the solid rubber wheels, the truck can have pneumatic wheels.

Replace the wheel if the depth of the tread groove is less than 5 mm or if the mark shows the
limit.

See the type plate of the truck for the correct wheel size and wheel pressure for the front and
rear wheels.

6 MAINTENANCE

6.1 Maintenance intervals

MANDATORY ACTION
Only adequately trained truck operators and service personnel are allowed to carry out
the daily and weekly check-ups.

Only trained service personnel are allowed to carry out other maintenance operations.

The terms of warranty prescribe the appropriate maintenance of the truck. Use original
spare parts.

To keep the truck in a good condition and to ensure reliable operation throughout its life cycle, it
must undergo regular maintenance and service. For a comprehensive list of all scheduled
maintenance tasks, see 16 Maintenance check list.

6.2 Truck covers

CAUTION
Risk of injury
Risk of equipment damage

If the truck is operated without the protective covers, there is a risk of dirt, debris or
water getting into the electric parts. Additionally, moving parts inside the truck can
cause injury to personnel. Do not operate the truck without the covers in place.

WARNING
Electric hazard

Note that there is DC voltage (48V) in the connectors under the truck covers. There can
be voltage in the electric system when you open the covers which causes a risk of
electric shock.

Set the power of the truck to OFF and disconnect the battery connector before you
open the covers of the truck.

Do not operate the truck with the electric panel uncovered.

After opening the covers, wait for 15 to 30 seconds for the voltage to discharge.

Figure 99: Truck covers

1. Pedal plate 6. Dashboard (lower part)

2. Side plate 7. Battery cover
3. Step cover 8. Battery door
4. Steering column covers 9. Covers of the hydraulic valve block
5. Dashboard (upper part) 10. Right-side cover

6.2.1 Remove the cover of the hydraulic valve block

1. Open the battery door, see 6.2.3 Open the battery door.

2. Open the battery cover, see 6.2.4 Open the battery cover.

3. Remove the 3 screws.

4. Remove the covers from the snaplock.

5. Remove the cover of the hydraulic valve block.

6.2.2 Remove the pedal plate

NOTE: There are 3 different pedal plates for the different pedal combinations. The pedal
plate in your truck can look different than the one that is shown here. For more information on
the pedal combinations, see 5.7 Pedals.

1. Remove the rubber mat.

2. Remove 2 screws.

3. Remove the pedal plate. You do not need to disconnect the cable.

4. Disconnect the pedal connectors for all applicable pedals.

6.2.3 Open the battery door

CAUTION
Risk of injury

If hand or fingers get trapped between the battery door and the truck frame, it can
result in crushing injury. When closing the battery door, do not hold the battery door
from the edges. Do not leave your hand between the door and the truck frame.

1. Pull the door handle.

2. Open the battery door.

6.2.4 Open the battery cover

CAUTION
Risk of injury

If hand or fingers get trapped between the battery cover and the truck frame, it can
result in crushing injury. When closing the battery cover, do not hold the cover from the
edges. Do not leave your hand between the cover and the truck frame.

NOTE: If you have a truck with a cabin, you must open the rear window (see 5.3.2.2 Open
the rear window), before you open the battery cover.

Before you open the battery cover:

Lift the steering wheel to the up position.

Set the operator’s seat to the back position.

Set the armrest to the back position.

Figure 100: Before you open the battery cover

1. Turn the handle of the battery cover on the right-hand side of the truck.

2. Lift the battery cover up.

3. Remove the locking pin from the holder.

4. Lock the battery cover on the upright position with the locking pin.

6.2.5 Remove the back cover

1. Remove the 2 screws.

2. Remove the back cover.

6.2.6 Remove the steering wheel cover

1. Remove the 4 screws and the rubber plugs.

2. Remove the top and bottom parts of the steering wheel cover.

6.2.7 Remove the control panel

1. Remove the 5 screws.

2. Remove the control panel cover.

3. Disconnect the connectors.

4. Remove the control panel.

6.2.8 Remove the side control panel

1. Open the battey cover. See 6.2.4 Open the battery cover.

2. Remove the 4 screws.

3. Remove the side control panel.

6.2.9 Remove the step cover

1. Remove the pedal plate. See 6.2.2 Remove the pedal plate.

2. Remove the 2 screws.

3. Remove the step cover.

6.2.10 Remove the side plate

This procedure is needed only when you replace the battery.

1. Open the battery cover, see 6.2.4 Open the battery cover.

2. Lift the side plate up and sideways.

6.2.11 Remove the right side cover

1. Open the battery door. See 6.2.3 Open the battery door.

2. Remove the screw.

3. Pull the right side cover out.

6.2.12 Open the roof cover (cabin trucks)

CAUTION
Risk of injury

When driving, open doors or roof cover can cause hazardous situation that can cause
injury or property damage. Do not operate a cabin truck with the steel doors or the roof
cover open.

NOTE: Only the truck models with the cabin have a roof cover.

1. Turn the handle of the roof cover.

2. Open the roof cover.

6.2.13 Remove the rear spoiler cover

1. Remove the 4 screws.

2. Remove the rear spoiler cover.

6.3 Cabin

6.3.1 Windshield washer tank

The windshield washer tank is located in the back of the truck behind the battery cover.

To add windshield washer fluid in the windshield washer tank:

1. Open the battery cover, see 6.2.4 Open the battery cover.

2. Open the cap of the windshield washer tank.

3. Add windshield washer fluid.

4. Close the cap of the windshield washer tank.

5. Close the battery cover.

6.3.2 Cabin seals

In a cabin truck, there are seals that you must replace when necessary. The seals are shown in
Figure 101, Figure 102, Figure 103 and Figure 104.

Figure 101: Rear window seals

NOTE: Before you replace the rear window seals, open the rear window, see 8.13.3 Rear
window.

Figure 102: Front window seals

Figure 103: Cabin door seals

NOTE: You must remove the cover from the cabin door before you remove the seals, see
Figure 103.

Figure 104: Roof cover seal

NOTE: Before you replace the roof cover seal, open the roof cover. See 6.2.12 Open the
roof cover (cabin trucks).

6.4 Drive unit

6.4.1 Fastening of the drive axle

For more information about the component, see 5.10 Drive axle.

1. Check the fastening of the drive axle. The correct torque for the fastening is 180 Nm.

2. Adjust the fastening of the drive axle if necessary. Repeat the check after every 1000 hours
of operation.

6.4.2 Leakage check of the drive axle

For more information about the component, see 5.10 Drive axle.

Check the drive axle visually for leakages. If you detect leakages, do the following:

1. Check the plugs of the drive axle. If the plugs are loose, tighten them.

2. If the drive axle still leaks, it needs to be removed. For more information, see 8.1.2 Remove
the drive axle.

6.4.3 Lubricate the drive axle

NOTICE
The approved range for the oil temperature in the drive axle is -20°C...+90°C
(-4°F...194°F). To ensure normal operation of the truck, follow the time limits set for
operation in freezing conditions.

NOTE: The drive axle is delivered already lubricated.

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are
not compatible with each other. Only use lubricants recommended by the manufacturer.

Figure 105: Lubrication points of the drive axle

1. Oil filling plug 2. Oil drain plug

The maintenance of the drive axle only includes measuring the oil volume, oil filling and oil
change.

Change the oil when the drive axle and the oil inside it are still warm. This makes the
draining of the oil easier.

The recommended oil type for the drive axle is SAE 80W/90 API GL5.

6.4.3.1 Oil volume measurement

CAUTION
Risk of injury

Oil is slippery. Be careful not to spill oil on the floor. If you spill oil on the floor, clean it
immediately.

MANDATORY ACTION
The oil used in the drive axle is hazardous waste. Recycle the used oil accordingly.

Table 38: Drive axle lubrication

COMPONENT VOLUME OIL TYPE

Drive axle 0.5 liter ± 10% / drive unit SAE 80W/90 API GL5

To measure the volume of oil and to add more oil to the drive axle:

1. Remove the oil filling plug and oil drain plug.

2. Drain the oil into the measuring container.

NOTE: Warm oil is easier to drain.

3. When all the oil has drained, put the drain plug back on and tighten it.

4. Measure the amount of oil in the container. See Table 38.

5. Add more oil if necessary.

6. Pour the oil back through the oil filling hole.

7. Put the oil filling plug back on and tighten it.

8. Run the drive unit.

6.4.4 Test the parking brake

Use TruckTool to check the functionality of the parking brake with Parking Brake test wizard.

6.4.5 Test the regenerative brake

To test the functionality of the regenerative brake, run Parking Brake Test wizard in TruckTool.

6.4.6 Electromechanical parking brake maintenance

WARNING

Electric hazard
Burn hazard

Remove all rings, watches and other metal jewelry before performing maintenance
on the electric system.

Turn the key switch/start of the truck to OFF position and disconnect the battery
connector before you open the cover of the motor or the electrical system.

After opening the covers, wait for 15 to 30 seconds for the voltage to discharge
before performing maintenance on the electric system.

NOTICE
Inadequate power supply can reduce the life span of the electromechanical brake. Make
sure that the truck supplies voltage to the brake according to the power requirements.

NOTICE
Do not disassemble the brake unit.

Measure the air gap

When the brake disc wears, the air gap in the brake increases. Measure the air gap regularly
using feeler gauges. Maximum air gap is 0.8 mm. If the air gap is 0.8 mm or more, replace the
brake.

Brake usage calculator

The truck has a usage calculator for the electromechanical parking brake. The system displays
a warning when the maximum number of brake operations is reached. In this case, replace the
brake regardless of the air gap. Clear the warning and reset the brake usage calculator in
TruckTool.

6.5 Hydraulics

6.5.1 Hydraulic system maintenance

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

For more information about the components, see 5.9.6 Hydraulic supply system.

During maintenance, clean the hydraulic oil suction filter in the oil tank.

6.5.2 Leakage check of the hydraulic system

For more information about the components, see 5.9.6 Hydraulic supply system.

Check visually that there are no leakages under the truck. If there are leakages:

Check the hydraulic connections and tighten them.

If the leakage comes from a hydraulic hose, the entire hose must be replaced.

If the leakage comes from somewhere else, check how the part in question must be
repaired. For more information, see 8 Repair.

6.5.3 Replace the hydraulic oil return filter

MANDATORY ACTION
The used hydraulic oil return filter (sieve) is dangerous waste and must be discarded
accordingly.

For more information about the components, see 5.9.6 Hydraulic supply system.

1. Open the cap of the hydraulic oil tank.

2. Turn the hydraulic oil return filter counterclockwise to open the lock of the filter.

3. Remove the hydraulic oil return filter.

4. Insert a new hydraulic oil return filter.

5. Turn the filter clockwise to lock the filter.

6. Close the cap of the hydraulic oil tank.

To install the hydraulic oil return filter, do the steps in a reverse order.

6.5.4 Replace the air breather filter

1. Turn the cap counterclockwise to open it.

2. Remove the air breather filter.

6.5.5 Cleaning of the hydraulic oil suction filter

For more information about the components, see 5.9.6 Hydraulic supply system.

6.5.5.1 Remove the hydraulic oil suction filter

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Drain the hydraulic oil tank. See 6.5.9 Hydraulic oil change.

2. Remove the step cover. See 6.2.9 Remove the step cover

3. Remove the screws and disconnect the hydraulic hoses.

4. Remove the hydraulic oil tank cover assembly.

5. Remove the hydraulic oil suction filter.

To install the hydraulic oil suction filter, do the steps in a reverse order.

6.5.6 Oil level

MANDATORY ACTION
Make sure that you check the oil level on a level surface with the forks lowered, parking
brake applied and the battery disconnected. Lowering the forks ensures that there is no
hydraulic oil in the circuit and the measurement is accurate. Clean the filler hole to
make sure that no dirt falls into the oil tank.

For more information about the components, see 5.9.6 Hydraulic supply system.

Check the oil level in the hydraulic oil tank by using a dipstick. The dipstick is attached to the
side of the hydraulic oil suction filter.

NOTE: Make sure that the oil level is between the minimum and maximum values which are
marked on the dipstick.

Figure 106: Location of the dipstick

6.5.7 Operation of the hydraulics

CAUTION
Risk of injury

If there is pressure in the hydraulic system, disconnecting a hose can result in a

hydraulic oil leak and cause parts of the truck to move unexpectedly. This can result in
personal injury.

When performing maintenance on the hydraulic system, make sure that the forks are
down and the tilt is set fully forwards or backwards.

Before starting any maintenance work, inspect the hydraulic system and make sure there are no
visible leaks. After this, make sure that the hydraulic system is working as intended.

For more information about the hydraulic components, see 5.9.6 Hydraulic supply system

6.5.8 Relief valves

For more information about the components, see 5.9 Hydraulic operation.

6.5.9 Hydraulic oil change

CAUTION
Risk of injury
If you overfill the oil tank, there is a risk of oil spill. Any oil on the floor presents a risk
of accident because oil is slippery. If you spill hydraulic oil, clean the spilled oil
immediately.

CAUTION
Toxic hazard

Oils used in the truck and the hydraulic system are toxic substances. Oil can cause
skin irritation if it gets in contact with skin.

Always wear protective gloves when you handle hydraulic oil.

Use proper tools to find oil leaks. Do not use your hands.

MANDATORY ACTION
Hydraulic oil is hazardous waste that must be disposed of accordingly.

For more information about the components, see 5.9.6 Hydraulic supply system. The filling hole
for hydraulic oil is shown in Figure 107.

Fill the hydraulic oil tank with oil between 17 and 19.5 liters. The oil tank is marked with
minimum and maximum levels.

Table 39: Hydraulic oil recommendations

Hydraulic oil additive FUCHS RENOLIN ANTI-STICK-SLIP

When replacing hydraulic oil, add 0.35 L hydraulic oil additive to 19 L hydraulic oil (corresponds
to the mixing ratio of 2% of the hydraulic oil volume) to prevent stick-slip and to reduce friction.

Figure 107: Filling hole for hydraulic oil

To drain the hydraulic oil tank:

1. Place a container for the waste oil under the truck.

2. Remove the plug.

3. Drain the hydraulic oil into the container.

4. After the tank is empty, insert the plug into the draining hole.

To fill the hydraulic oil tank:

1. Remove the pedal plate. See 6.2.2 Remove the pedal plate or 8.6.4 Remove the dual pedal
plate.

2. Remove top cap of the return filter and fill the oil tank through the return filter.

3. Check that the oil level is between the minimum and maximum values. Use a dipstick. For
more information, see 6.5.6 Oil level.

6.5.10 Hoses and cylinders

Visually inspect that there are no leakages in the hoses or cylinders of the truck. If there are
leakages in the hoses, the entire hose needs to be replaced. If there are leakages in the
cylinders, see the corresponding chapter for each cylinder:

Free lift cylinder, see 8.4.4 Repair free lift cylinder.

Side cylinders, see 8.4.5 Repair side cylinders.

Tilt cylinders, see 8.4.6 Repair tilt cylinders.

Integrated sideshift cylinder, see 8.5.6 Repair integrated sideshift carriage.

Fork positioner cylinders, see 8.5.7 Repair integrated fork positioner with sideshift.

6.5.11 Lubricate the pump axle splines

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

Lubricate the pump axle splines every 2 years. With regular lubrication, you can prevent
corrosion and make sure that the pump axle splines are always correctly lubricated.

NOTE: The correct lubricant is Molykote BR2 Plus (NLGI. No. 2 grade).

To lubricate the pump axle splines:

1. Remove the pedal plate, see 6.2.2 Remove the pedal plate.

2. Disconnect the hoses connected to the pump.

3. Remove the 2 screws that attach the pump to the pump motor.

4. Remove the pump.

5. Apply Molykote BR2 Plus (NLGI. No. 2 grade) lubricant to the pump axle splines.

6. Install the pump to the pump motor with 2 screws.

6.5.12 Clean the oil tank

MANDATORY ACTION
Hydraulic oil is hazardous waste that must be disposed of accordingly.

1. Drain the oil tank, see 6.5.5.1 Remove the hydraulic oil suction filter.

2. Clean the outside of the tank thoroughly.

3. Disconnect the hydraulic hoses.

4. Remove the screws from the top plate.

5. Remove the top plate.

6. Remove the top seal.

7. Clean the oil tank.

Add evaporating, solvent-based cleaner to the tank.

Shake the tank and let the clearner take effect.

Drain the waste oil and cleaner from the tank into a secure container. Waste oil is
hazardous waste and must be disposed of accordingly.

Let any excess cleaner left in the tank evaporate.

NOTE: If you do not have evaporating solvent-based cleaners available, you can
alternatively use diesel to dissolve caked-on waste oil from the tank.

8. Clean the top seal and add adhesive/sealing compound (Super Silicone RTV Black,
08933211) on both sides of the top seal.

9. Install the top seal.

10. Attach the top plate to the oil tank with the screws and tighten to max 4 Nm.

6.6 Mast

This section gives the regular maintenance procedures for masts. Regular maintenance makes
sure that the truck and its mast remain in good working condition and safe for the operators.

WARNING
Risk of falling

Mast maintenance work possibly requires work at height. Falling from height can result
in injury or death. Make sure that you use applicable access equipment and follow the
safety instructions of the equipment manufacturer.

MANDATORY ACTION
To do service on masts, you must be qualified to work on both mechanic and hydraulic
systems.

Make sure that you use applicable lifting devices and follow the safety instructions
given by the lifting device manufacturer. Make sure that the capacity of the used lifting
device is sufficient.

Daily maintenance
Examine the mast externally for any oil leaks.

Examine all the wheels for damages or outer wear.

Set the key switch to ON and lift and lower the forks to test the operation of the lifting
hydraulics.

Make sure that all the fastenings of the mast chains are done properly.

Examine the condition of the forks. For instructions, see 6.7.3 Fork inspection.

Monthly maintenance
Examine the tightness of all the screws, nuts and pipe / hose connections.

Examine the tension of the mast chains. All chain pairs must have equal tension to make
sure proper load distribution and mast operation. For instructions on how to examine the
mast chain tension and adjust the chains, see 6.6.3 Chain tension and 8.4.3.1 Adjust the
mast chains.

Apply grease on all unpainted areas in the mast channels.

Examine the condition of the welds visually. Pay special attention to the welds of the lifting
carriage.

Apply grease to the mast mounting axles.

Annual maintenance (1000h)

Clean and lubricate the mast chains. The main and free lift chains have been lubricated at
the factory. Avoid removal or contamination of the factory-applied lubrication. Do not wash,
sandblast, etch, steam clean, or paint the chains. If the chains require lubrication, see the
lubricant recommendations in 11.3.3 Mast chains.

Examine the chains for elongation. See 6.6.5 Chain wear measurement.

Examine all the cylinder fastenings.

Examine the cylinders for any damages, nicks, marring, or scratches.

Examine the fork base for cracks and wear.

Examine the welds of the fork carriage for cracks.

Examine the cross-member welds of outer and internal masts for cracks.

Examine the welds of the tilt cylinders and masts for cracks.

Examine the outer masts and cylinder support for cracks.

Examine the lift bracket welds for cracks.

Examine the rollers, roller pins and welds for cracks, and damage.

Examine the overhead guard for deformation, cracks, and damage.

Examine the mast mounting axles and bearings for wear.

6.6.1 Mounting of the mast

For more information about the component, see 5.15 Mast.

Check the wear of the mast mounting axles and bearings during annual maintenance.

Figure 108: Mast mounting axles and tilt cylinders

Table 40: Mast mounting axles lubricant

Lubricant NLGI. No. 1 or 2 grades

NOTE: Check the wear of the mast mounting axles when you replace the entire mast on the
truck.

For repair instructions, see 8.4.1 Remove the mast.

6.6.2 Wear level of the mast rollers and contact surfaces

Inspect visually the wear level of the mast rollers and the contact surfaces.

For more information about the components, see 5.15 Mast.

1. Check that the rollers are closely connected with the opposite side of the mast channel.

2. Check the mechanical condition of the rollers.

3. Visually inspect the mast channels. Clean the rails and add grease if necessary.

Vertical rail from both sides.

Horizontal rail.

4. Check the bottom of the mast channel for metal chips.

For repair instructions, see 8.5.1 Remove the lifting carriage, 8.4.1 Remove the mast, and 8.4.2
Disassemble the mast.

6.6.3 Chain tension

For more information about the components, see 5.15.4 Mast chains.

The tension of the mast chains must be examined every week. All chain pairs must have equal
tension to ensure proper load distribution and mast operation.

NOTE: Inspect the tension of the mast chains on level ground.

To determine if chain pairs have equal tension:

1. Make sure that the mast is in vertical position.

2. Lower the forks to the ground.

3. Make sure that the lift cylinders are fully retracted.

4. Lift the forks approximately 100 mm above the ground.

5. Set the key switch to the OFF position.

6. Put blocks that are approximately 90 mm high under the forks.

7. Push the center of the chains in the chain pair.

Both the chains must have equal give.

If the chains do not have an equal give, adjust the chains as instructed in 8.4.3.1 Adjust
the mast chains.

6.6.4 Chain lubrication

Lubricate the chains after each 300 hours of operation (or more frequently in severe or extreme
environments). For lubricants, see11.3.3 Mast chains.

6.6.5 Chain wear measurement

WARNING
Risk of accident

Examine and lubricate the mast chains after each 300 hours of operation (or more frequently in
severe or extreme environments).

During the inspection, examine the chains for the following:

Elongation

Edge wear

Turning or protruding pins

Cracked side plates

Fatigue cracks

Stress-corrosion cracks

Corrosion fatigue

Tight joints

Elongation
Measure elongation always when you do maintenance on the truck.

To measure the elongation of the chains, you must have a slide caliper and a chain gauge.

Measure the mast chain from the section that moves over the chain wheel as that part of the
chain flexes the most. If the chain is long, measure it at 2 different points.

Figure 109: Measure the elongation in the chain with a chain gauge

To measure the elongation:

1. Lift a load of approximately 300 kg up.

2. Use a slide caliper to measure the distance between 2 chain pins in millimeters.

3. Find the correct measurement value in the chain gauge.

4. Record the value below the measurement value. You must have the recorded value when
you count the number of pins in step 6.

5. Set the slot of the chain gauge on one of the chain pins.

6. Count the same number of chain pins as you recorded in step 4. Begin counting at the first
chain pin after the chain gauge. This gives you the length of the chain section under
inspection.

7. Check if the last chain pin you counted is approximately at the vertical line of the chain
gauge. If the chain is approximately at that line, the length of the chain is right.

8. Make sure that the elongation is not more than 2%. If the elongation is more than 2%, you
must replace the chain. See 8.4.3.2 Replace the mast chains.

You can also measure the elongation without a chain gauge.

When a chain with the original length of 330.2 mm has elongated to the length of 336.8 mm,
replace the chain (the elongation is approximately 2%). See 8.4.3.2 Replace the mast chains.

Figure 110: Measure the elongation in the chain without a chain gauge

Edge wear
Examine the chains for link plate edge wear by running your finger back and forth over the chain
edge. See Figure 111.

The wear of a link plate edge must not exceed 5%.

Figure 111: Edge wear in the chain

For repair instructions, see 8.4.3.2 Replace the mast chains.

Turning or protruding pins

A highly loaded chain operated with inadequate lubrication can generate abnormal friction
between the pins and the link plates. In extreme cases, the torque can surpass the press fit
force between the pins and the outside plates, resulting in pin rotation. When a chain is
operated in such a condition, a pin or a series of pins can begin to twist out of the chain,
resulting in a failure. See Figure 112.

Figure 112: Turning or protruding chain pins

Examine the chain pin heads to make sure that all the flats are still correctly aligned. Replace
chains with rotated or displaced heads or abnormal protrusion immediately. Do not attempt to
repair the chain by welding or driving the pin(s) back into the chain. Any wear patterns on the
pin heads or the sides of the link plates indicate misalignment. Such wearing damages the
chain and increases frictional loading and must always be corrected.

For repair instructions, see 8.4.3.2 Replace the mast chains.

Cracked side plates

Examine all the chains periodically for cracked plates, see Figure 113.

Figure 113: Cracked side plates

Examine the chains very carefully from all sides. If there is a cracked plate in a chain, the whole
chain must be replaced. However, before you replace the chain, determine the cause of the
crack to prevent the condition from repeating itself.

For repair instructions, See 8.4.3.2 Replace the mast chains.

Fatigue cracks
Fatigue cracks are a result of repeated cyclic loading exceeding the endurance limit of the
chain.

Fatigue cracks nearly always start at the link plate pin hole (the point of the highest stress) and
are perpendicular to the chain pitch line. In their early stages, fatigue cracks are microscopic.
Unlike with stretching, there is no noticeable yielding or stretching of the material.

For repair instructions, see 8.4.3.2 Replace the mast chains.

Stress-corrosion cracks
Stress corrosion is an environmentally assisted failure, caused by 2 conditions: corrosive agents
and static stress. In the chain, the press fit pin causes static stress on the pin hole. No cycle
motion is required, and the plates can crack even during idle periods. In addition, the reaction of
several chemical agents (such as battery acid fluids) with hardened steel can release hydrogen,
which attacks and weakens the grain structure of the steel.

The outside link plates of the chain, which are heavily press fitted to the pins, are particularly
susceptible to stress-corrosion cracks. Like other cracks, stress-corrosion cracks also initiate at
the highest stress point (pin hole), but tend to extend in an arch-like pattern between the holes
of the plate. A link plate often has more than one crack.

Figure 114: Link plate with stress-corrosion cracks

Do not attempt to electroplate a leaf chain or its components. The plating process releases
hydrogen, causing hydrogen embrittlement cracks, which look similar to stress-corrosion cracks.

If a plated chain is required, contact the manufacturer. Plated chains are assembled from
modified, individually plated components, which can reduce the rating of the chain.

For repair instructions, see 8.4.3.2 Replace the mast chains.

Corrosion fatigue
Corrosion fatigue is caused by the combined action of an aggressive environment and cyclic
stress (unlike in stress-corrosion cracks where static stress alone can be a cause).

Appearance-wise, corrosion fatigue cracks are very similar (and in many cases identical) to
normal fatigue cracks. They normally start at the pin hole and move perpendicularly to the chain
pitch line.

For repair instructions, see 8.4.3.2 Replace the mast chains.

Ultimate strength failure

This type of failure is caused by overloads that far exceed the maximum load of the mast.

Figure 115: Ultimate strength failure

For repair instructions, see 8.4.3.2 Replace the mast chains.

Tight joints
All the joints in a leaf chain must flex freely. Tight joints resist flexing and increase internal
friction, thus increasing the chain tension required to fit a given load. Increased tension
accelerates wearing and causes more fatigue problems.

Figure 116: Tight joints

6.6.6 Check the chain anchors and locking pins

Check the chain anchors and the locking pins for damage. If the chain anchors and the locking
pins are damaged, replace the whole chain. For instructions, see 8.4.3.2 Replace the mast
chains.

6.6.7 Check the cylinders and piston rods

For more information about the components, see 5.15 Mast.

1. Check all cylinder fastenings.

2. If you notice an oil leak, first make sure that the free lift cylinder piston is not damaged.

3. Check cylinders for any damages, nicks, marring, or scratches.

Examine the outside surface of the piston for any scratches on the whole length passing
the housing with the cylinder fully out.

If there are any scratches on the piston surface, do not replace the seals. The scratches
damage the new sealing and the leak continues. If there are scratches on the piston
surface, replace the whole piston.

Refer to the following sections for repair instructions:

Free lift cylinder, see 8.4.4.1 Replace the free lift cylinder and 8.4.4.2 Sealing housing of the
free lift cylinder.

Side cylinders, see 8.4.5.1 Replace the side cylinders and 8.4.5.2 Sealing housing of the
side cylinder.

Integrated sideshift carriage, see 8.5.6.4 Remove the piston of the integrated sideshift
cylinder and8.5.6.5 Sealing housing of the integrated sideshift cylinder.

Integrated fork positioner with sideshift carriage, see 8.5.7.6 Replace the seals of the fork
shifting cylinder.

6.6.8 Lifting and lowering speed

Check the lifting and lowering speeds of the truck with Trucktool.

Figure 117: Lowering valve in the hydraulic valve unit with fingertip controls

Figure 118: Maximum lowering speed adjustment in the valve unit with
manual levers

Table 41: Correct lifting and lowering speeds of the truck with simplex mast

CAPACITY 1.4 T 1.6T 1.8 T 2.0 T

Lifting speed with load / without load

0.55/0.62 0.52/0.62 0.46/0.62 0.42/0.62
[m/s]

Lowering speed with load / without

0.56/0.56 0.56/0.56 0.56/0.56 0.56/0.56
load [m/s]

If the lowering speeds are incorrect:

1. Loosen the nut on the of the lowering valve.

2. Turn the adjustment spindle:

Clockwise to increase the oil flow for higher lowering speed.

Counterclockwise to decrease the oil flow for slower lowering speed.

3. Using Trucktool, set Lowering, valve and maximum current (I MAX EVP2) to 100%.

4. Lift a nominal weight load above the free lift area.

5. Lower the forks so that the lowering lever is at max position.

6. Adjust the spindle of the lowering valve to maximum speed of 0.6 m/s.

7. Using Trucktool, set Lowering, Valve and maximum current (I MAX EVP2) so that the
lowering speed is correct when the lowering lever is at maximum position. For the correct
values, see Table 41.

Tighten the nut of the lowering valve after the adjustment. The correct torque is 2,5 Nm. Hold
the adjustment spindle in place when tightening the nut or the adjustment will be lost.

6.6.9 Lubrication of the mast channel surfaces

Apply grease on all unpainted areas in the mast channels. For lubricants, see 11.3.4 Mast
channels.

6.6.10 Lifting test

Test the lifting with rated load, and with customer-specific load if necessary.

If the truck is unable to lift a full load, check the amount of the hydraulic oil and the condition of
the hydraulic system.

If the lift function doesn't work check the electric system, hydraulic system and mechanical parts
for faults or damage.

6.6.11 Examine the welding in the mast for cracks

DANGER
Risk of accident

If the mast is damaged in any way, there is a risk of the mast frame collapsing. If a mast
collapses or a load falls, it can result in serious injury or death. Take a truck with a
damaged mast out of operation until the mast is fixed. Do not operate a truck with a
damaged mast.

Check the mast frame, the outer mast sections and the cylinder supports visually for any cracks
in the welding. If you notice cracks in the welding, replace the damaged mast section. Repair
welding a cracked mast section does not restore the full load capacity.

For repair instructions, see 8.4.1 Remove the mast, 8.4.2.1 Disassemble the simplex mast and
8.4.2.3 Disassemble the triplex mast.

6.6.12 Mounting of any attachments and load-carrying components

DANGER
Risk of accident

If the attachments or load-carrying components are damaged in any way, there is a risk
of them failing. If any load-carrying components or attachments fail or if a load falls, it
can result in serious injury or death. Take a truck with a damaged attachments or load-
carrying components out of operation until they are fixed. Do not operate a truck with
damaged attachments or load-carrying components.

Check the attachments and load-carrying components for cracks and leakage.

If you detect a leakage, find the source or cause of the leakage and repair it. If necessary,
replace the leaking component.

If you detect cracks, replace the cracked attachments or load-carrying component. Repair
welding a cracked attachments or load-carrying components does not restore the full load
capacity of these parts.

For more information, see 8.5.8 Repair hook-on sideshift carriage.

6.6.13 Examine the welding of the cylinders and masts for cracking

Examine the welding of the cylinders. If you detect any cracks in the welding, repair the
cylinders.

For repair instructions, see 8.4.5.1 Replace the side cylinders.

6.6.14 Examine the rollers, pins and welds for cracking and damage
For more information about the components, see 5.15 Mast.

Visually inspect the mechanical condition of the rollers and welds of the roller pins both in the
mast and in the lifting carriage.

For repair instructions, see 8.4.1 Remove the mast, 8.4.2.1 Disassemble the simplex mast,
8.4.2.2 Disassemble the duplex mast, 8.4.2.3 Disassemble the triplex mast, 8.5.1 Remove the
lifting carriage and 8.4.7 Replace the main rollers of the mast.

6.6.15 Apply grease to the lubrication points of the tilt cylinder

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are
not compatible with each other. Only use lubricants recommended by the manufacturer.

NOTE: Apply lubricants to prevent corrosion if the rod is to be left extended for longer
periods of time.

Figure 119: Lubrication points of the tilt cylinder

Lubricant NLGI. No. 1 or 2 grades

6.6.16 Additional mast attachments

Maintain the additional mast attachments according to the instructions of the manufacturers.

6.7 Lifting carriage

6.7.1 Examine the welding in lifting carriage for cracks

DANGER
Risk of accident

If the lifting carriage is damaged in any way, there is a risk of the lifting carriage
collapsing. If a lifting carriage collapses or a load falls, it can result in serious injury or
death. Take a truck with a damaged lifing carriage out of operation until the carriage is
fixed. Do not operate a truck with a damaged lifting carriage.

Check the lifting carriage visually for any cracks in the welding. If you notice cracks in the
welding, replace the lifting carriage. Repair welding a cracked lifting carriage does not restore
the full load capacity.

For repair instructions, see 8.5.1 Remove the lifting carriage.

6.7.2 Examine the load backrest for cracks

DANGER
Risk of accident

If the load backrest is damaged in any way, there is a risk of loss of the protection
function. If load falls or shifts unexpectedly and the load backrest is damaged, it can
result in serious injury or death. Take a truck with a damaged load backrest out of
operation until the backrest is fixed. Do not operate a truck with a damaged load
backrest.

Visually inspect the load backrest for cracks. If you see cracks in the welds, replace the load
backrest. Repair welding a cracked load backrest does not restore the full load capacity.

For repair instructions, see 8.5.5 Replace the load backrest.

6.7.3 Fork inspection

MANDATORY ACTION
Do any inspection, repair or exchange work for both forks at the same time. Often, both
forks are damaged. The fork inspection must be carried out carefully by trained
personnel only.

Examine the forks carefully after each 300 hours of operation (or more frequently in severe or
extreme environments).Examine the legibility of the markings on the fork arms. If the markings
in accordance with ISO 2330 are not clearly legible, remove the fork arm from service until
appropriate repairs are done.

Examine the forks for wear.

If the forks have worn out more than 10% of the original fork thickness, the fork has to be
taken out of service. 10% wear of the fork thickness already means a 20% reduction of fork
capacity. The basis for wear measuring is the original nominal thickness of the fork. For
example, if the original nominal thickness of the forks is 40 mm, the wear limit for the forks is
36 mm.

Worn forks must not be welded.

Figure 120: Examine the forks for wear

Examine the forks for cracks.

Pay special attention to the inner heel section and all welded areas.

If there are any cracks in the forks, remove the forks from service.

Figure 121: Examine the forks for cracks

Examine the height difference of the forks. The height difference of the fork tips must not
exceed 1.5% of the length of fork blade (L). Adjust or replace the fork if necessary.

The below formulas can be used to determine if the height difference is acceptable or if the
forks must be adjusted or replaced.

Acceptable: h max = L in mm / 66

Adjust the fork: h max = L in mm / 66 to L in mm / 33

Replace the fork: h > L in mm / 33

Figure 122: Examine the height difference of the forks

Examine the forks for permanent deflection. The below formulas can be used to determine if the
deflection is acceptable or if the forks must be adjusted or replaced.

Acceptable: k max = L in mm / 66

Adjust the fork: k max = L in mm / 66 to L in mm / 33

Replace the fork: k > L in mm / 33

Figure 123: Examine the forks for permanent deflection

CAUTION
Risk of accident

Do not try to bend the fork back in shape. The fork material can get weaker, which can
result in equipment damage and reduced operational safety.

NOTE: Sometimes forks with non-standard angular dimensions are used for special cases.
Examine the correct angularity before inspection.

The below measurements can be used to determine if the angularity of the forks is acceptable
or if the forks must be adjusted or replaced.

Ideal state 90°: d = 707 mm

Acceptable tolerance: d = 695-713 mm

Adjust the fork: d = 714-730 mm

Replace the fork: d = > 730 mm

Figure 124: Examine the angularity of the forks

Examine the condition of the fork locking devices. The locking devices prevent loads from
unintentionally slipping off the lifting carriage. Do not use forks with damaged locking devices.

Figure 125: Examine the fork locking devices

Examine the fork tips for signs of damage or wear.

If the fork tip is worn or damaged, the fork must be shortened or replaced.

Figure 126: Examine the condition of the fork tips

Examine the fork hook for lateral bending. Lateral forces and long-term use can cause lateral
bending of the fork hook. In case of bending, the fork hooks or the forks must be replaced.

Figure 127: Examine the fork hook for lateral bending

6.7.4 Maintenance of the integrated sideshift carriage

WARNING
Risk of injury

Figure 128: Maintenance of the integrated sideshift carriage

1. UNI 7763-AM6-5.8 ball head greasers 4. Frame

2. Lower hook screws 5. Upper sliding block
3. Cylinder rods 6. Lower sliding block

NOTE: If the equipment is used in dusty, humid or corrosive environment, we recommend

halving the working hours between maintenance.

Lubrication

Table 42: Recommended lubricants

Interior ISO X M2 (SHELL ALVANIA GREASE R2)

Exterior ISO CB 32 (ESSO NUTO32)

Maintenance work for every 1000 hours

Lubricate ball head greasers.

Examine the tightness of the lower hook screws. Use ISO 2936 10 mm Allen key.

Tightening torque for FEM2 positioner is 461 Nm.

Tightening torque for FEM3 positioner is 420 Nm.

Examine the cylinder rods and that gaskets are sealed.

Clean and lubricate the frame.

Examine the condition of the upper and lower sliding blocks.

Examine the hydraulic connections.

6.7.4.1 Check the sliding blocks

1. Replace the sliding blocks if the thickness is less than 2 mm.

6.7.4.2 Adjust the lower hooks

Integrated sideshift carriage has adjustable lower hooks. If they are loose or not correctly set,
reset them. See Figure 129.

Figure 129: Sideshift carriage with adjustable lower hooks

1. Lower hook 3. Lower section

2. Spacer sliding block 4. Adjustment shim

To adjust the lower hooks:

1. Adjust the lower hooks with shim plates. If the hook screws are loose:

Insert a 0.25 mm shim between the sliding block and the lower section.

Push the hook down to eliminate excess play.

2. Tighten the bolts with the following tightening torques:

Tightening torque for FEM2 positioner is 461 Nm.

Tightening torque for FEM3 positioner is 420 Nm.

6.7.5 Maintenance of the integrated fork positioner with sideshift

WARNING
Risk of injury

The equipment is delivered with guides and sliding blocks that are lubricated with good quality
grease. Grease the sliding area of the lower supports before you assemble the forks. Also,
grease the bearings sliding area on the chrome bar.

Figure 130: Grease points of the integrated fork positioner with sideshift

Lubrication

Table 43: Recommended lubricants

Normal ISO X M2 (SHELL ALVANIA GREASE R2) or similar

Dusty environment ISO CB 32 (ESSO NUTO32) or similar

Maintenance work for every 1000 hours

Examine the tightness of the grub screws. Use a 6 mm Allen key. If they are loose, clean the
grubs and the holes with a solvent and let them dry. Tighten the grub screws and use Loctite
270 threadlocker.

Examine the tightness of the hydraulic fittings.

Clean and grease the sliding block guides.

Do an overall inspection of the equipment.

Do a specific inspection on the pipes and their condition.

Examine the condition of the upper and lower sliding blocks, of both the side shifter and the
fork supports.

Examine the tightness of the screws of the lower hooks. The torque for the FEM2 positioner
is 145 Nm and for FEM3 positioner 235 Nm.

Examine the hydraulic connections. Tighten the fittings to the cylinders if necessary.

Examine the tightness of the cylinder seals. If there are leaks, disassemble the cylinders.
See 8.5.7.3 Disassemble the fork shifting cylinders.

Maintenance work for every 2000 hours

Disassemble the mobile frame. See 8.5.7.4 Disassemble the mobile frame of the positioner.

Clean the parts and examine the condition of the upper sliding blocks of the side shifter. The
minimum thickness is 2 mm. If it is less, replace the parts.

Clean the parts and examine the condition of the lower sliding blocks of the side shifter. The
minimum thickness is 3 mm. If it is less, replace the parts.

Disassemble the frame supports. See 8.5.7.5 Disassemble the fork supports.

Clean the parts and examine the condition of the lower sliding blocks. If the metal rubs
against the lower bar, replace the sliding blocks.

Examine the cylinder stems and the guide bushings.

If there are scratches or dents in the stem or there is excessive play to the stem (> 0.25
mm), replace the parts.

If the bushings are worn, replace them.

6.7.5.1 Check the sliding blocks

1. Replace the sliding blocks if the thickness is less than 2 mm.

6.7.5.2 Adjust the lower hooks

Integrated fork positioners have adjustable lower hooks. If they are loose or not correctly set,
reset them. See Figure 131. The main reference measurement is 0.25 mm. If it is not possible
to maintain this measurement, make sure that the measurement of the inclined surface is 0.5
mm.

Tighten the bolts with the following tightening torques:

The torque for FEM2 positioner is 461 Nm.

The torque for FEM3 positioner is 420 Nm.

Figure 131: Positioners with adjustable lower hooks

1. Lower hook 3. Lower section

2. Spacer sliding block 4. Adjustment shim

6.8 Rear axle

6.8.1 Lubricate the rear axle (3-wheel models)

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are
not compatible with each other. Only use lubricants recommended by the manufacturer.

The lubrication points of the rear axle are shown in Figure 132.

Figure 132: Rear axle lubrication points

1. Oil filler plug 2. Oil drain plug

The maintenance of the drive axle only includes the checking of the oil level, oil filling, and oil
change.

Change the oil when the drive axle and the oil inside it are still warm. This makes the
draining of the oil easier.

The recommended oil type for the rear axle is SAE 80W/90 API GL5.

Table 44: Rear axle lubrication

COMPONENT VOLUME OIL TYPE

Rear axle (3-wheel models) 1.3 liters ± 10% SAE 80W/90 API GL5

6.8.1.1 Oil volume measurement and oil change

CAUTION
Risk of injury

Oil is slippery. Be careful not to spill oil on the floor. If you spill oil on the floor, clean it
immediately.

MANDATORY ACTION
The oil used in the drive axle is hazardous waste. Recycle the used oil accordingly.

Table 45: Rear axle lubrication

COMPONENT VOLUME OIL TYPE

Rear axle (3-wheel models) 1.3 liters ± 10% SAE 80W/90 API GL5

To measure the volume of oil and to add more oil to the drive axle:

1. Remove the oil filling plug and oil drain plug.

2. Drain the oil into the measuring container.

NOTE: Warm oil is easier to drain.

3. When all the oil has drained, put the drain plug back on and tighten it.

4. Measure the amount of oil in the container. See Table 45.

5. Add more oil if necessary.

6. Pour the oil back through the oil filling hole.

7. Put the oil filling plug back on and tighten it.

8. Run the drive unit.

6.8.2 Lubricate the rear axle (4-wheel models)

The lubrication points of the rear axle are shown in Figure 133.

Figure 133: Rear axle lubrication points

Table 46: Rear axle lubrication

Grease In accordance with Heliolene Grease GRA 2 Black

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are
not compatible with each other. Only use lubricants recommended by the manufacturer.

6.8.3 Examine the operating condition of the bearings, check for

looseness of the bearings
1. Remove the dust covers of the bearings.

2. Check the condition of the bearings visually.

3. If you notice any looseness, replace the bearings.

6.8.4 Examine the welds for cracks

Check the welds of the rear axle visually. If you notice any cracks in the welds, replace the rear
axle. For more information, see .

6.8.5 Examine the mounting of the rear axle

Check the mounting of the rear axle visually. If there are any cracks in the mounting, replace the
rear axle. For more information, see . Check also the torque for the mounting screws (8 x M16).
The correct torque is 280 Nm. Adjust if needed.

6.8.6 Examine the condition of the rubber spring

Check the conditon of the rubber spring visually. If there are any cracks, replace the rubber
spring.

6.9 Wheels

6.9.1 Damage and wear in the wheels

Check the wheels for damage and wear. For more information, see 5.16 Wheels

6.9.2 Before you replace the wheels

WARNING
Risk of injury

The truck is heavy. If the truck tips over or falls on a person, it will result in a serious
injury or death.

Do not replace the wheels when the truck is loaded.

Make sure that no one is on the truck when you lift the front or rear wheels.

Do not lift the truck more than is necessary. Stop lifting the truck when the wheels
are lifted from the ground.

When lifting the truck, make sure that the capacity of the lifting equipment is
sufficient.

Do not put your hands or other body parts under the truck until you have supported
the truck with safety blocks or rigid stands.

CAUTION
Risk of accident

The size, quality and possible wear of the wheels can affect the stability and
performance of the truck.

Do not mix different sizes or types of wheels because it can affect the stability of the
truck.

MANDATORY ACTION

Before you replace a wheel:

1. Make sure that the truck is parked in a safe area on a level surface.

2. Lower the forks until the tips of the forks touch the ground.

3. Set the driving direction selection switch to the neutral position.

4. Set the key switch to the OFF position.

5. Make sure that you have the necessary tools at hand (jack and wheel blocks).

6. Put wheel blocks below the wheels that are not lifted off the ground during the replacement
procedure.

6.9.3 Front wheels

Before you install the front wheel, make sure that the following parts are clean, free from grease
and not damaged:

Wheel shaft

Face of the rim mounting

Wheel nuts and bolts.

6.9.3.1 Remove the front wheel

NOTE: Before you lift the front part of the truck up, you must put wheel blocks below the
rear wheels.

1. Loosen the 5 nuts that attach the front wheel to the truck. Turn the nuts approximately 2
turns but do not remove the nuts.

2. Lift the front part of the truck up with a jack. Make sure that the front wheels are lifted off the
ground.

3. Put supports below the truck frame.

4. Remove the 5 nuts that attach the front wheel to the truck.

5. Remove the front wheel.

If the wheel shaft bolts are defective, replace them. For instructions, see 6.9.3.3 Replace the
wheel shaft bolts of the front wheel.

6.9.3.2 Install the front wheel

NOTE: The correct nut type for the front wheels is M16×1.5..

1. Align the hole pattern of the rim with the wheel shaft bolts and move the front wheel into the
correct position.

2. Install the 5 nuts and tighten them finger tight.

NOTE: Make sure that the nuts and the wheel shaft bolts are clean.

3. Remove the supports below the truck frame.

4. Lower the truck with a jack until the wheel touches the ground.

5. Tighten the nuts to the final torque. The correct tightening torque is 230 Nm.

6. Lower the truck to the ground.

NOTE: After you have replaced the wheel, operate the truck for a while, and then measure
the torque of the nuts again. Make sure that the nuts do not loosen.

6.9.3.3 Replace the wheel shaft bolts of the front wheel

See the manufacturer’s instructions on how to replace the front wheel wheel shaft bolts.

6.9.4 Rear wheels

Figure 134: Rear wheels

6.9.4.1 Remove the rear wheels (3-wheel models)

NOTE: Before you lift the rear part of the truck up, you must put wheel blocks under the
front wheels.

1. Turn the wheels sideways.

2. Loosen the 6 nuts that attach the rear wheel to the truck. Turn the nuts approximately 2
turns, but do not remove the nuts.

3. Lift the rear part of the truck up with a jack. Make sure that the rear wheels are lifted off the
ground.

4. Put supports below the truck frame.

5. Remove the 6 nuts that attach the rear wheel to the truck.

6. Remove the rear wheel.

6.9.4.2 Install the rear wheel (3-wheel models)

NOTE: The correct nut type for the rear wheels is M16 × 1.5.

1. Put supports below the truck frame.

2. Align the hole pattern of the rim with the wheel shaft bolts and move the front wheel into the
correct position.

3. Install the 6 nuts and tighten them finger tight.

NOTE: Make sure that the nuts and the wheel shaft bolts are clean.

4. Remove the supports below the truck frame.

5. Lower the truck with a jack until the wheel touches the ground.

6. Tighten the nuts to the final torque. The correct tightening torque is 230 Nm.

7. Lower the truck to the ground.

NOTE: After you have replaced the wheel, operate the truck for a while and measure the
torque of the nuts again. Make sure that the nuts do not loosen.

6.9.4.3 Replace the wheel shaft bolts of the rear wheel (3-wheel)

Figure 135: Wheel shaft bolts overview, 3-wheel models

1. Remove the rear wheel, see 6.9.4.1 Remove the rear wheels (3-wheel models).

2. The wheel bolts are press fit into the flanged hub. Press from outwards inwards.

6.9.4.4 Remove the rear wheels (4-wheel models)

NOTE: Before you lift the rear part of the truck up, you must put wheel blocks under the
front wheels.

1. Loosen the 5 nuts that attach the rear wheel to the truck. Turn the nuts approximately 2
turns, but do not remove the nuts.

2. Lift the rear part of the truck up with a jack. Make sure that the rear wheels are lifted off the
ground.

3. Put supports below the truck frame.

4. Remove the 5 nuts that attach the rear wheel to the truck.

5. Remove the rear wheel.

6.9.4.5 Install the rear wheel (4-wheel models)

NOTE: The correct nut type for the rear wheels is M14×1.5.

1. Put supports below the truck frame.

2. Align the hole pattern of the rim with the wheel shaft bolts and move the front wheel into the
correct position.

3. Install the 5 nuts and tighten them finger tight.

NOTE: Make sure that the nuts and the wheel shaft bolts are clean.

4. Remove the supports below the truck frame.

5. Lower the truck with a jack until the wheel touches the ground.

6. Tighten the nuts to the final torque. The correct tightening torque is 160 Nm.

7. Lower the truck to the ground.

NOTE: After you have replaced the wheel, operate the truck for a while and measure the
torque of the nuts again. Make sure that the nuts do not loosen.

6.9.4.6 Replace the wheel shaft bolts of the rear wheel (4-wheel)

Figure 136: Wheel shaft bolts overview, 4-wheel models

If the wheel shaft bolts are defective, you must replace them.

1. Remove the rear wheel, see 6.9.4.4 Remove the rear wheels (4-wheel models).

2. Remove the rear wheel hub.

3. Attach a nut on the wheel shaft bolt to avoid breaking the bolt during removal.

4. Hit the wheel shaft bolt to disconnect it from the wheel hub.

5. Remove the nut.

6. Remove the wheel shaft bolt.

7. Install a wheel shaft bolt to the wheel hub. Do not damage the screw threads!

8. On the screw head side, hit the screw all the way to the bottom.

6.10 Electrics

6.10.1 Test the functionality of sensors

Before you do the functionality check to any sensor manually, examine the sensor functionality
using TruckTool. Activate and deactivate the sensor and check the values in the software. If
there is no response, do the functionality check as instructed in this section.

For instructions on how to replace a broken sensor, see 8.12 Repair sensors and switches.

6.10.1.1 Traction motor sensors

The left and right traction motors each have separate temperature and rotation sensors.

Figure 137: Temperature sensor of the traction motor

Figure 138: Rotation sensor of the traction motor

Temperature sensors
The left and right traction motors have separate temperature sensors.

Table 47: Temperature sensor specifications

Type PTC resistor

Switching output Variable resistance based on temperature

Equipment identification R35 (left), R36 (right)

Electrical wiring 2 wires: red and white. No polarity.

The condition of the temperature sensor can be verified with a multimeter. The value should be
~1080 Ω in +20°C.

Figure 139: Resistance variation according to temperature

Rotation sensors
The left and right traction motors have separate rotation sensors.

Table 48: Rotation sensor specifications

Type Speed sensor

Vs 4.5…24 V

Output signal 64 ppr

Switching output 0.1...20 kHz

Equipment identification B31 (left and right)

1 = Supply
3 = Channel A
Electrical wiring
2 = Channel B
4=0V

Sensing range 0.3...1.7 mm

1. Measure the output against the 0 V.

2. Move the edge of a metal object.

3. Measure the channels individually with a multimeter.

When you use 2 multimeters, you should be able to measure clear 1 and 0 from the output, with
a 90º phase difference. The measured voltage should fluctuate between +12 volt and 0.

6.10.1.2 Steering motor sensors

Figure 140: Temperature sensor of the steering motor

Figure 141: Rotation sensors of the steering motor

Temperature sensor

Table 49: Temperature sensor specifications

Type PTC resistor

Switching output Variable resistance based on temperature

Equipment identification R39

Electrical wiring 2 wires: red and white. No polarity

The condition of the temperature sensor can be verified with a multimeter. The value should be
~1080 Ω in +20°C.

Rotation sensors
The number of rotation sensors on the steering motor depends on the truck model. The sensors
are the same type in all truck models.

3-wheel models have one rotation sensor

4-wheel models have two rotation sensors

Table 50: Rotation sensor specifications

Type Rotational speed sensor

Vs 5…24 V

Output signal 32 ppr

Switching output 0...20 kHz

Equipment indentification B39.1 (first), B39.2 (second)

1 = Supply
3 = Channel A
Electrical wiring
2 = Channel B
4=0V

Sensing range 0.2...1.5 mm

1. Measure the output against the 0 V.

2. Move the edge of a metal object.

3. Measure the channels individually with a multimeter.

When you use 2 multimeters, you should be able to measure clear 1 and 0 from the output, with
a 90º phase difference. The measured voltage should fluctuate between +12 volt and 0.

6.10.1.3 Pump motor sensors

Figure 142: Temperature sensor of the pump motor

Figure 143: Rotation sensor of the pump motor

Temperature sensors

Table 51: Temperature sensor specifications.

Type PTC resistor

Switching output Variable resistance based on temperature

Equipment identification R37

Electrical wiring 2 wires: red and white. No polarity.

The condition of the temperature sensor can be verified with a multimeter. The value should be
~1080 Ω in +20°C.

Rotation sensor

Table 52: Rotation sensor specifications.

Type Speed sensor

Vs 4.5…24 V

Output signal 64 ppr

Switching output 0.1...20 kHz

Equipment identification B32

1 = Supply
3 = Channel A
Electrical wiring
2 = Channel B
4=0V

Sensing range 0.3...1.7 mm

1. Measure the output against the 0 V.

2. Move the edge of a metal object.

3. Measure the channels individually with a multimeter.

When you use 2 multimeters, you should be able to measure clear 1 and 0 from the output, with
a 90º phase difference. The measured voltage should fluctuate between +12 volt and 0.

6.10.1.4 Battery door sensor

Figure 144: Battery door sensor

Table 53: Battery door sensor specifications

Type Inductive switch

Vs 10 - 60 Vdc

Switching output PNP, NO

Equipment identification S51

1 = Supply
Electrical wiring 4 = Output signal
3 = 0V

Sensing range 8 mm

Connection type Plug-in connector

1. Connect a supply voltage between pins:

+12 Vdc to pin 1.

0 V to pin 3.

2. Measure the output signal between pins 4 and 3.

When a supply is connected and there are no metallic objects within the sensing range,
the value is approximately 0 Vdc.

When a metallic object is moved within the sensing range, the value is approximately +12
Vdc.

6.10.1.5 Pressure sensor

The optional pressure sensor is used for monitoring the hydraulic pressure of the hydraulic
system. The pressure sensor has an output signal of 1–5 Vdc in the range of 0-250 bar oil
pressure.

Figure 145: Pressure sensor

1. Pressure sensor with the armrest controls 2. Pressure sensor with the manual levers

Table 54: Pressure sensor specifications

Type Pressure transmitter

Vs 8 - 36 Vdc

Output signal 1 - 5 Vdc

Equipment identification B42

1=0V
Electrical wiring 2 = Output signal
3 = Supply

1. Lower the forks to their lowest position to minimize the oil pressure in the hydraulic system.

2. Measure the output signal level with a multimeter between terminals 2 and 1.

The nominal output signal level is ~1 Vdc when the hydraulic pressure is 0 bar.

The output signal level rises relatively to the hydraulic oil pressure, and with the maximum
load the value is close to 4 Vdc. The maximum capacity of the truck is stated on the type
plate.

6.10.1.6 Rear axle sensor

The functionality check of the rear axle sensor depends on the truck model.

If the truck is a 3-wheel model, see 6.10.1.6.1 Rear axle sensor (3-wheel models).

If the truck is a 4-wheel model, see 6.10.1.6.2 Rear axle sensor (4-wheel models).

6.10.1.6.1 Rear axle sensor (3-wheel models)

Figure 146: Rear axle sensor (3-wheel models)

The 3-wheel truck models can be configured with a 180° or 360° steering range.

180° is the default steering range. The rear axle can turn the steered wheels 90° left and
right from the center position. This makes the total steering range 180°.

With the 360° steering range, the rear axle can freely rotate a full circle in both directions
around its axis.

Table 55: Rear axle sensor (3-wheel models)

Type Redundant, HALL-effect angle sensor

Vs 8 - 36 Vdc

Output signal 10% ... 90% Ub, 2 triangle waves

Equipment identification B38

1 = Supply for output A

2 = Supply for output B
3 = Output signal A
Electrical wiring
4 = Output signal B
5 = 0 V for output A
6 = 0 V for output B

Sensing range +/- 360° continuous

Functionality check with 180° steering range

Figure 147: Voltages for outputs A and B in different wheel positions with
180° steering range

1. Connect a supply voltage to pins.

+5 Vdc to pins 1 and 2.

0 V to pins 5 and 6.

2. Turn the wheels to the center position.

The voltage on output channel A must be close to 0.5 V.

The voltage on output channel B must be close to 2.5 V.

3. Turn steering slowly to the left and measure the output voltage from pins 3 and 4.

The voltage between pins 3 and 5 must approach 2.5 V steplessly.

The voltage between pins 4 and 6 must must approach 0.5 V steplessly.

4. Turn steering slowly to the right and measure the output voltage from pins 3 and 4.

The voltage between pins 3 and 5 must approach 2.5 V steplessly.

The voltage between pins 4 and 6 must approach 4.5 V steplessly.

Functionality check with 360° steering range

Figure 148: Voltages for outputs A and B in different wheel positions with
360° steering range

1. Connect a supply voltage to pins.

+5 Vdc to pins 1 and 2.

0 V to pins 5 and 6.

2. Turn the wheels to the center position.

The voltage on output channel A must be close to 0.5 V or 4.5 V, depending on the
position of the rear axle.

The voltage on output channel B must be close to 2.5 V.

3. Turn steering slowly to the left and measure the output voltage from pins 3 and 4.

The voltage between pins 3 and 5 must approach 2.5 V steplessly.

The voltage between pins 4 and 6 must approach 0.5 V or 4.5 V steplessly, depending on
the position of the rear axle.

4. Turn the wheels back to the center position.

5. Turn steering slowly to the right and measure the output voltage from pins 3 and 4.

The voltage between pins 3 and 5 must approach 2.5 V steplessly.

The voltage between pins 4 and 6 must approach 0.5 V or 4.5 V steplessly, depending on
the position of the rear axle.

6.10.1.6.2 Rear axle sensor (4-wheel models)

Figure 149: Rear axle sensor (4-wheel models)

Table 56: Rear axle sensor (4-wheel models)

Type Redundant, HALL-effect angle sensor

Vs 8 - 36 Vdc

Output signal 10% ... 90% Ub, Crossed signal curves

Equipment identification B38

1 = Supply for output A

2 = Supply for output B
3 = Output signal A
Electrical wiring
4 = Output signal B
5 = 0 V for output A
6 = 0 V for output B

Sensing range +/- 110° from the center position

The rear axle sensor in 4-wheel models has 2 analogue output signal that are crossed together.
The output signal varies between 0.5…4.5 Vdc depending on the steering angle.

Figure 150: Angle sensor output signals

Measure the sensor output voltage between each output and 0 V terminal individually with a
multimeter.

1. Connect a supply voltage to pins.

+5 Vdc to pins 1 and 2.

0 V to pins 5 and 6.

2. Turn the wheels to the center position. The voltage on both output channels must be close to
2.5 V.

3. Turn steering slowly to the left and measure the output voltage from pins 3 and 4.

The voltage between pins 3 and 5 must decrease steplessly.

The voltage between pins 4 and 6 must increase steplessly.

4. Turn steering slowly to the right and measure the output voltage from pins 3 and 4.

The voltage between pins 3 and 5 must increase steplessly.

The voltage between pins 4 and 6 must decrease steplessly.

6.10.1.7 Tilt angle sensor

Figure 151: Tilt angle sensor

Table 57: Tilt angle sensor specifications

Type Redundant angle sensor

Vs 4.5-5.5 Vdc

Tilt cylinder retracted 0.5 V

Output signal 1 Tilt cylinder extended 4.5 Vdc

Tilt cylinder retracted 4.5 V

Output signal 2 Tilt cylinder extended 0.5 Vdc

Equipment identification B52

1 = 0V for output 1
2 = Supply for output 1
3 = Output signal 1
Electrical wiring
4 = 0V for output 2
5 = Supply for output 2
6 = Output signal 2

Sensing range 50º

The tilt angle sensor has 2 analogue output signals that are crossed together. The output signal
varies between 0.5…4.5 Vdc depending on the position of the tilt cylinder.

Figure 152: Angle sensor output signals

1. Connect a supply voltage to pins.

+5 Vdc to pins 2 and 5.

0 V to pins 1 and 4.

2. Measure the output signal 1 with the tilt cylinder retracted and extended.

Pin 3 is the output.

Pin 1 has 0 V.

3. Measure the output signal 2 with the tilt cylinder retracted and extended.

Pin 6 is the output.

Pin 4 has 0 V.

When measuring the output signal, the signal value should move towards the specified
minimum and maximum value when retracting and extending the tilt cylinder.

6.10.1.8 Mast height sensor

Figure 153: Mast height sensor overview

1. Mast height sensor of the simplex mast 2. Mast height sensor of the duplex and
unit triplex mast units

Table 58: Mast height sensor

Type Inductive sensor

Vs 10 - 30 Vdc

Switching output PNP, NO

Equipment identification S40

1 = Supply
Electrical wiring 4 = Output signal
3=0V

Sensing range 10 mm

1. Connect a supply voltage between pins.

+12 Vdc to pin 1.

0 V to pin 3.

2. Measure the output signal between pins 3 and 4.

When a supply is connected and there are no metallic objects within the sensing range,
the value is approximately 0 Vdc.

When a metallic object is moved within the sensing range, the value is approximately +12
Vdc.

6.10.1.9 Steering wheel sensor

Figure 154: Steering wheel sensor

Table 59: Steering wheel sensor specifications

Type Redundant, HALL-effect angle sensor

Vs 5 Vdc

Output signal 10% ... 90% Ub, 2 triangle waves

Equipment identification B20

1 = Supply for output 1

2 = Supply for output 2
3 = Output signal 1
Electrical wiring
4 = Output signal 2
5 = 0 V for output 1
6 = 0 V for output 2

Sensing range +/- 360° continuous

Figure 155: Angle sensor output signals

Measure the sensor output voltage between each output and 0 V terminal individually with a
multimeter.

1. Connect a supply voltage to pins.

+5 Vdc to pins 1 and 2.

0 V to pins 5 and 6.

2. Turn steering slowly to the left and measure the output signal from pins 3 and 4.

The output signals must go in the opposite directions from each other.

If the output signal 1 increases, the output signal 2 must decrease.

If the output signal 1 decreases, the output signal 2 must increase.

3. Turn steering slowly to the right and measure the output signal from pins 3 and 4.

Signals must change direction in relation to the previous step, again going in the opposite
directions from each other.

If the output signal 1 decreases, the output signal 2 must increase.

If the output signal 1 increases, the output signal 2 must decrease.

When you use 2 multimeters, you should be able to measure clear 1 and 0 from the output, with
a 90º phase difference. The measured voltage should fluctuate between +0.5 and 4.5 V.

6.10.1.10 Mini steering wheel sensors

Figure 156: Mini steering wheel sensors

1. Mini steering wheel sensor 2. Mini steering wheel armrest sensor

6.10.1.10.1 Mini steering wheel sensor

Table 60: Mini steering wheel sensor specifications

Type Redundant, HALL-effect angle sensor

Vs 5 Vdc

Output signal 10% ... 90% Ub, 2 triangle waves

Equipment identification B24

A/1 = Supply for output 1

A/2 = Supply for output 2
B/4 = Output signal 1
Electrical wiring
B/2 = Output signal 2
B/1 = 0 V for output 1
B/3 = 0 V for output 2

Sensing range +/- 360° continuous

Figure 157: Angle sensor output signals

Measure the sensor output voltage between each output and 0 V terminal individually with a
multimeter.

1. Connect a supply voltage to pins.

+5 Vdc to pins A/1 and A/2.

0 V to pins B/1 and B/3.

2. Turn steering slowly to the left and measure the output voltage from pins B/4 and B/2.

The voltage between pins B/4 and B/1 must decrease steplessly.

The voltage between pins B/2 and B/3 must increase steplessly.

3. Turn steering slowly to the right and measure the output voltage from pins B/4 and B/2.

The voltage between pins B/4 and B/1 must increase steplessly.

The voltage between pins B/2 and B/3 must decrease steplessly.

When you use 2 multimeters, you should be able to measure clear 1 and 0 from the output, with
a 90º phase difference. The measured voltage should fluctuate between +0.5 and 4.5 V.

6.10.1.10.2 Mini steering wheel armrest sensor

Table 61: Mini steering wheel armrest sensor

Type Magnetic reed switch

Electrical connection Cable

Cable length 1m

Conductors 2 × 0.75 mm²

Equipment identification S50

1 = Supply
Electrical wiring
2 = Switch output

Type of actuation Magnet

Measure at the resistance area to make sure the contacts inside the magnetic reed switch are
not stuck together.

1. Connect the multimeter between pins 1 and 2.

When the armrest is turned down, the value on the multimeter is 0 Ω.

When the armrest is turned up, the value on the multimeter is ~∞Ω.

6.10.1.11 Accelerator pedal sensor

Figure 158: Accelerator pedal sensor overview

Table 62: Accelerator pedal sensor specifications

Type Redundant angle sensor

Vs 4.5-5.5 Vdc

Pedal in neutral position 0.5 Vdc

Output signal 1 Pedal pressed down 4.5 Vdc

Pedal in neutral position 4.5 Vdc

Output signal 2 Pedal pressed down 0.5 Vdc

Equipment identification B21

1 = Supply for output 1

2 = 0 V for output 1
3 = Output signal 1
Electrical wiring
4 = Supply for output 2
5 = 0 V for output 2
6 = Output signal 2

Sensing range 15º

The accelerator pedal sensor has 2 analogue output signals that are crossed together. The
output signal varies between 0.5-4.5 Vdc depending on the pedal operating angle.

NOTE: You cannot change the accelerator pedal sensor, you must change the entire pedal
assembly.

Figure 159: Accelerator pedal output signals

1. Connect a supply voltage to pins.

+5 Vdc to pins 1 and 4.

0 V to pins 2 and 5.

2. Measure the output signal 1 with the accelerator pedal in neutral position and pressed down.

Pin 3 is the output.

Pin 2 has 0 V.

3. Measure the output signal 2 with the accelerator pedal in neutral position and pressed down.

Pin 6 is the output.

Pin has 0 V.

When measuring the output signal, the signal value should move towards the specified
minimum and maximum value when pressing down and releasing the pedal.

6.10.1.12 Brake pedal sensor

Figure 160: Brake pedal sensor overview

Table 63: Brake pedal sensor specifications

Type Redundant angle sensor

Vs 4.5-5.5 Vdc

Pedal in neutral position 0.5 Vdc

Output signal 1 Pedal pressed down 4.5 Vdc

Pedal in neutral position 4.5 Vdc

Output signal 2 Pedal pressed down 0.5 Vdc

Equipment identification B22

1 = Supply for output 2

2 = 0 V for output 2
3 = Output signal 2
Electrical wiring
4 = Supply for output 1
5 = 0 V for output 1
6 = Output signal 1

Sensing range 15º

The brake pedal sensor has 2 analogue output signal that are crossed together. The output
signal varies between 0.5…4.5 Vdc depending on the pedal operating angle.

Figure 161: Angle sensor output signals

1. Connect a supply voltage to pins.

+5 Vdc to pins 1 and 4.

0 V to pins 2 and 5.

2. Measure the output signal 1 with the brake pedal in neutral position and pressed down.

Pin 6 is the output.

Pin 5 has 0 V.

3. Measure the output signal 2 with the brake pedal in neutral position and pressed down.

Pin 3 is the output.

Pin 2 has 0 V.

When measuring the output signal, the signal value should move towards the specified
minimum and maximum value when pressing down and releasing the pedal.

6.10.1.13 Electronic friction lock pedal sensor

Figure 162: Electronic friction lock pedal overview

Table 64:

Type Reed switch

Contact rating 200 Vdc / 1.5 A

Equipment identification S5

1 = Switch output
Electrical wiring
2 = 0V

Switching output 1 x NO, momentary action

Measure at the resistance area to make sure the contacts in the pedal are not stuck together.

1. Connect the multimeter between pins 1 and 2.

When the electronic friction lock pedal is in neutral position, the contacts are open and the
resistance is ~∞Ω.

When the pedal is pressed down, the resistance between the pins is ~0 Ω.

6.10.1.14 Dual pedal sensors

Figure 163: Dual pedal sensors

1. Direction sensors 2. Angle sensor

6.10.1.14.1 Dual pedal direction sensors

Table 65: Dual pedal direction sensors

Type Inductive sensor

Vs 10-30 Vdc

Switching output PNP, NO

S34 (forward)
Equipment identification S35 (reverse)
Connected to connectors X13.1 and X6.1.

Connector X13.1:
1 = Forward
2 = Reverse
Electrical wiring 3 = Supply
4 = Neutral
Connector X6.1:
8=0V

Sensing range 2 mm

1. Connect a supply voltage to the wires.

+12 Vdc to pin 3 on connector X13.1.

0 V to pin 8 on connector X6.1.

2. Measure the output signal from the corresponding pin for each dual pedal position.

When the dual pedal is in neutral position, the voltage between pins 4 and 8 is 12 V. The
voltage in pin 4 is always 12V.

When the forward pedal is pressed, the voltage between pins 1 and 8 is 12 V.

When the reverse pedal is pressed, the voltage between pins 2 and 8 is 12 V.

6.10.1.14.2 Dual pedal angle sensor

Table 66: Dual pedal angle sensor

Type Redundant angle sensor

Vs 4.5 - 5.5 Vdc

Pedals in neutral position 2.5 Vdc

Output signal 1 Pedals in forward position 4.5 Vdc
Pedals in reverse position 0.5 Vdc

Pedals in neutral position 2.5 Vdc

Output signal 2 Pedals in forward position 0.5 Vdc
Pedals in reverse position 4.5 Vdc

Equipment identification B23

1 = 0 V for output 1
2 = Supply for output 1
3 = Output signal 1
Electrical wiring
4 = 0 V for output 2
5 = Supply for output 2
6 = Output signal 2

Sensing range 50º

The dual pedal angle sensor has 2 analogue output signals that are crossed together. The
output signal varies between 0.5…4.5 Vdc depending on the pedal operating angle.

Figure 164: Angle sensor output signals

1. Connect a supply voltage to pins.

+5 Vdc to pins 2 and 5.

0 V to pins 1 and 4.

2. Measure the output signal 1 with the dual pedal in neutral, forward and reverse position.

Pin 3 is the output.

Pin 1 has 0 V.

3. Measure the output signal 2 with the dual pedal in neutral, forward and reverse position.

Pin 6 is the output.

Pin 4 has 0 V.

When measuring the output signal, the signal value should move towards the specified
minimum and maximum value when moving the pedals between forward and reverse positions.

6.10.1.15 Manual lever sensors

Figure 165: Lever sensors

Table 67: Manual lever sensors

Type HALL-effect angle sensor

Vs 4.5…12 V

Lever position:
Neutral 2.4 Vdc
Output signal Pulled 1.3 Vdc
Pushed 3.4 Vdc

Equipment identification A10

1 = Optional lever / Attach 2 output

2 = Sideshift / Attach 1 output
3 = Tilt output
Electrical wiring
4 = Lift/lower output
7=0V
8 = Supply

1. Connect a supply voltage to pins.

+12 Vdc to pin 8.

0 V to pin 7.

2. Measure the output signal from the corresponding pin for each lever.

Pin 4 is the output for Lift/lower lever.

Pin 3 is the output for Tilt lever,

Pin 2 is the output for Sideshift / Attach 1 lever.

Pin 1 is the output for Optional / Attach 2 lever.

Pin 7 has 0 V.

6.10.1.16 Seat belt switch

Figure 166: Seat belt switch

Table 68: Seat belt switch

Type Micro switch

Contact rating 60 V / 0.5 A

Equipment identification S29 / Seat connector X134

3 = Supply
Electrical wiring
6 = Switch output

Switching output 1 X NO

Measure at the resistance area to make sure the contacts in the seat belt switch are not stuck
together.

1. Connect the multimeter between pins 3 and 6.

When the switch is in neutral position, the contacts are open and the resistance is ~∞Ω.

When the seat belt is connected to the buckle, the resistance between the pins is ~0 Ω.

6.10.1.17 Seat switch

Figure 167: Seat switch

Table 69: Seat switch

Type Micro switch

Contact rating 60 V / 0.5 A

Equipment identification S30 / Seat connector X134

1 = Switch output
Electrical wiring
3 = Supply

Switching output 1 X NO

Measure at the resistance area to make sure the contacts in the seat switch are not stuck
together.

1. Connect the multimeter between pins 3 and 1.

When the switch is in neutral position, the contacts are open and the resistance is ~∞Ω.

When the seat is activated, the resistance between the pins is ~0 Ω.

6.10.1.18 Side control panel switches

Figure 168: Side control panel switch positions

Table 70: Functionality of the switches in different positions

POSITION

# DESCRIPTION IDENTIFIER A B C

Manual working Front working

1 S16 OFF All ON
lights lights ON

Automatic
2 working lights S8 OFF N/A Auto
(option)

Windshield wiper
Wiper and washer ON
3 and washer S26 OFF Wiper ON
(momentary)
(option)

Rear window Wiper and washer ON

4 S27 OFF Wiper ON
wiper (option) (momentary)

Ready to
Trigger. Toggles the
Rear window operate /
5 S31 OFF rear window heater on
heater (option) OFF until
for 10 minutes.
triggered

Table 71: Switches of the side control panel

Type Mechanical switch

Contact rating 15 A / 28 VDC

Dielectric strength 1,500 V RMS

Contacts Silver alloy, silver tin-oxide, fine silver

Measure the output resistance:

When the switch is in OFF position, resistance is ~∞ Ω.

When the switch is in ON position, resistance is ~0 Ω.

See Table 72 for the correct pins and resistances for different switch positions.

Table 72: Resistances of the switches in different positions

POSITION

EQUIPMEND
DESCRIPTION PINS A B C
IDENTIFICATION

S16 1. Manual working lights 2-3 ∞Ω 0Ω 0Ω

5-6 ∞Ω ∞Ω 0Ω

2. Automatic working lights

S8 2-3 ∞Ω N/A 0Ω
(option)

3. Windshield wiper and washer

S26 1-2 0Ω ∞Ω ∞Ω
(option)

2-3 ∞Ω 0Ω 0Ω

6-5 ∞Ω ∞Ω 0Ω

S27 4. Rear window wiper (option) 1-2 0Ω ∞Ω ∞Ω

2-3 ∞Ω 0Ω 0Ω

6-5 ∞Ω ∞Ω 0Ω

S31 5. Rear window heater (option) 2-3 ∞Ω 0Ω 0Ω

5-6 ∞Ω ∞Ω 0Ω

6.10.1.19 Steering column driving direction selection switch

Figure 169: Driving direction selection switch

Table 73: Steering column driving direction selection switch

Type Micro push button switch

Vs 12 Vdc

Current 1A

Equipment identification S15 (Connector X8)

1 = Neutral
2 = Supply for Forward and Reverse
Electrical wiring 3 = Forward
4 = Supply for Neutral
5 = Reverse

Measure at the resistance area to make sure the contacts in the driving selection switch are not
stuck together.

Neutral position:

1. Connect the multimeter between pins 4 and 1.

When the switch is in neutral position, the contacts are closed, and the resistance is ~0 Ω.

When the switch is anything else than neutral, the resistance between the pins is ~∞Ω.

Forward position:

1. Connect the multimeter between pins 2 and 3.

When the switch is in forward position, the contacts are closed, and the resistance is ~0
Ω.

When the switch is anything else than forward, the resistance between the pins is ~∞Ω.

Reverse position:

1. Connect the multimeter between pins 2 and 5.

When the switch is in reverse position, the contacts are closed, and the resistance is ~0
Ω.

When the switch is anything else than reverse, the resistance between the pins is ~∞Ω.

6.10.1.20 Clamp release switch

Figure 170: Clamp release switch

Clamp release switch can be installed on manual levers 3 or 4 depending on the configuration.

Table 74: Clamp release switch

Equipment identification S12

1 = Supply
Electrical wiring
2 = Switch output

1. Connect the multimeter between pins 2 and 1.

2. Press the clamp release switch.

When the switch is in neutral position, the contacts are open and the resistance is ~∞Ω.

When the switch is pressed, the resistance between the pins is 0Ω.

6.10.1.21 Autolight sensor

Figure 171: Autolight sensor

Table 75: Autolight sensor specification

Type Photodiode

Vs 5 Vdc

Equipment identification B43

1 = Supply
Electrical wiring
2 = Sensor output

1. Connect the negative probe of the multimeter to the negative pole of the battery.

2. Connect the positive probe of the multimeter to the pin 1 of the autolight sensor.

3. Measure the output signal from pin 2 by adjusting the light in the surrounding area. The
output signal must change according to the amount of light the photodiode receives.

0V in the dark.

~+5V when shining a a flashlight at the sensor.

6.10.2 Steering wheel functions

Check the following functionalities of the steering wheel:

Check that the wheels of the truck turn to the right and left when you turn the steering wheel

Check that the turn signal/light switch functions correctly.

Check that the operation direction selection switch functions correctly (all three positions).

If these functionalities do not work correctly, the steering wheel unit must be repaired. For more
information, see 8.7 Repair steering wheel.

6.10.3 Horn
There are a total of three possible locations for horn switches in the truck. Up to two horn
switches can be installed at the same time.

Table 76: Horn switches

Equipment identification S6, S9

Electrical wiring All horn switches have corresponding pins 1 and 2.

To check the functionality of the horn:

1. Press the horn and make sure that the horn makes a sound.

2. If the horn does not make any sound:

Check the connections of the horn.

Check the condition of relay K32 and the related fuse

3. If the horn still does not make any sound, replace the horn. For more information, see 8.11.2
Replace the horn.

6.10.4 Electrical connections tightening torques

See 11.1 Special tightening torques for the specific tightening torques of electrical connections.

6.10.5 Cables and wiring

Examine the cables and wiring of the truck and make sure they are not damaged.

If the cables or wiring are damaged, repair them if possible.

If it is not possible to repair the damage, replace the cables or wiring.

6.10.6 Examine and clear the alarm history

To examine and clear the alarm history, see the instructions in TruckTool.

6.10.7 Insulation resistance test

6.10.7.1 Test voltage

The insulation resistance of the truck and the traction battery are checked separately. The test
voltage is greater than the nominal voltage but no more than 100 V or three times the nominal
voltage:

Table 77: Nominal voltage and test voltage

NOMINAL VOLTAGE TEST VOLTAGE

Up to 24 V 50 V

Over 36 V 100 V

6.10.7.2 Check the insulation tester

Connect the test probe to the frame of the truck (for example, to a non-painted bolt or bracket)
and the other test probe to another bolt or bracket. The tester should show a value of zero.

Figure 172: Check the insulation tester

6.10.7.3 Measure the insulation resistance

The test is performed with the battery disconnected from the truck. All the electrical components
must be in place.

1. Release the emergency stop and turn the key switch to the ON position.

2. Connect the test probe to the frame of the truck (for example, to a non-painted bolt or
bracket).

3. Connect the other test probe to the measuring point.

4. Read the resistance value.

For more information, see 6.10.7.3.1 Insulation resistance of the truck and 6.10.7.3.2 Insulation
resistance of the battery.

6.10.7.3.1 Insulation resistance of the truck

Figure 173: Measure the insulation resistance of the truck

Measuring points when measuring the insulation resistance of the truck:

Positive terminal of the battery connector

+BF terminal on the left traction controller

–B terminal on the left traction controller

Table 78: Insulation resistance

NOMINAL VOLTAGE MINIMUM INSULATION RESISTANCE

24 V 24,000 Ω

36 V 36,000 Ω

48 V 48,000 Ω

80 V 80,000 Ω

6.10.7.3.2 Insulation resistance of the battery

NOTE: It is only necessary to measure the insulation resistance of the battery if your truck
has lead-acid battery. It is not necessary to measure the insulation resistance of a lithium-ion
battery.

Figure 174: Measure the insulation resistance of the battery

The insulation resistance of the disconnected, filled and charged traction battery mounted on
the truck is at least 50 Ω multiplied by the nominal voltage of the truck system between the live
parts and the frame of the truck. If the battery is fitted into more than one container, this test is
carried out with the electrically-connected sections (including metal battery containers).

Measuring points when measuring the insulation resistance of the battery:

Positive terminal on the battery connector.

Negative terminal on the battery connector.

Table 79: Insulation resistance

NOMINAL VOLTAGE MINIMUM INSULATION RESISTANCE

24 V 1,200 Ω

36 V 1,800 Ω

48 V 2,400 Ω

80 V 4,000 Ω

6.10.8 Discharge the controllers

CAUTION
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before you
start to do maintenance on the controllers, you must discharge them. Also, if you
continue the maintenance work of the controllers after you have switched the power of
the truck ON and OFF, you must discharge the controllers again.

NOTE: It is not necessary to discharge each controller separately. If you discharge one
controller, the other controllers are discharged at the same time.

To discharge the controllers:

1. Switch the power of the truck OFF.

2. Disconnect the battery connector.

3. Connect the red cable of the bleeder resistor to the B+ pole. See Figure 175.

4. Connect the black cable of the bleeder resistor to the B- pole. See Figure 175.

Keep the bleeder resistor connected for at least 5 seconds.

5. Disconnect the cables of the bleeder resistor.

6. Measure the voltage between the terminals with a multimeter.

The value must be under 5 V.

Figure 175: Positive and negative poles of the controller voltage feed

6.10.9 Emergency stop button functionality check

Figure 176: Emergency stop button

Table 80: Emergency stop button specifications

Type Complete emergency stop

Contact rating 125 Vdc / 0.55 A

Electrical wiring Quick connect terminals 2.8 x 0.5 mm

Switching output 1 x NC

1. Measure at the resistance area that the contacts in the emergency stop button are not stuck
together.

When the emergency stop button is released (the contacts are closed together), the
resistance is ~0 Ω.

When the emergency stop button is pushed down, the resistance is ~∞Ω.

2. If the contacts are stuck together or broken, replace the emergency stop button.

6.10.10 Key switch functionality check

Figure 177: Key switch

Table 81: Key switch specifications

Type Key switch

Contact rating 80 Vdc / 0.5 A

Electrical wiring Plug-in connector 6 poles

Switching output 2 x NO

1. Measure at the resistance area that the contacts in the key switch are not stuck together.

When the key switch is in the 0 position, the resistance is ~0 Ω between the pins 6-1 and 4-
5.

When the key switch is turned clockwise once, the resistance is ~0 Ω between the pins 6-1,
4-5, 6-4, 6-3, 1-4 and 1-3.

When the key switch is turned clockwise for the second time, the resistance is ~0 Ω between
the pins 6-1, 4-5, 6-5, 6-2, 1-5 and 1-2.

2. If the contacts are stuck together or broken, replace the key switch.

6.11 Safety

6.11.1 Inspect the seat belt

MANDATORY ACTION

If the seat belt is damaged or you identify any other defects, replace the seat belt.

Examine the seat belt regularly.

Check the mounting points of the seat belt and lock for wear and damage.

Fasten the seat belt and pull it on the lock side to make sure it is secure.

Pull the seat belt sharply. If the seat belt is operating correctly, the retractor locks the belt.

Pull the seat belt completely out of the retractor.

Make sure the retractor is not jammed.

Inspect the belt for damage like fraying, stretching and cuts.

Make sure that the seat belt returns to the retractor completely when you release it.

To replace the seat belt, see 8.10 Repair operator's seat.

6.12 General

6.12.1 How to clean the truck

It is important that you keep the truck clean. With regular cleaning, you can prevent damage to
the truck and help make the life span of the truck long.

WARNING

Fire hazard

Using flammable liquids to clean the truck can create flammable fumes. Even a small
spark can ignite the fumes and create a fire that can result in serious personal injury.
Additionally, flammable liquids can cause warning decals to come off the truck. This
can result in reduced operational safety. Do not clean the truck with flammable cleaning
liquids.

CAUTION
Electric hazard

Water can cause damage to the electric devices. Do not clean the electric devices with
water.

Before you start to clean the truck:

Disconnect the battery connector.

Take precautions against spark formation.

If you use water jet or pressure washer to clean the truck, put covers on the electric and
electronic devices to make sure that no water touches the devices.

To clean the truck:

After you put covers on the electric and electronic devices, you can use water to clean the
truck.

To clean the electric devices, use low pressure compressed air or suction. Make sure that
your compressor has a water separator. You can also use an antistatic brush to clean the
electric devices.

To clean the battery, see 7 Battery maintenance.

6.12.2 Lubrication
Check visually that all necessary parts have been lubricated with suitable lubricants.

6.12.3 Examine the welding in the truck frame for cracking

DANGER
Risk of accident

Using a truck with deformations, cracks or damage in the frame or other structures is
dangerous and can lead to an accident. If it is not possible to fix the welding, using the
truck must be prohibited. Label the truck accordingly to prevent anyone from using it.

Check the truck frame visually for any cracks in the welding. If you notice cracks in the welding,
fix the welding immediately if possible.

6.12.4 Examine the truck frame and the lifting carriage

Check the truck frame and lifting carriage visually for any damage. If the lifting carriage is
damaged, see 8.5 Repair lifting carriage.

6.12.5 Examine the overhead guard for deformation, cracking and damage

DANGER
Risk of accident

Using a truck with deformations, cracks or damage in the frame or other structures is
dangerous and can lead to an accident. If the overhead guard is damaged, using the
truck must be prohibited. Label the truck accordingly to prevent anyone from using it.
Contact your truck dealer for instructions.

Check the overhead guard visually for any deformation, cracking and damage.

6.12.6 Examine the gas springs

Test the functionality of the gas springs. The truck has gas springs in several locations. If the
gas springs do not work correctly, they must be replaced. For more information, see 8.13.1.4
Replace the gas spring of the operator door, 8.7.2 Remove the steering wheel gas
spring and 8.13.3.1 Replace the gas spring of the rear window.

6.12.7 Examine the condition and position of the identification plates

For more information about the component, see 4.2 Identification plates and decals.

1. Check that the text on the type plate and capacity plate is visible and readable.

2. Check that the type plate and capacity plate are securely fastened on the truck.

3. If either the type plate or capacity plate is damaged or the text is not readable, you must
order a new plate. Contact your dealer directly to order a new type plate or capacity plate.

6.12.8 Examine the covers

Examine the truck covers visually. If the truck covers are damaged, they need to be replaced.
For more information, see 6.2 Truck covers.

6.12.9 Safety functions

Check the condition and functionality of the following safety functions:

Brakes

Electronic friction lock pedal (if applicable)

Battery door sensor

Warning stickers

Emergency stop button

Key switch

6.12.10 Examine the fastening of the steering wheel

For more information about the component, see 5.5.1 Steering wheel.

1. Check that the steering wheel is not loose.

2. If the steering wheel is loose, remove the dust cover of the steering wheel. See 6.2.6
Remove the steering wheel cover.

3. Tighten the nut that fastens the steering wheel to the truck.

4. Re-install the dust cover of the steering wheel.

7 BATTERY MAINTENANCE

7.1 Lead-acid batteries

7.1.1 Safety with lead-acid batteries

Read the operating instructions of the battery and keep them near the
battery. Follow general safety practices in accordance of local, state and
federal (for example OSHA) regulations, B56.1, UL583 and NFPA505
standards. Only skilled personnel can do work on batteries.

Use protective glasses and clothes when you work on batteries. Pay
attention to the accident prevention rules.

No smoking.
Do not expose batteries to naked flames, glowing embers or sparks,
because it can cause the battery to explode.

Acid splashes in the eyes or on the skin must be washed immediately with
water.
In case of an accident, consult a doctor immediately.
Clothing contaminated by acid must be washed with water.

Risk of explosion and fire, avoid short circuits.

Metal parts of the battery are always live. Do not place tools or other metal
objects on the battery.

Electrolyte is highly corrosive.

Batteries and cells are heavy. Ensure secure installation. Use only suitable
handling equipment, for example lifting gear.

Dangerous electrical voltage.

Pay attention to the hazards that can be caused by batteries.

The lead-acid battery must not be disposed of with household or industrial

waste.

The lead-acid battery should be returned to your service partner or supplier

for disposal or delivered to an approved and certified recycling company.

7.1.2 General information

Follow these instructions to ensure that handling the battery is safe and that it remains in good
working condition throughout its life cycle:

Always keep the battery clean and dry to prevent tracking currents.

Follow the instructions of the battery manufacturer when you use and maintain the battery.

Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
After cleaning, repair all damages to the insulation of the tray to prevent tray corrosion and to
make sure that the insulation value complies with the standard IEC 62485-3.

If the battery is taken out of service for a longer period, make sure that the battery is fully
charged and store it in a dry, frost-free room. The storage time should be taken into account
when considering the lifetime of the battery.

In order to minimize the risk of injury during work on live equipment, only insulated tools
according to IEC 60900 shall be used.

In case of any malfunctions on the battery or in the charger, contact the battery manufacturer
immediately.

When you use batteries and chargers, always make sure that you follow the current
standards, laws, rules and regulations in force in the country of use.

7.1.3 Requirements for battery charging areas

The battery charging areas must be in compliance with the standard IEC 62485-3.

The battery charging area must be clearly defined by marking it permanently on the floor.
The floor coating must be acid resistant and have a resistance to ground less than 100 MΩ
to avoid sparks by electrostatic discharge.

The battery charging area must be adequately spaced from materials that can constitute a
hazard, such as flammable or explosive goods.

Except during essential maintenance or repair, the battery charging area must not be
subjected to any sources of ignition, such as sparks or sources of high temperature. The
exception is where high temperature equipment is required for work on the battery and this
must be in the control of trained and authorized personnel who take all necessary
precautions.

It is important to prevent electrostatic discharges when working with batteries.

Make sure that you do not wear clothes and footwear that can build up electrostatic
discharge.

Absorbent cloth for battery cleaning must be antistatic and used moistened only with
water without any cleaning agents.

In order to minimize the risk of injury during work on live equipment, only insulated tools
according to IEC 60900 shall be used.

When the battery is being charged or serviced, there must be a space 0.8 m (7.5 ft) wide on
the sides of the truck that require access.

When charging batteries on or off the truck, the ventilation requirements of IEC 62485-3
clause 6 must be met. The required air flow must preferably be ensured by natural
ventilation, otherwise by forced artificial ventilation.

The charger and other devices in the battery charging area, for example the battery
changing equipment, must be installed so that they do not get damaged if the truck moves.

The battery charging area must not be vulnerable to falling objects, drip water or liquids that
can leak from damaged pipes.

If you use battery replacement equipment, make sure that it is suitable for the battery trays
and weights. Examine the battery replacement equipment regularly for damage. Battery
replacement must be done by personnel trained to handle heavy weights. It is recommended
that the batteries are replaced laterally with certified supporting devices to minimize the risk
of batteries tipping over, crushing or damaging other equipment, etc.

The battery charging area must contain appropriate warning signs:

Follow the instructions

Battery hazard

Dangerous voltage

Highly corrosive electrolyte

Use protective clothes and goggles

Prohibition of naked flame

Explosion hazard.

The battery charging area must contain fire extinguishing equipment.

The disassembly and disposal of batteries must be done according to the prevailing local
regulation and by qualified personnel only.

7.1.4 Charge the battery

WARNING
Explosion hazard

Lead-acid battery can produce combustible gases. If the ventilation is insufficient,

these gases can accumulate in the working space. Even a small spark can ignite the
gas. This can result in an explosion that will cause personal injury or death. Make sure
that the charging area is properly ventilated. Do not overcharge the battery.

WARNING
Electric hazard
Fire hazard

Wrong type of charger can damage the battery. This can result in hazardous situations
with risk of electric shock or a fire. Always make sure that you charge the battery with a
compatible charger.

READ THE INSTRUCTIONS

See the charger manual for detailed charging instructions.

Figure 178: Battery charging connectors

1. Charger connector 3. Truck connector

2. Battery connector

CAUTION
Make sure that the charger is the appropriate model (correct battery type and voltage)
and that the battery has sufficient ventilation.

1. Park the truck in the battery charging area.

2. Set the power of the truck to the OFF position. Make sure that the charger is set to the OFF
position.

3. Open the battery door. For instructions, see 6.2.3 Open the battery door.

4. Open the battery cover. For instructions, see 6.2.4 Open the battery cover.

5. Disconnect the battery connector from the truck connector.

6. Connect the battery connector to the charger connector.

7. Set the charger to the ON position.

7.1.4.1 After the battery is charged

1. Set the charger to OFF.

2. Disconnect the battery connector from the charger connector. Hold the connectors; do not
pull the cables.

3. Examine the battery according to the battery maintenance instructions of the manufacturer.

4. Connect the battery connector to the truck connector. Make sure that the battery cables
remain completely safe within the frame of the truck.

5. Close the battery cover and the door.

WARNING
Fire hazard

If the cables are left outside the truck after charging, they can get damaged and cause a
serious fire hazard. Do not leave the battery cables outside of the truck.

7.1.5 Battery maintenance

DANGER
Explosion hazard

Dust on batteries can cause tracking currents that can lead to self-discharge of the
battery. If there is a flow of higher tracking currents, electric sparking can occur and
there is a risk of explosion of the charging gas. Keep the battery clean and dry.

DANGER
Explosion hazard

Using a dry cloth to wipe the battery can cause sparks. If there is combustible charging
gas from the battery in the working space, even a small spark can ignite the gas. This
can result in an explosion that will cause personal injury or death. Only use antistatic
cleaning wipes or cloths moistened with water to clean the battery.

MANDATORY ACTION
Use protective eyewear and protective clothing.

Make sure that the surface resistance of your safety clothes, boots and gloves is ≤ 100
MΩ to prevent build-up of static electricity.

READ THE INSTRUCTIONS

Read and follow the safety instructions of the battery manufacturer.

These maintenance instructions apply only to open lead-acid batteries. Consult the battery
supplier for instructions for other types of batteries.

A properly maintained battery:

Can prevent accidents.

Is less likely to become damaged.

Is less likely to become damaged by corrosion or tracking currents.

Has a long life and operating time.

7.1.5.1 General maintenance

Refer to the maintenance decal for maintenance information.

Keep the battery clean and dry to prevent tracking currents. Do the cleaning of the battery
according to the ZVEI code of practice, see 7.1.5.2 How to clean the battery.

If there is liquid in the battery tray, remove it and follow an approved procedure to discard it.
Repair damage to the insulation of the tray after you have cleaned the tray. If you must remove
cells, contact the battery manufacturer.

7.1.5.2 How to clean the battery

How to clean batteries with a damp cleaning cloth:

Before you clean the battery, remove the battery from the truck.

Make sure that you collect the rinsing water that contains electrolyte and discard it in a
correct procedure.

When you discard used electrolyte water or rinsing water, refer to the instructions for health
and safety at work, accident prevention and how to discard water and waste.

Do not remove or open the cell plugs. See the instructions of the manufacturer.

Clean the plastic parts of the battery, especially the cell containers, with a cleaning cloth and
clean water. Do not use cleaning agents.

After the battery has been cleaned, dry the battery with compressed air or damp antistatic
cleaning cloth (cotton, for example). You can also use other applicable methods to dry the
battery.

If there is liquid in the battery tray, remove it by suction and follow an approved procedure to
discard it.

If you need to remove the cells, contact the battery manufacturer.

How to clean batteries with high-pressure cleaning equipment:

Observe the operating instructions of the high-pressure cleaning device.

Make sure that you do not cause damage to the plastic parts of batteries, such as lids, the
insulation of the intercell connectors and other connectors.

Before you clean the battery, tighten the intercell connectors down or push them in tightly.

Make sure that the connectors are in their correct position and closed.

Do not use cleaning agents.

The maximum permitted temperature setting for the high pressure cleaning equipment is 140
°C (284 °F). Make sure that the temperature is no more than 60 °C (140 °F) measured at 30
cm (11.8 in.) behind the jet nozzle.

Make sure that the distance between the jet nozzle of the high pressure cleaning equipment
and the battery is no less than 30 cm (11.8 in.).

Make sure that the maximum working pressure should not be more than 50 bar (725 psi).

Clean large surface areas of the battery at a time to avoid heating the battery too much.

Do not leave the jet on one spot for a longer period of time than 3 seconds.

After you have cleaned the battery, dry the battery with compressed air or damp antistatic
cleaning cloth (cotton, for example). You can also use other applicable methods to dry the
battery.

Do not use air heaters with an open flame or with glow wires.

Make sure that the surface temperature of the battery is no more than 60 °C (140 °F).

If there is liquid in the battery tray, remove it by suction and follow an approved procedure to
discard it.

If you need to remove the cells, contact the battery manufacturer.

7.1.5.3 Daily maintenance

Charge the battery after every discharge.

For batteries with electrolyte circulation, measure the electrolyte level towards the end of the
charging and, if necessary, top it up to the specified level with deionized water according to
the instructions of the manufacturer. The electrolyte level must not fall below the anti-surge
baffle, the top of the separator or the electrolyte minimum level mark.

For batteries with filling level sensors, look at the illuminated display daily. If the display is
green, the level is OK. If the display shows a blinking red color, the filling level is too low.

For batteries with float indicator in the water filling plug, make sure that the white indicator is
on the height of the window.

For batteries with standard vent plugs, open the plug and visually inspect the electrolyte.

If water level is low, top it up with demineralized water after the end of the charge.

7.1.5.4 Weekly maintenance

After recharging, examine the battery visually for signs of dirt or mechanical damages to the
components of the battery. Pay special attention to the battery charging connectors and cables.
In special cases when charging with an IU characteristic curve, also an equalizing charge must
be carried out.

Make sure that the air holes of the battery cell plugs are not plugged up (does not apply to
maintenance-free batteries).

7.1.5.5 Monthly maintenance

At the end of the charge, set the charger to OFF and disconnect the connectors. After 2 hours,
measure and record the voltages of each cell or block battery.

After the charging is completed, measure and record the electrolyte density, electrolyte
temperature and the filling level (when filling level sensors are used) of all cells.

If there are any significant changes compared to earlier measurements or differences between
the cells or block batteries, charge the battery fully and allow it to rest for the minimum of two
hours. If the problem persists, contact the battery manufacturer. For more information, see
7.1.5.5.1 Measure the specific gravity of the battery.

Before you contact the battery manufacturer, measure and record:

Total voltage

Voltage per cell

If the voltage readings are irregular, also measure the specific gravity of each cell, see
7.1.5.5.1 Measure the specific gravity of the battery.

7.1.5.5.1 Measure the specific gravity of the battery

Measure the specific gravity of the battery water according to the instructions of the battery
manufacturer. The specific gravity of a fully charged battery is 1.28 to 1.30 at 30 °C (86 °F). The
gravity is:

1.24 when the battery is 3/4 charged.

1.20 when the battery is 1/2 charged.

1.16 when the battery is 1/4 charged.

1.15 when the battery is empty. Charge the battery immediately.

7.1.5.6 Annual maintenance

The insulation resistance of the truck and the battery are measured in accordance with the
standard IEC 62485-3 at least once per year. The insulation resistance of the disconnected,
filled and charged traction battery mounted on the truck must be at least 50 Ω multiplied by the
nominal voltage of the truck system between the live parts and the frame of the truck.

For batteries fitted with an electrolyte circulation system, examine the filter of the air pump and
clean or replace it if necessary. It is possible that the filter must be replaced earlier than
expected if there are no leaks in the air pipes, but for some reason the defect signal of the air
mixing system on the charger or on the battery (on the DC air pump or remote signal) is
illuminated.

During annual maintenance, also test the correct operation of the air pump.

7.1.6 Malfunctions

If you find malfunctions in the battery or in the charger, contact the battery manufacturer
immediately.

7.1.7 Acquire a new battery

When you acquire a battery for the truck, take the following sections of standards ANSI/ITSDF
B56.1 and UL583 requirements into consideration:

Hazardous locations

Maintenance and inspection

Nameplates and markings

The battery label should include at least the following information:

Name of the manufacturer

Model

Battery type indentification (E, EO, EE, or EX)

Class and group identification of hazardous locations in which a type EX battery can be used
when EX is specified in battery type indentification

Nominal voltage

Ampere hour capacity (Ah / 6h)

Service weight.

Batteries for use in electric trucks must have the battery weight legibly stamped on the battery
tray near the lifting means as follows: Service Weight______kg.

NOTE: Weight value must be accurate within ± 5%.

Figure 179: Example of a battery label

7.1.8 Storage

If you remove a battery from service for a long period of time, make sure that:

The battery is fully charged

The storage is dry and frost-free

To make sure that the battery is always prepared for operation, you can select one of these
charging procedures:

Do the equalizing charge monthly

Do float charging at a charging voltage of 2.23V × the number of cells.

Have a system to monitor and keep track of the batteries that are in storage. This enables you
to schedule regular charging and maintenance procedures for each battery.

7.2 Lithium-ion batteries

7.2.1 General information

The lithium-ion battery is only intended for use in an electric truck designed for this purpose. It is
not intended for any other use. If used in other applications, the user is responsible for any
damage that may result from misuse.

Due to the complexity of the lithium-ion battery technology, conventional lead-acid batteries
cannot be replaced with lithium-ion batteries without making modifications to the electric system
of the truck because of compliance and safety regulations.

Each lithium-ion battery has its own type plate. The type plate includes battery performance
information and a serial number. Always enter the serial number when making inquiries. Do not
remove the type plate.

Only factory approved and supplied lithium-ion batteries and chargers must be used. Use of
non-approved battery can lead to a hazardous situation and is therefore strictly prohibited.
Warranty on the electrical system or the battery of the truck does not apply if a non-approved
lithium-ion battery or charger is used.

If the lithium-ion battery is not used for a long time (more than 2 hours), the battery will
automatically enter sleep mode. The battery can be reactivated by restarting the truck or by
pressing the power button on the external multifunction display (if available). It is recommended
to switch off the truck whenever it is left unattended.

7.2.2 Safety signs

Read and follow the operating instructions. A lithium-ion battery should only
be serviced by a local service partner or supplier. These instructions must
be kept close to the lithium-ion battery and must always be available to
users in their work area when questions arise.

Do not disassemble or modify the lithium-ion battery. Do not use in

potentially explosive atmospheres. Do not allow it to come into contact with
fire or be short circuited. The battery should only be charged with a lithium-
ion battery charger approved by the manufacturer. Failure to follow these
rules may result in liquid or gas leakage, fire hazard or excessive heat
generation.

In the event of a lithium-ion battery fire, evacuate personnel from the

affected area. Do not breathe fumes or touch leaked or spilled materials
with bare hands. Wear protective equipment. Take the battery out or into a
well-ventilated room. Use large amounts of water to cool the battery.
Other extinguishing methods can only increase the heat. If extinguishing
attempts with water fail or water is not readily available, dry powder can be
used as an alternative. Covering with sand or fire extinguishing powder
removes oxygen from the fire source.

Lithium-ion battery terminals can be live. There is a risk of a short circuit.

Never attempt to open or disassemble the lithium-ion battery. The

electrolyte is very corrosive. Under normal working conditions, contact with
the electrolyte is not possible. If the battery container is damaged, do not
touch the electrolyte.

If lithium-ion battery electrolyte comes into contact with your skin or eyes,
rinse immediately with plenty of water. Contact a doctor immediately. If your
clothing becomes contaminated, remove it immediately.

The lithium-ion battery must not be disposed of with household or industrial

waste.

The lithium-ion battery should be returned to your service partner or supplier

for disposal or delivered to an approved and certified recycling company.

Do not lift the lithium-ion battery diagonally or unevenly. The battery must
always be upright. Always use a battery lifting beam. Disconnect the
battery/charger connectors before lifting.

Figure 180: Lithium-ion battery decal

7.2.3 Requirements for battery charging areas

Battery charging areas must meet the following requirements:

The battery charging area must be located indoors in a frost-free and dry room with an
ambient temperature of 0°C to +40°C.

The battery charging area must be adequately spaced from materials that can constitute a
hazard, such as flammable or explosive goods, minimum distance 5 meters.

The battery charging area must not be vulnerable to falling objects, drip water or liquids that
can leak from fractured pipes.

Install the charger where the wall outlet is within reach of its power cable (within 2 meters).
The power cable must not be extended.

The lithium-ion battery charger must be installed so that it cannot be damaged when the
truck enters or leaves the battery charging area.

The lateral distance to the next charger must be at least twice the width of the charger. If this
condition cannot be guaranteed, the chargers must be staggered. Keep a distance of at least
0.5 m to adjacent walls.

The charging location must be arranged so that the ventilation openings are not covered and
the cooling air flow is not blocked. The charger must not be placed near radiators or other
heat sources. The accumulation of heat in the charger, e.g. due to blockage of the ventilation
openings, must be prevented.

When charging batteries, ensure optimal ventilation of the charger. The required air flow
must preferably be ensured by natural ventilation, otherwise by forced artificial ventilation.

Make sure that corrosive gases such as acid gas, conductive substances such as salt, soot
or metal dust, non-conductive dust and liquids do not enter the charger.

In order to minimize the risk of injury during work on live equipment, only insulated tools
according to IEC 60900 shall be used.

When the battery is being charged or serviced, there must be a space 0.8 m wide on the
sides of the truck that require access.

7.2.4 Charge the battery

WARNING
Electric hazard
Fire hazard

Wrong type of charger can damage the battery. This can result in hazardous situations
with risk of electric shock or a fire. Always make sure that you charge the battery with a
compatible charger.

WARNING
Electric hazard

Lithium-ion battery terminals can be live. Tampering with the terminals can cause a
short circuit and an electric shock. Do not tamper with or attempt to modify the battery
terminals.

Figure 181: Battery charging connectors

1. Charger connector 2. Battery connector

Different battery types and chargers are not interchangeable. The lithium-ion battery can only
be charged with a lithium-ion battery compatible charger. Use the charging connector to connect
the lithium-ion battery to the charger.

The lithium-ion battery communicates with the charger and is ready for charging when the
battery identification code (including battery capacity and charging current) is transmitted. See
also the installation and operating instructions of the certified battery charger.

7.2.4.1 Recharging a lithium-ion battery

It is important to charge the battery before it is fully discharged and switches off.

When the battery charge is 15%, the battery integrated alarm horn sounds once. The battery
should be charged as soon as possible.

When the battery charge is less than 10%, the battery integrated alarm horn sounds steadily.
The battery must be charged immediately.

When the battery charge is 0%, the battery is turned off.

NOTICE
Discharging the battery completely should be avoided at all costs, as sudden
disconnection of the battery can lead to a dangerous situation.

After one minute, the battery can be activated one more time by pressing the power
button to drive the truck directly to the charger. After this, the battery can no longer be
switched on again, but will remain switched off to avoid any further damage to the
battery. Then the truck must be transported to the charger in another way.

NOTICE
If the battery is switched off due to a low discharge level, it must be charged
immediately. Long downtimes for discharged batteries must be avoided at all costs.
Failure to charge the battery in a timely manner can damage the battery.

7.2.4.2 Before charging

1. Park the truck next to the lithium-ion battery certified battery charger.

2. Set the power of the truck to the OFF position. Make sure that the charger is set to the OFF
position.

3. Check that all cables and connectors are in working order.

4. If the truck has a cabin, open the side window for the duration of the battery charging.

5. Connect the charger connector to a battery socket that is mounted on the side door.

NOTE: Do not disconnect the battery connector from the truck connector

6. Set the charger to the ON position.

NOTE: The charger will activate automatically after 5 seconds. During charging, the
truck's electrical system is electronically disconnected from the lithium-ion battery using an
internal switching device.

The lithium-ion battery is fully charged when the charge level is 100%.

7.2.4.3 After charging

1. Set the charger to the OFF position.

2. Disconnect the charger connector from the battery socket. Hold the connector, do not pull the
cables.

WARNING
Fire hazard

If the cables are left outside the truck after charging, they can get damaged and cause a
serious fire hazard. Do not leave the battery cables outside of the truck.

Certified chargers are equipped to control and end the charging cycle automatically.
Immediately after charging, the truck can be used again. The lithium-ion battery does not
require a resting phase or cooling.

Before each use, check the lithium-ion battery for possible external damage (e.g., loose
connector connections, defective cables, etc.). If you notice a fault, contact your local service
partner or supplier immediately. Never make any repairs yourself.

7.2.4.4 Opportunity charging

Opportunity charging is a feature that permits operators to charge the lithium-ion battery
sufficiently during truck downtime.

This allows one lithium-ion battery to last longer than traditional power supplies. The goal is to
eliminate the need of changing the discharged battery during a working shift.

Unlike conventional lead acid batteries, lithium-ion battery opportunity charging is highly
recommended or even essential depending on the application.

To start opportunity charging, follow the charging instructions described earlier in this section
and allow the battery to charge for the duration of the truck downtime. Opportunity charging can
be interrupted at any time and the truck can be used immediately.

7.2.4.5 Battery balancing

The lithium-ion battery must be balanced at least once a week (preferably more often). This is
done by allowing the battery to charge full.

To start charging, follow the charging instructions described earlier in this section and allow the
battery to charge until the battery light is on and the display shows 100%. The battery should be
balanced for at least an hour. Certified chargers are designed to control and end the charging
cycle automatically when it is complete.

7.2.5 Battery maintenance

NOTICE
Do not attempt to open the lithium-ion battery or do maintenance work on it. The
lithium-ion battery is sealed and opening it can cause damage.

The lithium-ion battery is a maintenance and emission-free, valve-regulated system. The

lithium-ion battery does not require the addition of liquids or other substances.

The lithium-ion battery is sealed and must not be opened. Do not attempt to open and repair the
battery even if it is not functioning properly. The lithium-ion battery service and repair work
should only be performed by your service partner or supplier.

7.2.5.1 Examine the battery

Check the lithium-ion battery for external damage before each use (e.g., loose connections,
defective cables, etc.).

If there is a fault, please notify your service partner or supplier immediately.

If the lithium-ion battery is mechanically damaged, e.g. due to an accident, or if any of the
following conditions are met, stop using the lithium-ion battery and contact your service partner
or supplier immediately:

The battery container is damaged.

The battery emits an odor.

Liquid or other substances are leaking.

The battery becomes hot.

An error code is displayed.

The battery cannot be turned on.

7.2.5.2 How to clean the battery

NOTICE
Never use acidic or abrasive cleaning fluids when cleaning the battery. Never clean the
battery with a high-pressure cleaner or steam jet.

The lithium-ion battery must always be kept clean and dry. Clean the lithium-ion battery only
when the truck is switched off. Clean the battery container with a soft, clean cloth.

7.2.5.3 Malfunctions

If you notice any malfunction of the battery or charger, contact the battery supplier immediately.

For more information about the charger functions, see the installation and operating instructions
for the certified battery charger.

7.2.5.4 Service and repair

The lithium-ion battery must be inspected regularly by an authorized service partner or supplier.
If repairs are necessary or malfunctions occur, notify your service partner or supplier
immediately. Under no circumstances do the repairs yourself. Only original spare parts may be
used for repairs.

7.2.6 Acquire a new battery

The truck must be fitted with a compatible lithium-ion battery.

When acquiring a new lithium-ion battery, contact your local service partner or supplier.

7.2.7 Storage
If the lithium-ion battery is taken out of service, store it fully charged in a dry and well-ventilated
place. The battery has a low discharge rate of approx. 3 % per month at a temperature of 23°C.
It is recommended that the lithium-ion battery is recharged every 3 months. Higher ambient
temperatures increase the self-discharge rate and accelerate the natural aging process of the
battery. Recommended storage temperature is 0°C to +40°C.

NOTICE
The battery system can be permanently damaged if it is discharged for a long time. A
fully charged system can be stored for up to 3 months before it needs to be charged.

7.3 Replace the battery

7.3.1 General safety instructions

Follow these instructions to ensure that replacing the battery is safe and that it is not damaged
during the replacement procedure:

Always follow the instructions of the manufacturer when you replace the battery.

When you replace the battery, use a battery with similar dimensions and weight to maintain
the stability and the braking properties of the truck. The minimum weight of the battery is
indicated on the identification plate of the truck.

Before you install the charged battery, verify the battery type and voltage.

When you install a battery, use the applicable tools to move, connect and attach the battery
correctly. Do not keep tools or other metal objects on top of uncovered batteries.

Make sure that the capacity of the used lifting device is sufficient.

CAUTION
Risk of injury
Risk of equipment damage

The battery is heavy. A falling battery can cause crushing injury or spill battery acid.
Make sure that the capacity of the used lifting device is sufficient. Use care when
handling the battery.

MANDATORY ACTION
When you use a lifting device to lift the battery, put a non-conductive antistatic plate on
top of the battery to prevent the risk of a short circuit and sparking. This is not
necessary if the lifting device has sufficient insulation and is equipped with a
distributor, or if the pole shoes and cell combinations are fully protected.

The lead-acid battery must not be disposed of with household or industrial

waste.

The lead-acid battery should be returned to your service partner or supplier

for disposal or delivered to an approved and certified recycling company.

7.3.2 Replace the battery with a lifting device

WARNING
Crushing hazard

Battery is heavy. A falling battery can cause a serious injury or death. Use extreme care
when handling batteries.

Use an appropriate lifting device to replace the battery.

Stay at a safe distance from the hanging battery in case the lifting device fails.

The use of protective shoes is mandatory.

Figure 182: Battery replacement overview

1. Battery connector 3. Battery locking device

2. Battery

NOTE: If you have a truck with a cabin, you must open the roof cover (see 6.2.12 Open the
roof cover (cabin trucks)) and the rear window (see 5.3.2.2 Open the rear window) before
you replace the battery.

NOTE: If you have a wide battery, you must remove the left side plate. See 6.2.10 Remove
the side plate.

To replace the battery with a lifting device:

1. Open the battery door, see 6.2.3 Open the battery door.

2. Open the battery cover, see 6.2.4 Open the battery cover.

3. Disconnect the battery connector.

4. Open the battery locking device by pulling the knob to unlock the latch and push the latch
simultaneously backwards.

5. Attach 4 lifting hooks (size 6) to the battery. Note the correct lifting chain lengths.

NOTE: Make sure that you use applicable lifting devices and follow the safety
instructions given by the lifting device manufacturer.

6. Remove the battery.

7. Insert a new battery to the truck.

8. Connect the battery connector.

9. Guide the battery cable. Make sure the cable does not get stuck or compressed anywhere.

10. Close the battery locking device.

11. Close the battery door.

12. Close the battery cover.

7.3.3 Remove the battery with the battery sideway exchange tools

When you remove the battery with the battery sideway exchange tool, follow the arrow decals to
guide the battery correctly.

Figure 183: Decals for guiding the battery

NOTE: Always replace the battery in the battery replacement area.

1. Open the battery door.

2. Disconnect the battery connector.

3. Open the battery locking device.

4. Move the power pallet truck under the truck so that the battery sideway exchange tool is
connected to the battery tray.

5. Lift the forks of the power pallet truck by approximately 20 mm / 0.8 inches.

6. Move the power pallet truck backward so that the rear part of the battery is still in the truck.

7. Lift the forks of the power pallet truck so that the battery is lifted up from the floor of the
battery compartment.

8. Remove the battery with the power pallet truck.

9. Move the battery from the power pallet truck to the battery stand. To release the battery
sideway exchange tool, push the release handle with your foot.

7.3.4 Install a battery with the battery sideway exchange tools

1. Move the power pallet truck near the battery. Lock the battery to the battery sideway
exchange tool.

2. Lift the forks slightly and make sure that the battery connects to the battery sideway
exchange tool.

3. Slide the battery carefully out of the battery stand with a power pallet truck. Do not lift the
battery as long as it is on top the battery stand.

4. When the battery is no longer on top of the battery stand, lift the battery on a power pallet
truck away from the battery stand.

5. Open the battery door. See 6.2.3 Open the battery door.

6. With the power pallet truck, move the battery so that the rear part of the battery is inside the
battery compartment.

7. Lower the forks of the power pallet truck so that the wheels of the battery tray touch the floor
of the battery compartment.

8. With the power pallet truck, push the battery inside the battery compartment.

9. Lower the forks of the power pallet truck slightly.

10. To release the battery sideway exchange tool, push the release handle with your foot.

11. Move the power pallet truck away from the battery replacement area.

12. Close the battery locking device.

13. Connect the battery connector.

14. Close the battery door.

8 REPAIR

8.1 Repair drive unit

8.1.1 Drive axle lifting and handling

CAUTION
Risk of equipment damage
Risk of injury

The drive axle is heavy. It can break or cause personal injury if it falls or tips over
during handling. Use appropriate handling and hoisting equipment to avoid injuries and
damage to the product.

When lifting the component in its original packaging, refer to the instructions on the packaging
on lifting and handling.

After unpacking the component, handle it according to the following instructions:

Use a tackle lift when handling the product to avoid unnecessary collisions and damage.

When handling the device upside down, always make sure to lift it by the appointed hoisting
points and keep the component as close to the working surface as possible.

Make sure that the component is well balanced and stable.

Wear appropriate safety gear when handling the component.

Make sure that the lifting equipment is set properly, so that there are no objects restricting
the movement of the lifted component.

Figure 184: Lifting points of the drive axle

8.1.2 Remove the drive axle

You can remove or install one drive axle at the time, independent of the other drive axle.

CAUTION
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before you
remove the drive axle, disconnect the battery connector.

NOTICE
The drive axle can get damaged if it drifts, tips or falls when it is moved with a pallet
truck. Place support, for example wooden blocks, under the drive axle when moving it.

NOTE: Before dismantling any part of the truck during maintenance or service tasks,
see 11.1 Special tightening torques.

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Remove the mast, see 8.4.1 Remove the mast.

2. Remove the front wheel, see 6.9.3.1 Remove the front wheel.

3. Disconnect all the wiring.

4. Lift the front part of the truck up.

5. Put supports below the truck frame.

6. Push a pallet truck below the drive axle. Make sure that the drive axle rests on the forks of
the pallet truck.

7. Remove the 6 screws.

8. Remove the drive axle with the pallet truck.

8.1.3 Disassemble the drive axle

CAUTION
Risk of accident
Toxic hazard

Any oil on the floor presents a risk of accident because oil is slippery. Oils used in the
truck and the hydraulic system are toxic substances. Oil can cause skin irritation if it
gets in contact with skin.

Before you disassemble the axle, remove the oil from the transmission.

If you spill oil, clean the spilled oil immediately.

Always wear protective gloves when you handle oil.

NOTICE
Any dirt or dust that gets into the surfaces of the axle can cause equipment damage
and malfunction. When you disassemble the axle, keep the filter valve areas clean.

Figure 185: Exploded view of the drive axle

1. Hub 18. Oil filling plug

2. Seal ring 19. Electric motor housing
3. Bearing 20. Support
4. Oil breather plug 21. Washer
5. Gearbox housing 22. Greaser
6. Screw 23. Screw
7. Oil drain plug 24. Pin
8. O-ring 25. Seal ring
9. Spacer 26. Ring
10. Nut 27. Electric motor
11. Pin 28. Brake pinion gear
12. Toothed ring 29. Shaft key
13. Coupling 30. Screw
14. Reduction assembly 31. Circlip
15. Support 32. Brake
16. Bearing 33. Gasket
17. Sun gear

NOTE: Component numbers in the images in the disassembly and reassembly procedures
correspond to the part list in Figure 185. Not all steps are required for all types of
maintenance and repair procedures.

Before disassembling the drive axle, make sure that all oil is drained. For instructions, see 6.4.3
Lubricate the drive axle.

1. Remove the mast. See 8.4.1 Remove the mast.

2. Remove the oil filler and drain plugs from the gearbox housing.

3. Remove the oil breather plug fron the gearbox housing.

4. Remove the gasket.

5. Remove the screws that connect the brake to the electric motor.

6. Remove the brake.

7. Remove the circlip.

8. Remove the brake pinion gear.

9. Remove the shaft key.

10. Remove the screw from the electric motor.

11. Remove the electric motor.

12. Remove the pin from the electric motor housing.

13. Remove the seal ring.

14. Remove the screws that connect the gearbox housing to the electric motor housing.

15. Remove the gearbox housing and the hub.

16. Remove the support.

17. Remove the bearing and the sun gear.

18. Remove the two bearings from each side of the sun gear.

19. Remove the O-ring from the gearbox housing.

20. Remove the reduction assembly.

21. Remove the pin and the toothed ring from the gearbox housing.

22. Remove the coupling.

23. Remove the ring nut.

NOTICE
When lifting the unit, attach the ring nut to the flanged hub to prevent the gearbox
from falling.

24. Install a pad with the provided dimensions to the gearbox housing when lifting it from the
hub.

25. Remove the bearing from the gearbox housing.

26. Remove the two bearings from the gearbox housing.

27. Lift the spacer off the gearbox hub.

28. Remove the bearing from the gearbox hub.

29. Remove the seal ring from the gearbox hub.

NOTICE
Removing the seal ring damages it. Remove the seal ring only when replacing it.

8.1.4 Assemble the drive axle

Before reassembly, inspect all parts. Gears, bearings, and seals particularly are subject to
heavy wear and can be damaged.

When replacing used or damaged parts, note the following:

Remove any dirt from the parts, and properly clean the seals, bearings and locking ring
seatings.

Lubricate the parts before connecting them.

If a gear is damaged, always replace the entire reduction assembly, never only one gear.

When reconnecting a part, always replace all of the seals, oil plugs, washers and O-rings.

When replacing damaged parts, always use original spare parts only and carefully follow the
manufacturer’s maintenance and repair instructions.

1. Install the bearing inside the gearbox housing.

2. Install two pads with the provided dimensions inside the gearbox housing.

3. Place the bearing onto the pad.

4. Place the gearbox housing onto the pad and bearing.

5. Install the spacer to the gearbox housing.

6. Install the bearing to the gearbox housing.

7. Apply Loctite 243 to the seal ring.

8. Install the seal ring to the gearbox housing.

9. Install the seal ring to its place using a flat pad.

10. Apply Tecnolube Seal GS730/0 to the seal ring.

11. Install the hub to the gearbox housing.

12. Press the hub inside the gearbox housing.

13. Apply Loctite 243 to the ring nut.

14. Install the ring nut inside the gearbox housing. Use a torque multiplier to tighten the nut. The
correct tightening torque is 950–1050 Nm.

NOTICE
When lifting the unit, attach the ring nut to the flanged hub to prevent the gearbox
from falling.

15. Install the coupling to the gearbox housing.

16. Install the pin and toother ring to the gearbox housing.

17. Install the reduction assembly.

18. Install the O-ring to the gearbox housing.

19. Place the sun gear bearing on a pad with the provided dimensions. Make sure that the
central openings are aligned.

20. Connect the sun gear to the sun gear bearing.

21. Install the second sun gear bearing to the sun gear.

22. Install a pad with the provided dimensions on top of the sun gear bearing and push it down.

23. Install the shaft key into the slot on the shaft of the electric motor.

24. Install the brake pinion gear to the shaft of the electric motor.t

25. Install s circlip to the top of the brake pinion gear.

26. Install the brake to the electric motor.

27. Install the screws that secure the brake to the electric motor. The correct tightening torque is
25 Nm.

28. Install the gasket on top of the brake.

29. Apply Loctite 243 to the seal ring.

30. Place the seal ring to the electric motor housing.

31. Install the seal ring using a pad with the provided dimensions.

32. Install the ring to the electric motor housing.

33. Install the pin to the electric motor housing.

34. Place the electric motor housing on the electric motor.

35. Connect the electric motor to the housing with screws. The correct tightening torque is 15
Nm.

36. Install the sun gear to the electric motor housing.

37. Use a depth slide gauge to check the axial distance, to ensure the correct assembly.

38. Install the support on top of the sun gear and the bearing.

39. Make sure that the O-ring remains in the gearbox housing during installation.

40. Place the gearbox housing to the electric motor housing. Make sure that the components are
correctly aligned.

41. Connect the gearbox housing to the electric motor housing with screws. The correct
tightening torque is 70 Nm.

42. Install the oil breather plug to the gearbox housing. The correct tightening torque is 9±1 Nm.

43. Install the oil filler and drain plugs to the electric motor housing. The correct tightening torque
is 10±2 Nm.

8.1.5 Install the electromechanical parking brake

CAUTION
Risk of accident

Lubricating the guiding splines of the electromechanical brake can change the
performance of the brake. This can lead to an accident. Do not grease or lubricate the
guiding splines of the electromechanical brake.

Figure 186: Electromechanical parking brake

1. Electric motor 5. Circlip

2. Brake pinion gear 6. Brake
3. Shaft key 7. Gasket
4. Screw

1. Install the shaft key into the slot on the shaft of the electric motor.

2. Install the brake pinion gear to the shaft of the electric motor.

3. Install a circlip to the top of the brake pinion gear.

4. Install the brake to the electric motor and secure it in place using screws. The correct
tightening torque is 25 Nm.

NOTICE
Make sure you do not damage the splines of the brake disc.

5. Install the gasket on top of the brake.

6. Connect the parking brake to an external power and supply 36-48 V directly to the brake.
Confirm that the friction disc rotates freely.

8.1.6 Install the drive axle

NOTICE
The drive axle can get damaged if it drifts, tips or falls when it is moved with a pallet
truck. Place support, for example wooden blocks, under the drive axle when moving it.

1. Use a pallet truck to insert the drive axle inside the chassis.

2. Push the axle into its place.

3. Connect the axle to the chassis with 6 bolts. The torque is 180 Nm.

4. Connect the wiring.

8.1.7 Test the drive axle

CAUTION
Risk of equipment damage
Risk of injury

Malfunctions such as overcurrent, overheating, noise or vibration can cause serious

damage to the equipment or danger to the personnel. If the drive axle malfunctions
during testing, cut the power immediately and notify service personnel.

NOTE: Check the oil level before testing the drive axle. If necessary, add more oil. See
6.4.3 Lubricate the drive axle.

Follow the safety instructions and use extreme caution during the following procedure:

1. Make sure that the electric wiring is connected properly.

2. Connect the battery connector.

3. Turn the key switch / start switch to the ON position.

4. Start the drive axle without load and at rated voltage.

5. Check the brake opening.

6. Operate the drive axle at low speed. Make sure it works properly and does not cause noise
or vibration. Then, increase the speed slowly.

7. Examine voltage and current values.

8. Make sure that the rotation speed and direction of rotation are correct.

9. Make sure that the operation continues to be smooth and that there is no excessive noise or
vibration.

10. Stop the first run.

11. Examine the drive axle for oil leaks.

12. Check the transmission oil level. See 6.4.3 Lubricate the drive axle.

13. Visually inspect the drive axle for damage or other issues.

8.2 Repair rear axle

8.2.1 Rear axle lifting and handling

CAUTION
Risk of equipment damage
Risk of injury

The rear axle is heavy. It can break or cause personal injury if it falls or tips over during
handling. Do not handle the component manually when installing. Use appropriate
handling and hoisting equipment to avoid injuries and damage to the product.

When lifting the component in its original packaging, refer to the instructions on the packaging
on lifting and handling.

After unpacking the component, handle it according to the following instructions:

Use a tackle lift when handling the product to avoid unnecessary collisions and damage.

When handling the device upside down, always make sure to lift it by the appointed hoisting
points and keep the component as close to the working surface as possible.

Make sure that the component is well balanced and stable.

Wear appropriate safety gear when handling the component.

Make sure that the lifting equipment is set properly, so that there are no objects restricting
the movement of the lifted component.

Figure 187: Rear axle lifting points (3-wheel models)

Figure 188: Rear axle lifting points (4-wheel models)

8.2.2 Rear axle (3-wheel models)

8.2.2.1 Remove the rear axle (3-wheel models)

1. Lift the rear part of the truck up with a jack. Make sure that the rear wheels are lifted off the
ground.

2. Put supports below the truck frame.

3. Remove the rear wheels. See 6.9.4.1 Remove the rear wheels (3-wheel models).

4. Turn the rear axle straight.

5. Disconnect the electric wires.

6. Remove the 4 bolts and disconnect the steering motor from the rear axle.

7. Push a pallet truck below the rear axle. Make sure that the rear axle rests on the forks of the
pallet truck.

8. Remove the 4 bolts that attach the rear axle to the counterweight.

9. Pull the rear axle out.

See 8.2.2.4 Install the rear axle (3-wheel models) for installation instructions.

8.2.2.2 Disassemble the rear axle (3-wheel models)

CAUTION
Risk of accident
Toxic hazard

Before you disassemble the axle, remove the oil from the transmission.

If you spill oil, clean the spilled oil immediately.

Always wear protective gloves when you handle oil.

NOTICE
Any dirt or dust that gets into the surfaces of the axle can cause equipment damage
and malfunction. When you disassemble the axle, keep the filter valve areas clean.

Figure 189: Exploded view of the rear axle gearbox housing

1. Screw 16. NILOS-ring 31. Oil filling plug

2. Electric motor 17. Bearing 32. O-ring
3. O-ring 18. Seal ring 33. Support
4. Sun gear 19. Support 34. Seal ring
5. Reduction assembly 20. Bearing 35. Spacer
6. Sun gear 21. Sun gear 36. Bearing
7. Reduction assembly 22. Pin 37. Hub studs kit
8. Electric motor housing 23. Gasket 38. Bearing
9. Screw 24. Gearbox housing 39. Spacer
10. Screw 25. Oil drain plug 40. Nut
11. Sensor 26. Bearing 41. Split pin
12. Screw 27. NILOS-ring 42. Cap nut
13. Cover plate 28. Circlip 43. Gearbox kit
14. Ring nut 29. Toothed ring
15. Lock spring washer 30. Seal ring

NOTE: Component numbers in the images in the disassembly and reassembly procedures
correspond to the part list in Figure 189. Not all steps are required for all types of
maintenance and repair procedures.

Before disassembling the rear axle, make sure that all oil is drained. For instructions, see 6.8.1
Lubricate the rear axle (3-wheel models).

1. Remove the rear axle. See 8.2.2.1 Remove the rear axle (3-wheel models).

2. Remove the O-ring from the electric motor.

3. Remove the oil filling plug and oil drain plug from the electric motor housing.

4. Remove the sun gear from the electric motor housing.

5. Remove the reduction assembly from the electric motor housing.

6. Remove the second sun gear from the electric motor housing.

7. Remove the second reduction assembly from the electric motor housing.

8. Remove the screws that connect the sensor to the electric motor housing cover.

9. Remove the sensor from the cover.

10. Remove the screw under the sensor.

11. Remove the screws that connect the cover to the electric motor housing.

12. Lift the cover off of the electric motor housing.

13. Use the tool M50 KM10 to remove the ring nut.

14. Remove the lock spring washer.

15. Remove the screws that connect the electric motor housing to the gearbox housing.

16. Remove the electric motor housing.

Use two M8 eyebolts in the holes indicated with red arrows (pointing down) for lifting the
electric motor housing.

Separate the electric motor housing from the gearbox housing using a rubber hammer.

NOTICE
Do not use a scalpel to separate the electric motor housing and the gearbox
housing. Sharp tools can damage the mating surfaces.

After these two housings are separated, carefully remove the old sealing paste from the
mating surfaces.

17. Remove the NILOS-ring.

18. Remove the bearing.

19. Remove the support.

20. Remove the seal ring from the electric motor housing.

21. Remove the circlip and the gasket.

22. Remove the sun gear from the gearbox housing.

23. Remove the toothed ring form the gearbox housing.

24. Remove the two bearings from the sun gear.

25. Remove the gearbox housing.

26. Remove the seal ring from the gearbox housing.

NOTICE
Removing the seal ring damages it. Remove the seal ring only when replacing it.

27. Remove the bearing from the bottom of the gearbox housing.

28. Remove the O-ring.

29. Remove the bearing.

30. Remove the NILOS-ring.

31. Remove the cap nut from the hub studs kit.

32. Remove the split pin.

33. Remove the nut from the hub studs kit.

34. Remove the spacer.

35. Remove the hub studs kit.

36. Remove the bearing and the spacer.

37. Remove the bearing from the hub studs kit.

38. Remove the seal ring from the hub studs kit.

NOTICE
Removing the seal ring damages it. Remove the seal ring only when replacing it.

39. Remove the bearing from the hub studs kit.

40. Remove the bearing from the other side of the hub studs kit.

8.2.2.3 Assemble the rear axle (3-wheel models)

NOTICE
After you have assembled the rear axle, remember to refill the transmission oil.

Before reassembly, inspect all parts. Gears, bearings, and seals particularly are subject to
heavy wear and can be damaged.

When replacing used or damaged parts, note the following:

Remove any dirt from the parts, and properly clean the seals, bearings and locking ring
seatings.

Lubricate the parts before connecting them.

If a gear is damaged, always replace the entire reduction assembly, never only one gear.

When reconnecting a part, always replace all of the seals, oil plugs, washers and O-rings.

When replacing damaged parts, always use original spare parts only and carefully follow the
manufacturer’s maintenance and repair instructions.

1. Use a pad with the provided dimensions to install the bearing to the hub studs kit.

2. Use another pad with the provided dimensions to install the bearing to the bottom of the hub
studs kit.

3. Install the seal ring to the hub studs kit using a flat pad.

4. Apply Tecnolube Seal GS730/0 to the seal ring.

5. Install the spacer.

6. Install the bearing.

7. Install the hub studs kit.

8. Install the bearing to the hub studs kit.

9. Install the spacer to the hub studs kit.

10. Connect the nut to the hub studs kit. The correct tightening torque is 60 Nm.

1. Rotate the hub 2-3 turns in both directions.

2. Retighten the nut. The target torque is a rolling torque of 2±1 Nm.

11. Install the split pin to the hub studs kit.

12. Fill the hub studs kit with Mobilgrease Special.

13. Install the cap nut to the hub studs kit.

14. Install the NILOS-ring.

15. Apply Mobilgrease Special to the NILOS-ring.

16. Install the bearing.

17. Apply Mobilgrease Special to the bearing.

18. Install the O-ring.

19. Install the bearing to the bottom of the gearbox housing using a flat pad with the provided
dimensions.

20. Install the seal ring to the gearbox housing using a pad with the provided dimensions.

21. Install the gearbox housing.

22. Install the toothed ring using a pad with the provided dimensions.

23. Install the circlip.

24. Install the two bearings to both sides of the sun gear using a pad with the provided
dimensions.

25. Install the sun gear with the two bearings to the gearbox housing.

26. Install the gasket on the mating surface of the gearbox housing.

27. Install the seal ring to the electric motor housing using a pad with the provided dimensions.

28. Install the bearing to the electric motor housing using a pad with the provided dimensions.

29. Insert the guide pad with the provided dimensions for seal ring installation.

30. Connect the electric motor housing to the gearbox housing.

31. Remove the guide pad for seal ring installation.

32. Connect the electric motor housing to the gearbox housing with new bolts M8x45-10.9 and
washers ISO 7092-8-300HV B.

33. Pre-tighten two screws on the opposite sides of the assembly.

34. Tighten all screws to 35 Nm in the specified order. Once you have tightened all screws,
tighten them again to make sure the torque is correct.

35. Apply grease (Mobilgrease Special or equivalent) to the area shown in the picture.

36. Install the bearing using a pad with the provided dimensions.

37. Apply grease (Mobilgrease Special or equivalent) to the area shown in the picture.

38. Install the NILOS-ring.

39. Install the lock spring washer.

40. Lubricate the lock spring washer with oil (Synthy Pneumist 3000 or equivalent).

41. Install the ring nut.

1. Tighten the ring nut to 100 Nm.

2. Rotate the support 5-6 turns in both directions.

3. Retighten the ring nut to 170 Nm.

4. Secure the lock spring washer. If it does not match the slot of the ring nut, rotate the ring
nut clockwise but do not tighten more than 220 Nm.

42. Apply Dowsil 7091 on the mating surface of the bottom casting without interruption of the
film.

43. Place the cover plate over the opening.

44. Connect the cover plate to the electric motor housing with screws. The correct tightening
torque is 3 Nm.

45. Install the sensor to the cover plate with screws. See 8.12.3 Replace the rear axle sensor.

46. Install the reduction assembly inside the electric motor housing.

47. Install the sun gear between the two reduction assemblies.

48. Install the second reduction assembly.

49. Install the sun gear after the reduction assemblies.

50. Install the O-ring to the bottom of the electric motor.

51. Install the oil filler and drain plugs. The correct tightening torque is 10±2 Nm.

52. Install the rear axle to the truck. See 8.2.2.4 Install the rear axle (3-wheel models).

53. Install the electric motor to the electric motor housing.

54. Connect the electric motor to the housing with screws. The correct tightening torque is 10
Nm.

8.2.2.4 Install the rear axle (3-wheel models)

1. Make sure that the rear axle is properly assembled.

2. Clean all mating surfaces.

3. Apply protective paste on all mating surfaces to protect the components from corrosion. Use
Klüberpaste 46 MR 401 or Tecnolube WRL 115 or a similar product.

4. Lift the rear part of the truck.

5. Use a pallet truck to insert the rear axle under the counterweight.

6. Use four M16x60 bolts to mount the rear axle to the counterweight.

NOTE: When mounting the rear axle:

Clean the threaded bolt holes carefully.

Replace the locking washers (Nord-lock NLX 16SP) with new ones.

Apply Molykote 100 Thread Paste to the bolts.

7. Tighten the bolts. The correct tightening torque is 280 Nm.

8. Connect the electric wires.

9. Fil the rear axle with transmission oil. See 6.8.1 Lubricate the rear axle (3-wheel models).

8.2.2.5 Test the rear axle (3-wheel models)

CAUTION
Risk of equipment damage
Risk of injury

Malfunctions such as overcurrent, overheating, noise or vibration can cause serious

damage to the equipment or danger to the personnel. If the drive axle malfunctions
during testing, cut the power immediately and notify service personnel.

NOTE: Check the oil level before testing the drive axle. If necessary, add more oil. See
6.8.1 Lubricate the rear axle (3-wheel models).

Follow the safety instructions and use extreme caution during the following procedure:

1. Make sure that the electric wiring is connected properly.

2. Connect the battery connector.

3. Turn the key switch / start switch to the ON position.

4. Start the rear axle without load and at rated voltage.

5. Operate the rear axle at low speed. Make sure it works properly and does not cause noise or
vibration. Then, increase the speed slowly.

6. Examine voltage and current values.

7. Make sure that the rotation speed and direction of rotation are correct.

8. Make sure that the operation continues to be smooth and that there is no excessive noise or
vibration.

9. Measure the oil temperature. It must not exceed 85-90°C.

10. Stop the first run.

11. Examine the rear axle for oil leaks.

12. Check the rear axle lubrication oil level.

13. Visually inspect the rear axle for damage or other issues.

8.2.3 Remove and install the rear axle (4-wheel models)

Remove the rear axle

1. Disconnect the hydraulic hoses.

2. Disconnect the connector of the rear axle sensor. See 8.12.3 Replace the rear axle sensor.

3. Push a pallet truck below the rear axle. Make sure that the rear axle rests on the forks of the
pallet truck.

4. Remove the 4 bolts that attach the rear axle to the counterweight.

5. Lift the rear part of the truck.

6. Pull the rear axle out.

Install the rear axle

NOTE: The correct bolt type for mounting the rear axle is M16×50. The correct tightening
torque is 280 Nm. Use Molykote 1000 Thread Paste when installing the bolts.

To install the rear axle, do the steps of the removal procedure in a reverse order.

8.3 Repair hydraulic system

8.3.1 Remove the pump motor

CAUTION
Electric hazard

There is voltage in the electric system that can cause an electric shock. Before you
remove the pump motor, disconnect the battery connector.

NOTE: Before dismantling any part of the truck during maintenance or service tasks,
see 11.1 Special tightening torques.

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Remove the pedal plate. See 6.2.2 Remove the pedal plate.

2. Disconnect the hydraulic hoses.

3. Disconnect the power cables of the pump motor from the electric panel.

4. Remove the four bolts that attach the pump motor bed to the truck.

5. Remove the 2 bolts and the pump.

6. Remove the 4 bolts and pull out the pump motor bed.

8.3.2 Disassemble the steering unit

Figure 190: Steering unit

1. Pump 4. Filling cap for hydraulic oil tank

2. Hoses for rear axle 5. Motor
3. Oil tank for the pump 6. Electric connectors for the motor

1. Remove the battery. See 7.3 Replace the battery.

2. Leave the battery cover open.

3. Disconnect the hydraulic hoses.

4. Remove two bolts and the oil tank.

5. Remove the oil tank support.

6. Remove the two bolts and the pump.

7. Remove the screws and the pump motor.

8.3.3 Set the lifting pressure

NOTE: The main relief pressure is factory set. Do not change it.

NOTE: The lifting pressure is set with maximum load on the forks above free lift range.

Figure 191: Location of the pressure relief valve in the hydraulic valve unit
with fingertip controls

Figure 192: Location of the pressure relief valve in the hydraulic valve unit
with manual levers

1. Remove the cover of the hydraulic valve block. See 6.2.1 Remove the cover of the hydraulic
valve block.

2. Loosen the locking nut of the pressure relief valve.

3. Lift the forks with maximum load above the free lift height.

4. Adjust the pressure relief valve so that the load rises easily.

5. Tighten the locking nut of the pressure relief valve.

8.3.4 Disassemble the coils

NOTE: This procedure applies to truck models with the armrest.

1. Open the nut at the end of the valve.

2. Pull the coil of the valve out.

To assemble the valves, do the steps in a reverse order.

NOTE: During reassembly, manually tighten the nut at the end of the valve. Do not
overtighten the nut.

8.3.5 Disassemble the M1, M2 and M9 valves

NOTE: This procedure applies to truck models with the armrest.

Figure 193: M1 and M2 valves

Figure 194: M9 valve

1. Open the nut at the end of the valve.

2. Pull the coil of the valve out.

To assemble the valves, do the steps in a reverse order.

After assembling the coils or replacing the valve unit, adjust the lifting and lowering speeds.
See 6.6.8 Lifting and lowering speed.

NOTE: During reassembly, manually tighten the nut at the end of the valve. Do not
overtighten the nut.

8.3.6 Remove the clamp release valve

1. Remove the pedal plate, see 6.2.2 Remove the pedal plate.

2. Disconnect all the wires.

3. Disconnect the hydraulic pipes.

4. Remove the 2 screws that attach the clamp release valve to the truck.

5. Remove the clamp release valve.

8.4 Repair mast

8.4.1 Remove the mast

WARNING
Toxic hazard

If the forks are raised when you disconnect hydraulic hoses, oil will spill out of the
hydraulic system with hight pressure. Oils used in the truck and the hydraulic system
are toxic substances and can cause skin irritation if they get in contact with skin.
Before you remove the mast, lower the forks to the down position to minimize oil
pressure in the hydraulic circuit.

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

NOTE: If your truck has the tilt centering function, you must remove the lever of the tilt
centering sensor before you remove the mast.

1. Lower the forks all the way down.

2. To support the mast, attach a lifting device on top of the mast and tighten the lifting
ropes/chains.

NOTE: Make sure that you use applicable lifting devices and follow the safety
instructions given by the lifting device manufacturer.

3. Tilt the mast forward.

4. Disconnect the wire of the working lights.

5. Disconnect the hoses.

6. Remove the screw that attaches the tilt cylinder to the mast.

7. Remove the shaft with a special extraction tool, see 4.3 Special tools.

8. With the lifting device, tilt the mast further forward.

NOTE: Make sure that you use applicable lifting devices and follow the safety
instructions given by the lifting device manufacturer.

9. Disconnect the hydraulic piping.

10. Remove the greaser.

NOTE: When installing the mast, tighten the greaser to 9±1 Nm.

11. Remove the screws that attach the mast to the drive axle.

NOTE: When installing the mast, tighten the screws to 70 Nm.

12. With the lifting device, lift the mast up.

To install the mast, repeat the steps in a reverse order.

8.4.2 Disassemble the mast

8.4.2.1 Disassemble the simplex mast

MANDATORY ACTION
During the disassembly of the mast, mark down the direction of the different hydraulic
connectors, the correct attachment points, direction of the rollers and the correct
positioning of the hydraulic hoses and pipes.

During the assembly of the mast, make sure that all the hydraulic connections,
attachment points, roller directions and hose and pipe positions are the same as before
disassembly.

MANDATORY ACTION
Prepare a drip pan to catch any remaining oil in the pipes and hoses before
disconnecting each pipe. Take appropriate actions to prevent dust and dirt from
entering in the opening of the pipe and valve connections.

1. Remove the lifting carriage, see 8.5.1 Remove the lifting carriage.

2. Remove the mast, see 8.4.1 Remove the mast.

3. Remove the locking pins from the top chain anchors.

4. Remove the 2 nuts from the top chain anchors.

5. Remove the top chain anchors from the mounting holes.

6. Slide the chains off the chain wheels.

7. Remove the hydraulic piping from the cylinders.

8. Remove the hose fasteners.

9. Remove the hydraulic hoses.

10. Lay the mast down onto a pallet or a strong table.

11. Remove the 2 screws that attach the working light to the mast.

12. Remove the working light.

13. Remove the side cylinders, see 8.4.5.1 Replace the side cylinders.

14. Remove the 2 screws that hold the hose wheel holder in position.

15. Remove the hose wheel holder and the hose wheel.

16. Remove the circlip that attaches the hose wheel to the hose wheel holder.

17. Remove the hose wheel from the hose wheel holder.

18. Remove the circlip that attaches the chain wheel to the first internal mast.

19. Remove the chain wheel.

20. Push the first internal mast to the down position.

21. Remove the main rollers.

22. Remove the adjustment rings.

23. Slide the first internal mast out.

8.4.2.2 Disassemble the duplex mast

During the assembly of the mast, make sure that all the hydraulic connections,
attachment points, roller directions and hose and pipe positions are the same as before
disassembly.

1. Remove the lifting carriage, see 8.5.1 Remove the lifting carriage.

2. Remove the mast, see 8.4.1 Remove the mast.

3. Remove the locking ties from the chain anchors of the free lift cylinder.

4. Remove the 2 nuts from the chain anchors of the free lift cylinder.

5. Remove the chain anchors of the free lift cylinder from the mounting holes.

6. Remove the hydraulic piping from the cylinders.

7. Remove the upper and lower hose guides.

8. Remove the hydraulic hoses/pipes.

9. Slide the middle hose roller to the right and remove the second screw that attaches the hose
guide to the chain yoke.

10. Remove the chain yoke and the circlip.

11. Remove the screws that attach the free lift cylinder to the first internal mast.

12. Remove the free lift cylinder.

13. Remove the hose guide holder.

14. Remove the screws that attach the hose guides to the mast.

15. Remove the hose guides.

16. Lay the mast down onto a pallet or a strong table.

17. Remove the 2 screws that attach the working light to the mast.

18. Remove the working light.

19. Remove the screws that attach the hose guide holder to the first internal mast.

20. Remove the side cylinders. See 8.4.5.1 Replace the side cylinders.

21. Push the first internal mast to the down position.

22. Remove the main rollers.

23. Remove the adjustment rings.

24. Slide the first internal mast out.

When assembling the duplex mast, make sure that the hoses attached to the hydraulic pipes
are placed correctly. Measure that the bottom of the bend in the hydraulic hose is 10 cm from
the end of the hose guide. See Figure 195.

Figure 195: Measure the distance from the end of the hose guide to the
bottom of the bend in the hydraulic hose

8.4.2.3 Disassemble the triplex mast

During the assembly of the mast, make sure that all the hydraulic connections,
attachment points, roller directions and hose and pipe positions are the same as before
disassembly.

1. Remove the lifting carriage, see 8.5.1 Remove the lifting carriage.

2. Remove the mast, see 8.4.1 Remove the mast.

3. Remove the locking ties from the chain anchors of the free lift cylinder.

4. Remove the 2 nuts from the chain anchors of the free lift cylinder.

5. Remove the chain anchors of the free lift cylinder from the mounting holes.

6. Remove the hydraulic piping from the cylinders.

7. Remove the hose fasteners.

8. Remove the hydraulic hoses/pipes.

9. Remove the circlip that attaches the chain yoke cover to the hose guide.

10. Remove the chain yoke.

11. Remove the screws that attach the free lift cylinder to the first internal mast.

12. Remove the free lift cylinder.

13. Lay the mast down onto a pallet or a strong table.

14. Remove the 2 screws that attach the working light to the mast.

15. Remove the working light.

16. Remove the circlip that attaches the chain wheel to the chain wheel holder.

17. Remove the chain wheel from the chain wheel holder.

18. Remove the circlip that attaches the hose wheel to the second internal mast

19. Remove the hose wheel.

20. Remove the side cylinders. See 8.4.5.1 Replace the side cylinders.

21. Push the first internal mast to the down position.

22. Remove the main rollers.

23. Remove the adjustment rings.

24. Slide the first internal mast out.

25. Push the second internal mast to the down position.

26. Remove the main rollers.

27. Remove the adjustment rings.

28. Slide the second internal mast out.

8.4.3 Repair mast chains

8.4.3.1 Adjust the mast chains

Figure 196: Components used to adjust the mast chains

1. Anchor bolt 3. Upper double nut

2. Locking nut 4. Lower double nut

To adjust the mast chains:

1. Remove the blocks that were put under the forks during the inspection of the mast chain
tension.

2. Set the key switch to the ON position.

3. Lower the forks until they touch the ground.

4. Tilt the forks forward until the tips of the forks touch the ground. The chains become loose so
that you can adjust the chains.

5. Set the key switch to the OFF position.

6. Loosen the lower double nut.

7. Loosen the locking nut.

8. Turn the upper double nut to adjust the chain tension.

9. Set the key switch to the ON position.

10. Move the mast back to the vertical position.

11. Inspect the tension of the mast chain again, see 6.6.3 Chain tension.

12. To tighten the locking nut, hold the anchor bolt witch a wrench and tighten the locking nut to
the correct torque. Make sure that you do not twist the chain. See the correct tightening
torque in Table 82.

13. To tighten the lower double nut, hold the upper double nut with a wrench and tighten the
lower double nut to the correct torque. See the correct tightening torque in Table 82.

14. When the lift cylinders are fully extended or retracted, make sure that the protrusion of each
main roller is no more than 40% of the roller diameter. See Figure 197.

Figure 197: Protrusion of the main rollers

Table 82: Tightening torques of the mast chain nuts

1.4 - 2.0 TON CLASS

Locking nut 55 - 70 Nm

Lower double
100 - 120 Nm
nut

8.4.3.2 Replace the mast chains

WARNING
Risk of accident

Figure 198: Principles of chain routing

When you replace the mast chains, make sure that the new chains are of the correct length.
Replace the chain when the elongation is 2% or more.

To replace the mast chains:

1. Remove the mast chains. Mark down the correct attachment points of the chains. For
instructions on removing the mast chains, see the relevant steps in 8.4.2.1 Disassemble the
simplex mast.

2. Attach a chain anchor to one end of each new chain.

3. Slide the free end of the chain onto the chain wheel.

4. Install a locking tie to the top chain anchor.

5. Install the top chain anchor to the mounting hole. The principle for correct chain routing is
illustrated in Figure 198.

6. Install the 2 nuts to the top chain anchor. Do not tighten the nuts.

7. Attach the chain anchor to the other end of the chain.

8. Install the bottom chain anchor to the mounting hole. The principle for correct chain routing is
illustrated in Figure 198.

9. Install the 2 nuts to the chain anchor. Do not tighten the nuts.

10. Adjust the chain tension according to the instructions provided in 8.4.3.1 Adjust the mast
chains.

8.4.4 Repair free lift cylinder

8.4.4.1 Replace the free lift cylinder

MANDATORY ACTION
During the removal of lift cylinders, mark down the direction of the different hydraulic
connectors, the correct attachment points and the correct positioning of the hydraulic
hoses and pipes.

During the installation of new lift cylinders, make sure that all the hydraulic
connections, attachment points and hose and pipe positions are the same as before
disassembly.

MANDATORY ACTION
During the installation of new lift cylinders, make sure that the hose break valve is in
the correct position. The hose break valve is located at the bottom of the lift cylinder.

This valve is a safety valve which regulates the oil flow to prevent the fork from moving
down too quickly if the piping between the lift cylinder and lowering valve is broken, or
if the return oil flow from the lift cylinder becomes excessive due to an incorrectly
adjusted proportional valve or a fault of another component.

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Remove the free lift cylinder.

2. Remove the cap from the new free lift cylinder.

3. Install the hose break valve.

4. Attach the connector to the bottom of the free lift cylinder. Do not tighten the connector.

5. Install the adjustment plates.

6. Install the new free lift cylinder. Make sure that the hydraulic connectors point to the correct
direction.

7. Install the screws that hold the free lift cylinder in position.

8. Install the chain yoke to the top of the free lift cylinder.

9. Install the chain yoke locking screw.

10. Add protective wax to the chain yoke.

11. Install the free lift cylinder chain.

12. Attach and tighten the hydraulic pipes / hoses.

13. Install the hose fasteners.

14. Tighten all hydraulic connections.

8.4.4.2 Sealing housing of the free lift cylinder

Figure 199: Sealing housing of the free lift cylinder

1. Seal 3. Seal
2. O-ring 4. O-ring

If you notice an oil leak, first make sure that the cylinder piston is not damaged. Examine the
outside surface of the piston on the whole length passing the housing (with the cylinder fully out)
for any scratches.

If there are any scratches on the piston surface, replace the entire cylinder with a new
one. Otherwise the scratches will damage the new seals and the leak continues.

If the piston surface is not damaged, replace the seals.

The recommended solution is to replace the entire sealing housing (including the factory-
assembled seals). When replacing the entire sealing housing, the installation is simpler and you
can avoid damaging the gaskets when performing the installation. However, if you prefer to
replace just the seals, it is also possible to order only the gasket kit for each cylinder.

To disassemble the sealing housing:

1. Remove the free lift cylinder. For instructions, see the related steps in 8.4.4.1 Replace the
free lift cylinder.

2. Mount the free lift cylinder onto a work bench.

3. Use a hook spanner (see 4.3 Special tools) to unscrew the sealing housing.

To assemble the sealing housing, do the steps in a reverse order.

8.4.5 Repair side cylinders

8.4.5.1 Replace the side cylinders

During the installation of new lift cylinders, make sure that all the hydraulic
connections, attachment points and hose and pipe positions are the same as before
disassembly.

MANDATORY ACTION
During the installation of new lift cylinders, make sure that the hose break valve is in
the correct position. The hose break valve is located at the bottom of the lift cylinder.

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Remove the mast from the truck. For instructions, see 8.4.1 Remove the mast.

2. Remove the hydraulic hose.

3. Lay the mast down onto a pallet or a strong table.

4. Disconnect the hydraulic connector at the bottom of the side cylinder.

5. Remove the screw that attaches the side cylinder to the top of the mast.

6. Pull the internal masts out to extend the mast to its full height.

7. Remove the screw that attaches the side cylinder collar to the mast.

8. Remove the side cylinder piston.

8.4.5.2 Sealing housing of the side cylinder

Figure 200: Sealing housing of the side cylinder

1. O-ring 3. Rod seal

2. Sealing house 4. Wiper

If there are any scratches on the piston surface, replace the entire cylinder with a new one.
Otherwise the scratches will damage the new seals and the leak continues.

If the piston surface is not damaged, replace the seals.

To disassemble the sealing housing:

1. Remove the side cylinder. For instructions, see the related steps in 8.4.5.1 Replace the side
cylinders.

2. Mount the side cylinder onto a work bench.

3. Use a hook spanner (see 4.3 Special tools) to unscrew the sealing housing.

To assemble the side cylinder, do the steps in a reverse order.

8.4.6 Repair tilt cylinders

8.4.6.1 Remove the tilt cylinders

NOTE: When you change the tilt cylinder from the right side, first remove the right side
cover and the fuse box. See 6.2.11 Remove the right side cover.

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Remove the pedal plate, see 6.2.2 Remove the pedal plate.

2. Remove the step cover, see 6.2.9 Remove the step cover.

3. Attach a lifting device to the mast and tighten the chains or ropes

NOTE: Make sure that you use applicable lifting devices and follow the safety
instructions given by the lifting device manufacturer.

4. Remove the bolt that attaches the cylinder shaft to the mast.

5. Remove the first tilt cylinder shaft.

6. Disconnect the hydraulic hoses.

7. Remove the bolt that attaches the cylinder shaft to the truck frame.

8. Remove the second tilt cylinder shaft.

9. Remove the tilt cylinder.

8.4.6.2 Disassemble the tilt cylinder

Figure 201: Sealing housing of the tilt cylinder

1. Seal 3. Seal
2. O-ring

1. Remove the tilt cylinder, see 8.4.6.1 Remove the tilt cylinders.

2. Remove the head, the dust covers (on both ends), the sliding bearing and the greasing
nipple.

3. Remove the guide bushing, the seals and the o-ring.

4. Remove the cylinder tube, cylinder head and bushing.

8.4.7 Replace the main rollers of the mast

The main rollers must be replaced if they jam.

1. Disassemble the mast as instructed in 8.4.2 Disassemble the mast. Note the correct
placement of the main rollers for reassembly.

2. Check that the main roller moves freely in and out of the grooves. If the roller gets stuck in
the groove, hone the groove.

3. Clean the grooves with pressurized air.

4. Install the adjustment rings of the main rollers. If necessary, increase the number of the
adjustment rings. Make sure that the play in the tightest point is no more than 0.5 mm.

5. Install the new main rollers.

6. Grease all the groove surfaces with Vaseline.

7. Assemble the mast.

8.5 Repair lifting carriage

8.5.1 Remove the lifting carriage

WARNING
Risk of injury

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Lower the forks.

2. Remove the battery, see 7.3 Replace the battery.

3. Support the truck frame so that the front wheels are slightly lifted from the ground.

4. Lift the fork latch to free the fork.

5. Slide the forks to the middle of the lifting carriage.

6. Remove the forks from the lifting carriage.

7. Lift the lifting carriage up with a lifting device.

NOTE: Make sure that you use applicable lifting devices and follow the safety
instructions given by the lifting device manufacturer.

8. Remove the hydraulic connectors from the sides of the lifting carriage.

9. Put plugs in the hydraulic connectors on the mast side to prevent oil leakage.

NOTE: If your truck has a simplex mast, you can now remove the lifting carriage from
the mast.

10. Remove the hose holder parts from the middle of the lifting carriage.

11. Remove the locking nuts below the lifting carriage. Lift the chains off from the lifting carriage.

12. Put support blocks under the lifting carriage.

13. Lower the lifting carriage on the support blocks and remove the lifting device from the lifting
carriage.

14. Attach a lifting device to the top of the internal mast that the lifting carriage is mounted on.
Tighten the lifting ropes/chains.

NOTE: Make sure that you use applicable lifting devices and follow the safety
instructions given by the lifting device manufacturer.

15. Lift the mast up from the internal mast.

16. Remove the lifting carriage.

8.5.2 Adjust the rollers of the lifting carriage

Figure 202: Guidance roller components

1. Sliding pad 4. Shim plate

2. Main roller 5. Adjustment ring
3. Locking screw

To adjust the guidance rollers, add or remove shim plates.

To adjust the main rollers, add or remove adjustment rings.

8.5.3 Replace the guidance rollers of the lifting carriage

1. Remove the lifting carriage, see 8.5.1 Remove the lifting carriage.

2. Remove the screws that attach the guidance rollers to the lifting carriage.

3. Remove the guidance rollers.

4. Remove the holding brackets of the guidance rollers.

5. Remove the shim plates.

8.5.4 Replace the main rollers of the lifting carriage

1. Remove the lifting carriage, see 8.5.1 Remove the lifting carriage.

2. Remove the lower main rollers from the lifting carriage.

3. Remove the adjustment rings.

4. Remove the screws that attach the upper main rollers to the lifting carriage.

5. Remove the upper main rollers.

6. Remove the adjustment rings.

8.5.5 Replace the load backrest

CAUTION
Risk of accident

If the load backrest falls and hits a person, it can result in injury. Before you remove the
bolts of the load backrest, attach a lifting device to the load backrest and tighten the
lifting rope/chain to make sure that the load backrest does not fall.

To remove the load backrest:

1. Remove the 4 bolts from the sides of the load backrest.

2. Remove the load backrest.

To install the load backrest, do the steps in a reverse order.

If you remove the load backrest permanently, you must install a stopper plate with bolt on each
side of the lifting carriage to prevent fork arms from falling accidentally, see Figure 203.

Figure 203: Stopper plates

8.5.6 Repair integrated sideshift carriage

8.5.6.1 Troubleshooting integrated sideshift carriage

Table 83: Troubleshooting

FAULT CAUSE ACTION

Insufficient oil pressure Examine and / or adjust the truck’s hydraulic

and / or flow pump
Debris or deformity on
Clean the sliding tracks
Does not shift the sliding tracks
sideways Obstruction or breakage Remove the obstruction or replace the
in the hydraulic circuit damaged flexible hose
Examine or replace seals, rod guidelines or
Defective cylinders
cylinders
Insufficient oil pressure Examine and / or adjust the hydraulic pump
and / or flow of the truck and the oil level in the tank
Debris or deformity on
Side shifting is Clean the sliding tracks
the sliding tracks
slow and
uneven Examine or replace seals, rod guidelines or
Defective cylinders
cylinders
Residual air in the Examine the oil level in the tank. Remove
hydraulic circuit the residual air

8.5.6.2 Disassemble the mobile frame

WARNING
Risk of accident

Applying pressure to the hydraulic circuit causes mechanical movement in the

cylinders. This can result in injury. Additionally, hydraulic oil will splill out of the
system. Do not add pressure to the hydraulic circuit when the mobile frame has been
removed.

NOTE: Use lifting slings when removing and installing the mobile frame. Make sure that the
capacity of the used lifting device is sufficient.

1. Support the frame with lifting slings.

2. Remove the lower hooks with ISO 2936 Allen key.

3. Turn the lower part of the moveable frame forward.

4. Lift to separate from the lifting carriage chassis.

8.5.6.3 Replace the sliding blocks

1. Replace the sliding blocks if the thickness is less than 2 mm.

8.5.6.4 Remove the piston of the integrated sideshift cylinder

NOTICE
Dust and dirt can damage the cylinder piston rod and gaskets. When performing
maintenance on the cylinder piston rod and gaskets, take special precautions to make
sure that your hands, tools and working environment are clean.

1. Disassemble the mobile frame. See 8.5.6.2 Disassemble the mobile frame.

2. Remove the piston of the sideshift cylinder.

NOTE: If it is difficult to remove the piston, cover it with a layer of rubber and then turn it
in both directions with pliers until it comes out of the cylinder chamber.

8.5.6.5 Sealing housing of the integrated sideshift cylinder

Figure 204: Overview of the sealing housing of the integrated sideshift

cylinder

1. Wiper 3. Seal
2. First rod guide 4. Second rod guide

To disassemble the sealing housing of the integrated sideshift cylinder:

1. Remove the sideshift cylinder piston, see section 8.5.6.4 Remove the piston of the integrated
sideshift cylinder.

2. Remove the wiper.

3. Remove the first rod guide

4. Remove the seal.

5. Remove the second rod guide.

Figure 205: Gasket assembly direction

Ensure the rounded end of the rods are facing out once reassembled.

8.5.6.6 Disassemble the upper sliding blocks and lower rollers

1. Disassemble the mobile frame. See 8.5.6.2 Disassemble the mobile frame.

2. Disassemble the upper sliding blocks attached to the upper bar with a screwdriver.

3. Use a 4 mm pin punch to extract the elastic pin.

4. Slide out the pivot with the aid of a mallet.

To assemble the roller, do the steps in a reverse order.

To reassemble to mobile frame, do the steps in 8.5.6.2 Disassemble the mobile frame in a
reverse order.

8.5.6.7 Bleed the hydraulic circuit of the integrated sideshift carriage

There can be air in the hydraulic circuit after maintenance work. After you have reassembled
the integrated sideshift carriage and reconnected the hydraulic tubes, you must bleed the
hydraulic circuit to remove any air from it.

Figure 206: Bleed the hydraulic circuit of the integrated sideshift carriage

1. Bleeding plugs 2. ISO 2963 5 mm Allen key

To bleed the hydraulic circuit of the integrated sideshift carriage:

1. Shift the forks completely to the left with the control lever.

2. Loosen the bleeding plug carefully using a ISO 2936 5 mm Allen key to release the air inside
the hydraulic circuit.

3. When oil starts coming out of the bleeding plug, tighten the plug. The correct tightening
torque is 10 Nm.

4. Shift the forks completely to the right and repeat the process on the cylinder on that side.

8.5.7 Repair integrated fork positioner with sideshift

8.5.7.1 Troubleshooting the fork positioner with sideshift

Table 84: Troubleshooting

FAULT CAUSE ACTION

Obstacles or dirt Remove obstacles, clean and grease the sliding

on sliding tracks tracks
Examine and adjust the truck’s pump pressure.
Insufficient Do not exceed the maximum rated lifting pressure.
hydraulic Only increase the pressure if it is too low. For
pressure example, do not increase the pressure to dislodge a
Forks do not jammed part.
move
Obstruction or
breakage in the Remove the obstruction or replace the damaged hose.
hydraulic circuit
Internal leak in
the cylinder Examine and replace the gaskets.
(worn gaskets)
Examine and adjust the flow rate supplied from the
hydraulic circuit. Adjust the truck’s oil flow.
Insufficient oil
Use Trucktool to verify and adjust the opening of AUX
flow
hydraulic function valve and the pump speeds related
to AUX hydraulics.
Forks move
Obstruction or
too slowly Remove the obstruction or replace the damaged
breakage in the
flexible hose.
hydraulic circuit
Internal leak in
the cylinder Examine and replace the gaskets.
(worn gaskets)
Examine and adjust the flow rate supplied from the
Fork
hydraulic circuit. Adjust the truck’s oil flow.
movement
High oil flow Use Trucktool to verify and adjust the opening of AUX
occurs too
hydraulic function valve and the pump speeds related
fast
to AUX hydraulics.

Forks’ Obstacles or dirt Remove obstacles, clean and grease the sliding
movement is on sliding tracks tracks.
not Close the forks: bring them to the end of the stroke for
synchronized Small oil leaks
a few seconds.

Deformed frame Replace the frame.

Mud or other
obstructions on
Clean and lubricate the sliding blocks.
the track of the
lower pads
Flexible hoses
Replace the hoses.
are worn
Obstructions in
Side shifting the hydraulic Remove the obstruction.
does not circuit
work Insufficient
Increase pressure.
pressure
Pump
Repair or replace the truck’s pump.
deteriorated
Defective Replace the seals and / or the guides and if necessary
cylinder the rods.
Adjustable lower
hooks not Set them according to the instructions.
correctly set
Cylinder gasket Replace the seals and / or the guides and if necessary
seals worn the rods.
Replace the sliding blocks after you have cleaned and
Slide pads worn
greased them.
Emulsified oil,
the pump sucks Examine the oil level in the tank.
air
Side shifting Pump
occurs too Repair or replace the truck’s pump.
deteriorated
slowly
Increase the pressure.
Do not exceed the maximum rated lifting pressure.
Insufficient
Only increase the pressure if it is too low. For
pressure
example, do not increase the pressure to dislodge a
jammed part.
Adjustable lower
hooks not Set them according to the instructions.
correctly set
Air in the
Flush the truck system and examine the oil level.
hydraulic system
Debris or other
on the track of
Clean the track and lubricate the sliding blocks.
Side shifting the lower sliding
is jerky or blocks
irregular Replace the sliding blocks after you have cleaned and
Slide pads worn
greased them.
Adjustable lower
hooks not Set them according to the instructions.
correctly set

Side Air in the system Flush the plant.

movement
occurs only Defective Replace the seals and / or plugs with the relative
on one side cylinder guides and rods, if damaged.

8.5.7.2 Hydraulic system (Fork positioner)

Figure 207: Hydraulic diagram

Figure 208: Hydraulic connections

To open the forks, apply pressure on the middle valve.

Figure 209: Opening the forks

To close the forks, apply pressure on the lower valve.

Figure 210: Closing the forks

Table 85: Recommended oil flow and working pressures

Minimum 7 l / min
Oil flow rate, Fork positioner Recommended 9 l / min
Maximum 15 l / min

Minimum 4 l / min
Oil flow rate, Sideshift Recommended 10 l / min
Maximum 15 l / min

Hydraulic functions and pressure

recommendations

Fork adjustment pressure Min 14 Mpa, Max 25 MPa

Min 12 Mpa, Max 22 MPa (maximum sideshift

Side thrust pressure
connection 25 MPa)

Sideshifter hydraulic system

When you add oil in the right cylinder chamber, the positioner moves to the right. When you add
oil into the left cylinder chamber, the positioner moves to the left.

8.5.7.3 Disassemble the fork shifting cylinders

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Extend the cylinders as far as possible. Shift the positioner completely to either side
depending on which fork shifting cylinder you are disassembling.

Shift the positioner to the right when disassembling the left fork shifting cylinder.

Shift the positioner to the left when disassembling the right fork shifting cylinder.

2. Remove the nut of the fork support using the CH27 socket wrench. Block the rod with a
CH19 fixed wrench.

3. Retract the cylinder and disconnect the hydraulic hoses.

4. Remove the nut on the back with the CH30 socket wrench.

To assemble the cylinder, do the steps in a reverse order.

8.5.7.4 Disassemble the mobile frame of the positioner

WARNING
Risk of accident

Applying pressure to the hydraulic circuit causes mechanical movement in the

cylinders. This can result in injury. Additionally, hydraulic oil will splill out of the
system. Do not add pressure to the hydraulic circuit when the mobile frame has been
removed.

NOTE: Use lifting slings when removing and installing the mobile frame. Make sure that the
capacity of the used lifting device is sufficient.

1. Detach the auxiliary hydraulic hoses of the mast from the fittings of the fork positioner.

Follow the precautions in .

2. Disassemble the forks. See 8.5.7.7 Install the forks and do the steps in a reverse order.

3. Remove the lower adjustable hooks. Loosen the screws with a 10 mm Allen key.

4. Place lifting slings under the upper cross strut of the mobile frame. Attach them to a suitable
lifting device with suitable lifting capacity.

5. Tilt the frame forward slightly and then lift it to release it from the lifting carriage chassis
together with the hoses and the hose fastening bracket.

8.5.7.5 Disassemble the fork supports

1. Open the forks as wide as possible. Follow the precautions in .

2. Remove the forks from the supports. Do the steps in 8.5.7.7 Install the forks in a reverse
order.

3. Remove the screws using a 6 mm Allen key.

4. Hold the support and slide out one of the chromed bars half way.

5. Remove the nut of the fork support using a CH27 socket wrench. Block the rod with a CH19
fixed wrench.

6. Remove the support from the chromed bar carefully.

7. Clean the sliding block area and the bushings chamber.

8. Replace the sliding blocks if they are worn.

9. Grease the bushings chamber and the sliding blocks. Reassemble by doing the steps in a
reverse order.

10. Make sure you assemble both left and right fork supports correctly.

11. Tighten the screws with Loctite 270 threadlocker.

12. Center the attachment hole of the chromed bar.

13. Install the forks. See 8.5.7.7 Install the forks.

8.5.7.6 Replace the seals of the fork shifting cylinder

Figure 211: Fork shifting cylinder assembly

1. Wiper 5. Rod
2. Seal 6. Seal
3. Seal housing 7. Seal
4. Seal

1. Disassemble the fork shifting cylinders. See 8.5.7.3 Disassemble the fork shifting cylinders.

2. Unscrew the seal housing with a spanner wrench.

3. Remove the seal housing, rod, wiper and the seals (2, 4) from the cylinder housing.

4. Replace all seals.

5. To assemble the cylinder, do the steps in a reverse order.

6. Make sure the seals are clean and oriented correctly.

8.5.7.7 Install the forks

NOTE: The maximum allowed length of the forks is 2400 mm.

1. Loosen the 2 screws with a 19 mm Allen key and remove the pivot.

2. Lift the fork lock pivot.

3. Slide the fork into the FEM profile support and lower the fork lock pivot.

4. Place lock on the support and tighten the 2 screws to 150 Nm.

5. Repeat the procedure on the second fork.

8.5.7.8 Connect the hydraulic hoses

1. Connect the auxiliary hoses of the mast to the fitings of the fork positioner. Tighten according
to the used fittings’ standards.

2. Test the movement of the forks by using hydraulic features.

3. Examine the fitting area for leaks. In there is a leak, remove the affected fittings and clean
them thoroughly.

4. Test the speed and synchronised movement of the forks. The synchronisation of the forks is
provided by cylinders in series with varying diameters (Ø 35-42) and the device is integrated
into the cylinders. For recommended oil and pressure, see Table 85 in section 8.5.7.2
Hydraulic system (Fork positioner).

5. Use the sideshift without a load. Go to the end of the stroke in both directions. Hold the
control for a few seconds.

6. Examine the hydraulic connections. If there is an oil leak, disassemble and clean the fittings.
Tighten according to the standards.

NOTE: Forks could stop moving in a synchronised manner if there are very small oil leaks
and other causes related to use. Close the forks and hold them at the end of the stroke for a
few seconds.

8.5.7.9 Assemble the integrated fork positioner

To assemble the integrated fork positioner, repeat the steps in 8.5.7.4 Disassemble the mobile
frame of the positioner in a reverse order.

8.5.7.10 Reset the equipment and bleed the hydraulic circuit

To restore operation after maintenance and repair procedures, return the equipment to its initial
state and do the following tests.

After procedures described in sections 8.5.7.9 Assemble the integrated fork positioner,
8.5.7.8 Connect the hydraulic hoses and 8.5.7.7 Install the forks, sideshift the forks to the
end of the stroke. Hold the control for a few seconds to apply maximum nominal pressure to
the cylinder and fittings. If no leakage occurs, the fork positioner is ready for use.

Make sure that the hydraulic connections hold perfectly.

If there are even small oil leaks, disassemble and clean the fittings. Tighten them according
to the specifications.

If you have performed maintenance or repair operations on the hydrauli circuit of the equipment,
some air can remain in the circuit. As with the procedure used to synchronise the forks, close
the forks completely and hold the control for 10 to 15 seconds to bleed any air from the fork
positioning hydraulic circuit.

8.5.8 Repair hook-on sideshift carriage

8.5.8.1 Remove the hook-on sideshift frame

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

1. Lift the fork latch to free the fork.

2. Slide the forks to the middle of the lifting carriage.

3. Remove the forks from the lifting carriage.

4. Remove the screws that attach the hook-on sideshift cylinder to the lifting carriage.

5. Remove the hooks.

6. Disconnect the hoses.

7. Remove the hook-on sideshift frame from the lifting carriage.

8.5.8.2 Remove the hook-on sideshift cylinder piston

1. Remove the hook-on sideshift cylinder frame. See 8.5.8.1 Remove the hook-on sideshift
frame.

2. Lay the hook-on sideshift frame down onto a pallet or a strong table.

3. Remove the sideshift cylinder retainer pins.

4. Remove the upper bearings.

5. Remove the sideshift cylinder.

8.6 Repair pedals

8.6.1 Remove the accelerator pedal

1. Remove the pedal plate, see 6.2.2 Remove the pedal plate.

2. Disconnect the connector.

3. Remove the 2 screws that attach the pedal to the pedal plate.

4. Remove the pedal.

8.6.2 Remove the brake pedal

1. Remove the pedal plate. See 6.2.2 Remove the pedal plate.

2. Disconnect the connector.

3. Remove the 2 screws that attach the pedal to the pedal plate.

4. Remove the pedal.

8.6.3 Remove the electronic friction lock pedal

1. Remove the pedal plate. See 6.2.2 Remove the pedal plate.

2. Disconnect the connector.

3. Remove the 2 screws and remove the pedal from below.

8.6.4 Remove the dual pedal plate

1. Remove the rubber mat.

2. Remove the screws.

3. Remove the dual pedal plate.

8.6.5 Remove the dual pedal

NOTE: If you do not replace the bearings, you can skip steps 5-7.

1. Remove the dual pedal plate, see 8.6.4 Remove the dual pedal plate.

2. On the sides of the dual pedal, remove the 3 circlips.

3. Remove the shafts.

4. Disconnect the links.

5. Remove the shaft bushings.

6. Remove the bearings.

7. Remove the circlips below the dual pedals.

8. Remove the pins below the dual pedals.

9. Remove the pedals.

8.6.6 Adjust the dual pedal

1. Make sure that the pedals are in the neutral position.

2. Tighten the adjustment nut on both pedals so that there is no play between the shaft and the
dual pedal lever.

3. Tighten the locking nut on both pedals.

4. Apply Loctite 243 on the locking nut.

8.6.7 Adjust the direction sensor of the dual pedal

Make sure that the voltage from output 3 is 2.5±0.1 V when the dual pedal is in the neutral
position.

1. Make sure that the dual pedal is in the neutral position.

2. Adjust both sensors with the sensor attachment plates so that the gap between the sensor
and the plate is 1.5 mm.

The sensor is active when the light blinks. The activation should happen when the
potentiometer voltage increases or decreases 0.2–0.3 V from the neutral position (2.50 V).

8.6.8 Adjust the dual pedal angle sensor

1. Remove the dual pedal plate, see 8.6.4 Remove the dual pedal plate.

2. Remove the locking spring.

3. Disconnect the end of the threaded rod.

4. Turn the end of the threaded rod until the sensor rod and frame are aligned when attached.

5. Make sure that the rod of the sensor and the frame of the sensor are aligned when the
pedals are in the neutral position.

8.7 Repair steering wheel

8.7.1 Remove the steering wheel unit

1. Remove the steering wheel cover, see 6.2.6 Remove the steering wheel cover.

2. Disconnect the steering wheel connectors.

3. Remove the control panel, see 6.2.7 Remove the control panel.

4. Remove the 4 bolts that attach the steering wheel unit to the truck.

5. Remove the steering wheel unit.

8.7.2 Remove the steering wheel gas spring

1. Remove the steering wheel cover, see 6.2.6 Remove the steering wheel cover.

2. Remove the 2 screws.

3. Remove the circlips.

4. Remove the shaft.

5. Remove the gas spring.

8.7.3 Remove the lever unit

1. Remove the plastic cover on top of the steering wheel.

2. Remove the nut that holds the steering wheel in position.

3. Remove the steering wheel.

4. Remove the steering wheel cover, see 6.2.6 Remove the steering wheel cover.

5. Disconnect the connectors.

6. Remove the 4 screws that attach the lever unit to the truck.

7. Remove the lever unit.

To install the lever unit, do the steps in a reverse order.

NOTE: When you install the steering wheel, make sure that you align the pins of the
steering wheel sensor with the gaps in the steering wheel.

8.7.4 Remove the levers

1. Remove the lever unit, see 8.7.3 Remove the lever unit.

2. Remove the screws that attach the lever to the lever unit.

NOTE: The right lever is attached to the lever unit with three screws on one side and
two screws on the other side. The left lever is attached to the lever unit with two screws.

3. Remove the levers from the lever unit.

8.8 Repair mini steering wheel

8.8.1 Disassemble the mini steering wheel

To disassemble the mini steering wheel:

1. Remove the screw.

2. Remove the steering wheel.

3. Remove the armrest.

4. Remove four screws.

5. Remove the bottom cover of the mini steering wheel.

6. Remove the distance adjustment button.

7. Disconnect the connector.

8. Remove the top cover of the mini steering wheel.

9. Remove the steering gear bracket.

10. Remove the mini steering wheel sensor, the shaft and the bearings from the steering gear
bracket.

8.8.2 Disassemble the mini steering wheel holder

To disassemble the mini steering wheel holder:

1. Disconnect the connectors.

2. Remove the adjustment lever.

3. Remove the mini steering wheel holder.

4. Remove the three screws.

5. Remove the cover.

6. Remove the bolt and the nut.

7. Remove the side bracket.

8. Remove the side plates.

9. Remove the sensor.

8.9 Repair armrest

MANDATORY ACTION
Do not attempt to open and repair the armrest during the warranty period. Breaking the
seal on the armrest voids the warranty. During the warranty period, only replace
components that you can access without breaking the warranty seal.

8.9.1 Remove the armrest

1. Disconnect the armrest connector.

2. Remove the bolt under the armrest.

3. Push and hold down the distance adjustment button of the armrest.

4. Remove the armrest.

5. Remove the 4 screws that hold the armrest holder in position.

6. Remove the armrest holder from the armrest mounting plate.

8.9.2 Remove the armrest base plate

NOTE: If you remove the base plate during maintenance, you must calibrate the armrest
with TruckTool before the truck is returned to operation. For more information, see the
instructions of TruckTool.

1. Remove the armrest from the truck. See 8.9.1 Remove the armrest.

2. Remove the 5 screws that attach the base plate to the armrest.

3. Remove the base plate from the armrest.

8.9.3 Replace the armrest padding

1. Remove the armrest from the truck, see 8.9.1 Remove the armrest.

2. Remove the screws that attach the top and bottom parts of the armrest together.

3. Remove the top part of the armrest.

To install the armrest padding, do the steps in a reverse order.

8.9.4 Fingertip control armrest

8.9.4.1 Remove the armrest levers

NOTE: After you have opened and closed the armrest, you must calibrate it with TruckTool.
For instructions, see the instructions of TruckTool.

1. Remove the armrest from the truck. See 8.9.1 Remove the armrest.

2. Remove the base plate from the armrest. See 8.9.2 Remove the armrest base plate.

3. Remove the screw that attaches the lever to the armrest.

4. Remove the lever.

NOTE: If you want to remove the lever cap without the base under the lever, it is not
necessary to remove the base plate. In this case, it is not necessary to calibrate the armrest.

To remove the lever cap:

1. Spread the edges of the lever cap and detach it from the lever.

8.9.4.2 Remove the thumb plate

1. Remove the screw that attaches the thumb plate to the armrest.

2. Remove the thumb plate.

8.9.5 Ergologic armrest

8.9.5.1 Remove the joystick

1. Remove the armrest from the truck. See 8.9.1 Remove the armrest.

2. Remove the base plate from the armrest. See 8.9.2 Remove the armrest base plate.

3. Disconnect the joystick connectors.

4. Remove the four screws.

5. Remove the joystick from the base plate.

8.9.5.2 Replace the switches and horn button

Figure 212: Replaceable components in the Ergologic armrest

1. Slider wheel 3. Operating direction selection switch

2. Thumb wheel 4. Horn button

NOTE: F2 button is integrated to a sensor inside the joystick and can not be replaced
individually.

To replace any of the switches or the horn button on the Ergologic armrest:

1. Remove the armrest from the truck. See 8.9.1 Remove the armrest.

2. Remove the base plate from the armrest. See 8.9.2 Remove the armrest base plate.

3. Remove the joystick from the armrest. See 8.9.5.1 Remove the joystick.

4. Remove the five screws that hold the joystick handle together and open the joystick.

5. Disconnect the wires from the component that you are replacing.

NOTE: Note the location of the connector before disconnecting the wires.

6. Remove the component.

To install a new component, repeat the steps in a reverse order.

8.9.6 Dual joystick armrest

8.9.6.1 Remove the dual joystick

1. Remove the armrest from the truck. See 8.9.1 Remove the armrest.

2. Remove the base plate from the armrest. See 8.9.2 Remove the armrest base plate.

3. Disconnect the joystick connectors.

4. Remove the six screws and the bracket. The correct tightening torque is 0.9 +/-0.1 Nm.

5. Remove the joystick grips.

6. Remove the joysticks.

To install the dual joystick, do the steps in a reverse order.

8.9.6.2 Remove the operating direction selection switch

NOTE: After you have opened and closed the armrest, you must calibrate it with TruckTool.
For instructions, see the instructions of TruckTool.

1. Remove the armrest from the truck. See 8.9.1 Remove the armrest.

2. Remove the base plate from the armrest. See 8.9.2 Remove the armrest base plate.

3. Remove the screws that attach the lever to the base plate.

4. Remove the lever.

NOTE: If you want to remove the lever cap without the base under the lever, it is not
necessary to remove the base plate. In this case, it is not necessary to calibrate the armrest.

To remove the lever cap:

1. Spread the edges of the lever cap and detach it from the lever.

8.9.7 Calibrate the armrest

If you remove the base plate of the armrest during maintenance, you must calibrate the armrest
using TruckTool. For more information, see the instructions of TruckTool.

8.10 Repair operator's seat

The following repair procedures apply for all seat types.

The seat-specific repair procedures are described in separate sections.

8.10.1 Remove the operator's seat from the truck

1. Open the battery cover. See 6.2.4 Open the battery cover.

2. Lock the battery cover in place with the steering wheel.

3. Remove the screws below the battery cover that attach the operator’s seat to the cover.

4. Remove the operator’s seat from the truck.

To install the operator’s seat, do the steps in a reverse order.

8.10.2 Replace the seat switch

1. Remove the seat padding.

For MSG20 seat, see .

For MSG65 or MSG75 seat, see 8.10.3.1 Replace the seat padding.

2. Remove the pop rivet.

3. Push the metal plate.

4. Remove the plastic cover of the seat switch.

5. Remove the cable ties.

6. Remove the seat switch and wiring.

To install the seat switch, do the steps in a reverse order. See Figure 213 for the correct wire
routing.

Figure 213: Seat switch wire routing

8.10.3 MSG65

This section describes procedures that are specific to the MSG65 seat.

8.10.3.1 Replace the seat padding

To remove the seat padding:

1. Tilt the backrest forward.

2. Lift the seat padding and move it forward to remove it.

3. Remove the 2 screws on the backrest of the operator’s seat.

4. Tilt the backrest back to up position.

5. Remove the backrest padding.

To install the padding, do the steps in a reverse order.

8.10.3.2 Replace the seat base

WARNING
Risk of injury

There is a compressed spring under the seat base. If you do not secure the operator’s
seat with a bolt when you disconnect the seat base, the spring can push the seat base
up quickly and cause an injury. Before you disconnect the seat base from the
operator’s seat, you must secure the operator’s seat with a bolt.

Figure 214: Seat base

8.10.3.2.1 Remove the seat base

To remove the seat base:

1. Remove the operator’s seat from the truck, see 8.10.1 Remove the operator's seat from the
truck.

2. Remove the seat padding, see 8.10.3.1 Replace the seat padding.

3. Install the security bolt to the middle of the seat base. Make sure that the security bolt is
correctly installed.

4. Remove the 2 screws on top of the seat base.

5. Push the operator’s seat from the front and turn it clockwise to remove the seat base.

8.10.3.2.2 Install the seat base

To install the seat base:

1. Remove the black cover from the seat spring.

2. Put the seat base on the operator’s seat.

3. Make sure that the security bolt goes into the hole in the bottom of the operator’s seat.

4. Install the 2 screws on top of the seat base.

5. Tighten the security bolt on top of the seat base.

6. Remove the security bolt.

7. Install the seat padding.

8. Install the operator’s seat to the truck, see 8.10.1 Remove the operator's seat from the truck.

8.10.3.3 Replace the seat belt

MANDATORY ACTION
Only trained personnel are allowed to replace the seat belt. Use original spare parts.

1. Remove the pop rivet from the plastic cover.

2. Remove the plastic cover.

3. Remove the bolt from the seat belt.

4. Remove the seat belt.

To install the seat belt, do the steps in a reverse order.

8.10.3.4 Replace the weight adjustment handle

Figure 215: Weight adjustment handle (MSG65)

1. Weight adjustment handle 2. Sensor wire

1. Remove the seat padding, see 8.10.3.1 Replace the seat padding.

2. Remove the 2 shafts.

3. Remove the weight adjustment handle.

To install the weight adjustment handle, do the steps in a reverse order.

NOTE: When you install the weight adjustment handle, make sure that the sensor wire is in
the slot.

8.10.3.5 Replace the seat rails

1. Remove the operator’s seat from the truck. See 8.10.1 Remove the operator's seat from the
truck.

2. With the weight adjustment handle lift the operator’s seat up until you have space to remove
the 4 nuts of the seat rails.

3. Remove the 4 nuts of the seat rails.

4. Remove the seat rails.

8.10.3.6 Replace the gas spring

Figure 216: Gas spring in the operator's seat

The gas spring operates as the shock absorber of the operator’s seat.

1. Remove the rubber cover from the bottom part of the operator’s seat.

2. Remove the circlip from both ends of the gas spring.

NOTE: Be careful when you remove the circlips: make sure you do not cause injury to
your hands or lose the locking pins.

3. Remove the gas spring.

To install the shock absorber, do the steps in a reverse order.

8.10.3.7 Ground the operator's seat

To ground the operator’s seat, you must have an ESD ground wire (250 mm) and M5 and M6
ring terminals.

1. Remove the operator’s seat from the truck, see 8.10.1 Remove the operator's seat from the
truck.

2. Remove the seat padding, see 8.10.3.1 Replace the seat padding.

3. Install the M6 ring terminal to the metal plate on the operator’s seat with an M6 bolt.

4. Disconnect the rubber cover from the fasteners.

5. Guide the ESD ground wire below the rubber cover to the seat base.

6. Make a 3.5 mm hole to the bottom plate of the operator’s seat.

7. Attach the M5 ring terminal to the hole with a screw.

8. Install the rubber cover back.

9. Use a multimeter to make sure that there is a contact between the seat rail and the metal
plate on the seat base.

8.11 Repair electric system

WARNING

Electric hazard
Burn hazard

Remove all rings, watches and other metal jewelry before performing maintenance
on the electric system.

Turn the key switch/start of the truck to OFF position and disconnect the battery
connector before you open the cover of the motor or the electrical system.

After opening the covers, wait for 15 to 30 seconds for the voltage to discharge
before performing maintenance on the electric system.

8.11.1 Remove the electric panel

NOTE: Before dismantling any part of the truck during maintenance or service tasks,
see 11.1 Special tightening torques.

1. Remove the pedal plate. See 6.2.2 Remove the pedal plate.

2. Disconnect all the wires.

3. Disconnect the connector of the controller fan.

4. Remove the 2 screws that attach the electric panel to the truck.

5. Remove the electric panel.

8.11.2 Replace the horn

1. Remove the right side cover, see 6.2.11 Remove the right side cover.

2. Disconnect the connectors.

3. Remove the nut and the horn.

To install the horn, do the steps in a reverse order.

8.12 Repair sensors and switches

8.12.1 Replace the rotation sensor

There are rotation sensors in the following components:

Traction motors, see .

Pump motor, see .

Steering motor, see .

1. Remove the screw that attaches the rotation sensor to the motor.

2. Disconnect the sensor connector.

3. Remove the motor rotation sensor.

4. Install the new motor rotation sensor.

5. Connect the wires to the sensor connector.

6. Connect the sensor connector.

7. Install and tighten the screw.

8.12.2 Replace the battery door sensor

1. Open the battery door, see 6.2.3 Open the battery door.

2. Disconnect the sensor connector.

3. Unscrew the nut from the sensor.

4. Remove the sensor.

When you install the new sensor, make sure that there is at least 4 mm (0.16 in.) between
metal and the sensor.

8.12.3 Replace the rear axle sensor

3-wheel models
1. Remove the wire holders.

2. Remove the screws that attach the rear axle sensor to the rear axle.

3. Remove the rear axle sensor.

4. Remove the aluminum plate.

5. Remove the screws that attach the magnet to the rear axle.

6. Remove the magnet.

NOTE: The flat side of the magnet must always point to the rear of the truck.

4-wheel models
1. Remove the sensor cover screw.

2. Remove the sensor cover.

3. Remove the wire holders.

4. Remove the screws that attach the rear axle sensor to the rear axle.

5. Remove the rear axle sensor.

6. Remove the aluminum plate.

7. Remove the screws that attach the magnet to the rear axle.

8. Remove the magnet.

NOTE: The flat side of the magnet must always point to the wheel.

8.12.4 Replace the tilt angle sensor

1. Remove the 2 screws.

2. Remove the tilt angle sensor.

8.12.5 Replace the mast height sensor

Simplex mast
1. Disconnect the sensor connector.

2. Remove the two screws.

3. Remove the mast height sensor.

4. Adjust the sensor. See 8.12.5.1 Adjust the mast height sensor.

To install the mast height sensor, do the steps in a reverse order.

Duplex and triplex mast

1. Lift the mast so that the mast height sensor is visible.

2. Disconnect the sensor connector.

3. Remove the two screws.

4. Remove the mast height sensor.

5. Adjust the sensor. See 8.12.5.1 Adjust the mast height sensor.

To install the mast height sensor, do the steps in a reverse order.

8.12.5.1 Adjust the mast height sensor

NOTICE
If the gap between the mast height sensor and reading plate is not set correctly, there is
a risk of collision when the mast is raised. Adjust the gap between the sensor and
reading plate to 5 mm when there is no load on the forks to prevent equipment damage.

You must adjust the gap between the mast height sensor and reading plate any time you
replace the mast height sensor.

1. Make sure the mast is not loaded.

2. Loosen the mounting screws of the sensor holding bracket.

3. Adjust the gap between the sensor and reading plate to 5 mm.

Simplex mast

Duplex and triplex mast

4. Tighten the mounting screws of the sensor holding bracket.

8.12.6 Replace the sensors of the hydraulic valve unit with manual levers
1. Disconnect the connectors.

2. Remove the 8 screws.

3. Remove the sensor box.

8.12.7 Replace the manual lever switches

NOTICE
The wires and plastic parts inside the lever knob are fragile. Handle the lever switch
adapter and the internal wirings with care to avoid damaging them.

Repeat the following process for each manual lever switch that needs replacing:

1. Remove the screw on the back of the lever knob.

2. Slide down the knob.

3. Press the two release clips located on either side of the switch adapter to release it. Gently
remove the adapter from the lever shaft.

4. Pull the wire out from the shaft to expose the connector. You must simultaneously push the
wire at the base of the lever shaft to avoid damaging the wire or the connector.

5. Remove the switch cap using a flat-head screwdriver. Be careful not to damage any of the
plastic parts.

6. Push the switch out of the adapter.

7. Replace the switch and assemble the knob by doing these steps in a reverse order.

8.12.8 Replace the steering wheel sensor

1. Remove the control panel. See 6.2.7 Remove the control panel.

2. Remove the steering wheel cover. See 6.2.6 Remove the steering wheel cover.

3. Remove the steering wheel sensor.

4. Disconnect the wires.

5. To install the steering wheel sensor, do the steps in a reverse order.

8.12.9 Replace the mini steering wheel sensors

8.12.9.1 Replace the mini steering wheel sensor

1. Remove the top cover of the mini steering wheel. See 8.8.1 Disassemble the mini steering
wheel.

2. Disconnect the connector.

3. Remove the mini steering wheel sensor.

8.12.9.2 Replace the mini steering wheel armrest sensor

1. Remove the mini steering wheel holder cover.

2. Disconnect the connector.

3. Remove the mini steering wheel armrest sensor.

8.12.10 Replace the pressure sensor

NOTE: Put plugs in all hydraulic connectors in hoses and pipes after disconnecting them.

NOTE: The correct tightening torque for the pressure sensor and the plug is 30 Nm.

1. Disconnect the connector.

2. Remove the pressure sensor from the MHport.

3. Put a plug in the port.

4. To install the pressure sensor, do the steps in a reverse order.

8.12.11 Replace the horn switch

The truck can have up to two horn switches. This section contains the instructions to replace the
horn switch located on the optional reverse driving handle.

To replace the horn switch on the armrest with fingertip controls, see 8.9.4.2 Remove the
thumb plate.

To replace the horn switch on the manual levers, see 8.12.7 Replace the manual lever
switches.

1. Remove the reverse driving handle from the truck.

2. Remove the cover plate from the reverse driving handle.

3. Remove the horn switch.

8.12.12 Replace the side control panel switches

1. Remove the side control panel. See 6.2.8 Remove the side control panel.

2. Disconnect the connector.

3. Remove the switch.

8.12.13 Replace the autolight sensor

1. Disconnect the connector.

2. Remove the autolight sensor.

To install the autolight sensor, do the steps in a reverse order.

8.13 Repair cabin

8.13.1 Operator door

This section describes how to maintain the operator door.

8.13.1.1 Remove the opening handle of the operator door

Figure 217: Opening handle of the operator door

To replace the opening handle of the operator door:

1. Open the operator door, see 5.3.2.1 Open the operator door.

2. Remove the screws of the opening handle.

3. Remove the opening lever.

4. Pull out the handle bar.

To install the opening handle of the operator door, do the steps in a reverse order.

8.13.1.2 Remove the cover plate of the operator door

1. Open the operator door, see 5.3.2.1 Open the operator door.

2. Remove the opening handle, see 8.13.1.1 Remove the opening handle of the operator door.

3. Remove the screws of the cover plate.

4. Remove the cover plate.

8.13.1.3 Replace the lock of the operator door

Figure 218: Lock of the operator door

To replace the lock of the operator door:

1. Open the operator door, see 5.3.2.1 Open the operator door.

2. Remove the opening handle, see 8.13.1.1 Remove the opening handle of the operator door.

3. Remove the operator door cover plate, see 8.13.1.2 Remove the cover plate of the operator
door.

4. Remove the latching mechanism of the lock.

5. Remove the lock handle.

To install the lock of the operator door, do the steps in a reverse order.

8.13.1.4 Replace the gas spring of the operator door

1. Open the operator door.

2. Remove the locking pieces at the ends of the gas spring.

3. Remove the nuts at the ends of the gas spring.

4. Remove the gas spring.

To install the gas spring, do the steps in a reverse order.

8.13.1.5 Adjust the operator door

You can adjust the position of the operator door.

NOTE: Follow these instructions also when you want to adjust the side door.

Figure 219: Adjustment points of the operator door

Loosen the adjustment screws and adjust the position of the door until the door is in the correct
position.

To adjust the locking levers:

1. Put the door opening handle to the open position.

2. Remove the cover on top of the adjustment screws.

3. Adjust the adjustment screws until the door is in the correct position.

4. Install the cover on top of the adjustment screws.

8.13.1.6 Adjust the operator door lock

The operator door has a two-stage lock that is locked by two latches. For the door to close
properly, the locking pin must be positioned correctly

To adjust the operator door lock:

1. Loosen the locking pin screws.

2. Move the pin until it is in the correct position.

NOTE: The position of the locking pin is correct when the lock makes two clicks when
the door is closed.

3. Tighten the locking pin screws.

8.13.2 Side door

This section describes how to maintain the side door.

8.13.2.1 Replace the opening lever of the side door

To replace the opening lever of the side door:

1. Open the side door.

2. Remove the handle of the opening lever.

3. Remove the door cover plate.

4. Remove the lock.

5. Remove the lock handle.

To install the opening lever of the side door, do the steps in a reverse order.

8.13.2.2 Replace the gas spring of the side door

For instructions on how to replace the gas spring of the side door, see 8.13.1.4 Replace the gas
spring of the operator door.

8.13.3 Rear window

Figure 220: Rear window

The rear window of the cabin can be opened or removed. The gas spring can be used
to hold the window open.

8.13.3.1 Replace the gas spring of the rear window

To replace the gas spring of the rear window:

1. Open the rear window, see 8.13.3 Rear window.

2. Remove the upper screw of the gas spring.

3. Remove the lower screw of the gas spring.

4. Remove the gas spring.

To install the gas spring, do the steps in a reverse order.

8.13.3.2 Remove the rear window

1. Open the rear window, see 8.13.3 Rear window.

2. Remove the gas spring 8.13.3.1 Replace the gas spring of the rear window.

3. Remove the rear window with the hinges.

4. Disconnect the connector of the windshield wipers and the washing fluid hose.

5. Remove the window heater.

8.13.4 Manual holder

8.13.4.1 Replace the manual holder

To remove the manual holder:

1. Lift the locking lever slightly and open the manual holder.

2. Disconnect the 2 hooks from the manual holder.

3. Remove the 3 self-tapping screws from the backrest frame.

4. Remove the manual holder.

To install the manual holder, do the steps in a reverse order.

8.13.5 Windshield washer (cabin truck)

The front and rear windows of the cabin truck have windshield wipers.

Figure 221: Windshield washer

1. Windshield wipers 3. Windshield washer tank and pumps

2. Windshield wiper motors

8.13.5.1 Replace the windshield wiper

To replace the windshield wiper:

1. Remove the windshield wiper from the joint arm.

2. Install the new windshield wiper to the joint arm.

8.13.5.2 Remove the motor of the windshield wipers

1. Open the protective covers of the windshield wipers.

2. Remove the circlip from the windshield wiper.

3. Remove the nut from the windshield wiper.

4. Remove the motor cover of the windshield wipers.

5. Remove the windshield wipers.

6. Remove the nuts that attach the motor of the windshield wipers to the windshield.

7. Remove the motor of the windshield wipers.

8.13.6 Sun guard

Figure 222: Sun guard

8.13.6.1 Remove the sun guard

To remove the sun guard:

1. Close the sun guard.

2. Remove the 2 screws and remove the sun guard.

3. Remove the brackets that hold the sun guard when it is open.

To install the sun guard, do the steps in a reverse order.

9 TRUCKTOOL DIAGNOSTICS

9.1 Overview

Software maintenance can be performed with a diagnostics application called TruckTool. This
program runs on a laptop PC and connects to the data bus of the truck (CAN) via a special
adapter.

TruckTool can be used to receive, display and modify settings, update (flash) controller
firmware, reset settings to hardware defaults, review and clear alarms, perform calibrations,
execute a quick truck setup and monitor digital and analog inputs and outputs.

Additional training is required to use the program.

Figure 223: TruckTool Diagnostics

For more information, see https://www.trucktool-online.com/

9.2 Location of the service socket

Figure 224 shows the location of the service socket for connecting the truck to TruckTool.

Figure 224: Location of the service socket

10 PARAMETER DESCRIPTIONS

TRUCKTOOL
Always use the correct parameter list for the specific model you are servicing. See the
latest TruckTool version for the latest parameter set.

11 SERVICE DATA

11.1 Special tightening torques

Table 86: Special tightening torques

COMPONENT TIGHTENING TORQUE

230
Front wheel
Nm

Rear wheel. 3-wheel models 230 Nm

Rear wheel, 4-wheel models 160 Nm

Traction controller terminal bolts 13–15 Nm

Drive axle power terminals 8 Nm

Steering controller terminal bolts 2.5–3 Nm

Steering motor power terminals 8 Nm

Pump controller terminal bolts 13–15 Nm

Pump motor power terminals 8 Nm

Main contactor 11–12 Nm

Key contactor 6 Nm

Main fuse pillar spacer nuts 13 Nm

11.2 Tightening torques for standard bolts and nuts

Table 87: Tightening torques for standard bolts and nuts.

8.8 10.9 12.9

BOLT SIZE PITCH [MM] NM KG-M NM KG-M NM KG-M

M4 0.70 2.8 0.3 4.1 0.4 4.8 0.5

M5 0.80 5.5 0.6 8.1 0.8 9.5 1.0

M6 1.00 9.5 1.0 14 1.4 16.5 1.7

M7 1.00 15 1.5 23 2.3 28 2.9

M8 1.25 23 2.3 34 3.5 40 4.1

1.00 24 2.4 36 3.7 43 4.4

M10 1.50 46 4.7 68 6.9 79 8.1

1.00 52 5.3 76 7.7 89 9.1

1.25 49 5.0 72 7.3 84 8.6

M12 1.75 79 8.1 115 11.7 135 13.8

1.25 87 8.9 125 12.7 150 15.3

1.50 83 8.5 120 12.2 145 14.8

M14 1.75 125 12.7 185 18.9 215 21.9

1.50 135 13.8 200 20.4 235 24.0

M16 2.00 195 19.9 280 28.6 330 33.7

1.50 205 20.9 300 30.6 360 36.7

M18 2.50 280 28.6 390 39.8 460 46.9

1.50 310 31.6 440 44.9 520 53.0

2.00 290 29.6 420 42.8 490 50.0

M20 2.50 390 39.8 560 57.1 650 66.3

1.50 430 43.8 620 63.2 720 73.4

M22 2.50 530 54.0 750 76.5 880 89.7

1.50 580 59.1 820 83.6 960 97.9

M24 3.00 670 68.3 960 97.9 1,000 112.2

1.50 760 77.5 1,100 112.2 1,250 127.5

2.00 730 74.4 1,050 107.1 1,200 122.4

M27 3.00 1,000 102.0 1,400 142.8 1,650 168.3

1.50 1,100 112.2 1,600 163.2 1,850 188.6

2.00 1,050 107.1 1,500 153.0 1,800 183.5

M30 3.50 1,350 137.7 1,900 193.7 2,250 229.4

1.50 1,550 158.1 2,200 224.3 2,550 260.0

2.00 1,500 153.0 2,100 214.1 2,500 254.9

M33 3.50 1,850 188.6 2,600 265.1 3,000 305.9

1.50 2,050 209.0 2,900 295.7 3,400 346.7

2.00 2,000 203.9 2,800 285.5 3,300 336.5

M36 4.00 2,350 239.6 3,300 336.5 3,900 397.7

1.50 2,700 275.3 3,800 387.5 4,450 453.8

3.00 2,500 254.9 3,500 356.9 4,100 418.1

M39 4.00 3,000 305.9 4,300 438.5 5,100 520.1

1.50 3,450 351.8 4,900 499.7 5,700 581.2

3.00 3,200 326.3 4,600 469.1 5,300 540.4

11.3 Oils and lubricants

NOTE: Do not mix different lubricants. It is possible that different brands of lubricants are
not compatible with each other. Only use lubricants recommended by the manufacturer.

Table 88: Oils and lubricants

Hydraulic oil (volume: 17...19.5 l)

Ambient temperatures -40...0°C (-40...+32
ISO VG 15
°F)
Ambient temperatures -10...+30 °C
ISO VG 32
(+14...+86 °F)
Ambient temperatures +10...+50 °C
ISO VG 46
(+50...+122 °F)
FUCHS RENOLIN ANTI-STICK-SLIP
When replacing hydraulic oil, add 0.35 L
hydraulic oil additive to 19 L hydraulic oil
Hydraulic oil additive
(corresponds to the mixing ratio of 2% of the
hydraulic oil volume) to prevent stick-slip
and to reduce friction.
Transmission oil (volume: 0.5 l /
gearbox)
In accordance with SAE 80W-90; API GL-5
Lubrication points
NLGI. No. 1 or 2 grade multipurpose type
Grease
(lithium base)

11.3.1 Lubrication points

Grease NLGI. No. 1 or 2 grade multipurpose type (lithium base)

11.3.2 Rear axle

SAE 80W-90; API GL-5 (3-wheel models)

Grease NLGI. NO. 2 GRADE MULTIPURPOSE TYPE (LITHIUM BASE) (4-wheel
models)

11.3.3 Mast chains

NOTICE
If you use oil or grease to lubricate the chains in dusty or sandy operating conditions,
dirt particles can stick to the chains and cause rapid wear from abrasion. Take special
precautions to make sure that your hands, tools and working environment are clean.

For the best chain life, use graphite or molybdenum type lubricants (for example, sprays), which
evaporate and leave the graphite or molybdenum on the chain.

11.3.4 Mast channels

For the lubrication of the mast channels, use lubrication grease NLGI No. 2 that contains
molybdenum disulphide.

11.3.5 Pump axle splines

Grease Molykote BR2 Plus (NLGI. No.2 grade)

11.4 Troubleshooting

MANDATORY ACTION
Only adequately trained truck operators and service personnel are allowed to carry out
the daily and weekly check-ups.

Only trained service personnel are allowed to carry out other maintenance operations.

The terms of warranty prescribe the appropriate maintenance of the truck. Use original
spare parts.

When you start troubleshooting, always look at the truck display messages first. Follow the
instructions. See the examples in Table 89.

Before you contact the service personnel:

Make sure that the battery is fully charged (low battery voltage can cause error messages)

Restart the truck (some error messages can be cleared after the restart)

11.4.1 Troubleshooting case examples

Table 89: Troubleshooting case examples

EXAMPLE 1 EXAMPLE 2

Display Lift lever Internal Error

message Release to continue Call Service

The lift lever is active at There is an internal error in the control

Cause
start-up. system of the truck.

Restart the truck (turn the key switch off and

Release the lift lever.
on).
Action Continue to use the truck
If the problem persists, contact the service
normally.
personnel.

For further troubleshooting instructions, see below.

11.4.2 Traction

Table 90: When the truck does not move

QUESTION ANSWER ACTION

1. Connect the battery.

2. Set the emergency stop switch ON.
1. Does the truck NO 3. Turn the key switch / start switch ON.
display have power? 4. Start the truck again.
If this does not help, contact service.
YES Examine the display for error codes.
Push the accelerator pedal carefully.
If the display still has no error code, start the truck
NO
again and examine the display for error codes.
2. Does the display If this does not help, contact service.
have an error code?
Examine the display instructions.
YES If this does not help, start the truck again.
If this does not help, contact service.

11.4.3 Brakes

Table 91: When the brakes do not work correctly

QUESTION ANSWER ACTION

Select the correct operation mode

NO
1. Is the correct operation mode (PRO/ECO).
selected? Make sure that all pedals are released and
YES
they move freely.
1. Remove any obstacles that block the
movement.
NO
2. Are all pedals released and 2. Start the truck again.
move freely? If this does not help, contact service.
Start the truck again.
YES
If this does not help, contact service.

Table 92: Troubleshooting the electric brake

FAULT REASON ACTION

Power supply is too low or Adjust or reconnect the power

interrupted supply.
Brake does not
release The brake disc is worn Replace the brake.
The coil is damaged Replace the brake.
Voltage present at switch off
Brake does not Check the power supply.
position
brake
Grease on friction faces Replace the brake.
Nuisance braking Power supply is too low Adjust the power supply.

11.4.4 Hydraulics

Table 93: When the hydraulics do not work correctly

QUESTION ANSWER ACTION

Select the correct operation mode

NO
1. Is the correct operation mode (PRO/ECO).
selected? Make sure that the hydraulic levers are
YES
released and move freely.
1. Remove any obstacles that block the
movement.
NO
2. Are the hydraulic levers released 2. Start the truck again.
and move freely? If this does not help, contact service.
Start the truck again.
YES
If this does not help, contact service.

11.4.5 Steering

Table 94: When the steering does not work correctly

QUESTION ANSWER ACTION

1. Is the truck moving Make sure the traction wheel is not in a hole,
NO
when the problem against a wall or otherwise blocked.
occurs? YES Move on to the next question.

2. Is the steering wheel Examine the condition of the traction wheel and
NO
turned extremely fast the floor.
when the problem Start the truck again.
occurs? YES
If this does not help, contact service.

11.4.6 Charging

Table 95: When the charger does not work correctly

QUESTION ANSWER ACTION

1. Is the charger display NO Connect mains to the charger.

ON? YES Examine the battery connection.
NO Connect the battery.
2. Is the battery
connected? Examine the battery water level and battery
YES
voltage.
Add battery water.
3. Is the battery water NO
If this does not help, contact service.
level and battery voltage
OK? Start the charger again.
YES
If this does not help, contact service.

12 OPTIONS

12.1 Options overview

MANDATORY ACTION
Optional equipment can change some operating characteristics described in this
manual. Before you operate a lift truck that has optional equipment, make sure that you
read and understand the necessary instructions. Make sure that the instructions are
always available.

If your forklift truck has an attachment, refer to the attachment supplier for the proper
operating instructions.

This section provides information about the optional features available for the truck.

Figure 225: Options overview

Safety accessories
These safety accessories are available as options:

Table 96: Safety accessories

# OPTION DESCRIPTION

The smart backup alarm warns people around the

truck when the truck is reversing. The sound level of
1 Smart backup alarm the alarm adapts automatically in the range of 82-102
dB. The input voltage of the smart backup alarm is
36-80 Vdc. The housing is dust and waterproof.
The rear combination and tail lights kit includes the
following:
DC/DC converter
Wiring, switches, fuses and relays
Lever for operating the lights
Front light unit (12 V LED):
Rear combination and Position lights (2 x 0.6W)
2 Turn signals (2 x 18W)
tail lights kit
Low beam lights (2 x 7.5W)
Tail light unit (12 V LED):
Tail lights (2 x 0.5W)
Turn signals (2 x 2W)
Brake lights (2 x 2W)
Reverse lights (2 x 1.6W)

Flashing LED strobe warning light, input voltage of

3 Amber strobe
12-80 Vdc and a flash rate of 85 flashes per minute.
The truck can be equipped with a light sensor
(photodiode), which automatically switches on the
4 Autolight switch
working lights when the lighting of the working
environment is insufficient.
The truck can be equipped with blue point lights.
These are warning lights that project a focused beam
of blue light to the ground in front or behind the truck.
Available configurations are front or back point light
only, or both point lights. Blue point lights can
alternatively be replaced with red point lights.
Blue point lights (rear The input voltage of the warning light is 12-60 Vdc
5 and front), optionally red and its power consumption is 15 Watts. If selected as
point light a single standing option, an additional requirement is
the DC 300 W converter option.

NOTE: Bright Light Radiance - Risk Group 2. This

product can emit possibly hazardous optical
radiation that can be harmful to the eye. Do not
look directly at the operating light.

Working lights mounted on the mast and the rear of

6 Working lights
the truck.

Safety lights installed on both sides of the overhead

7 Red stripe guard. They project a red line on the ground to
indicate the moving area of the truck.

General accessories
These general accessories are available as options:

Table 97: General accessories

# OPTION DESCRIPTION

5 V USB-charging Socket for charging handheld devices (like mobile

8
socket phone)
This option makes it possible to automatically move
Tilt angle sensor / the fork tilt to the neutral position pressing the tilt
9
display status indication button and the F2 button on the armrest. An analogue
tilt angle sensor is integrated to this option.
10 Operator’s seat options Backrest extension and left hand armrest for MSG65
Possibility to store items, for example, pens, papers
11 Storage plastic locker
and a tape dispenser.
The truck can be equipped with a battery tray or roller
bed for the sideway exchange.
The battery sideway exchange tool is used in
Battery sideway combination with the battery tray for secure battery
12
exchange tools handling during the sideway exchange. The tool
latches to the front bracket of the battery tray and
enables the battery to be pulled out using a power
pallet truck.
A secure stand for the battery after it is removed from
13 Battery stand the truck during the battery sideway exchange
procedure.
The rear view mirror gives the driver more visibility to
14 Rear view mirror
the area behind the truck.
Side-view mirrors on the exterior of the truck give the
driver a better view of the area behind and to the
15 Side-view mirrors
sides of the truck. The mirrors are installed on the
right and left side of the truck on the overhead guard.
Gives the truck operator a panoramic back view and
16 Wide view mirror
thus enhances the safety of the truck operation.
17 Hydraulic accumulator Load cushioning (hydraulic accumulator).
Prevents driver’s vision from getting blocked by the
18 Sun guard
sunlight and protects the driver from the UV radiation.
An extra mounting bar which gives the possibility to
19 Accessory rack
add accessories to the A-pillar.
For holding A4 and A5 sized documents for reading
20 List bracket A4
and writing.
21 Computer holder For 10"-16" laptop computer.

22 Scanner holder Holder for the scanner in the accessory rack.

RAM Mount parts: RAM 235U D, RAM 201U D, RAM
23 Holder arm
202U D
24 Cabin fan A cooling fan installed into the cabin of the truck.
A lamp with a flexible gooseneck shaft that you can
25 Reading light
use for reading inside the cabin.
Reverse drive handle Handle attached to the rear of the overhead guard.
26
with horn button The handle can be used when the truck is reversed.
This option makes it possible to turn the operator’s
seat sideways. This makes it more comfortable to
drive the truck in reverse. The seat can be locked in a
27 Swivel seat
straight position or in a 20 degree angle either to the
left or the right. You can open the locking mechanism
with a mechanical lever under the operator’s seat.
28 Loose mast components Components for attaching the mast to the truck.
Hook-on sideshift An additional device for the lifting carriage for
29
carriage increased efficiency in load handling.
Standard lead-acid Available battery sizes 500 Ah, 625 Ah and 750 Ah
30
battery depending on the truck model.
Available battery sizes 296 Ah, 370 and 444 Ah
31 Lithium-ion battery
depending on the truck model.
Charger used to charge the battery.
Battery charger for the NOTE: Lead-acid and lithium-ion batteries require
32
lithium-ion battery their own chargers that are intended for each battery
type.
33 Front cover A protective cover made of rubber.
Extends the fenders to protect the area around the
34 Fender extensions truck from debris that can be pushed out from under
the tires.

Other options

Table 98: Other options

This option is required when electric equipment (such as terminals or barcode

Power
readers) is mounted to the truck. It supplies 12.4 V / 24 A (300 W) through a
supply
DC/DC converter. With the rear combination and tail lights kit (approximately 8
300 W
A), the available power is 180 W.
This option provides a personal access code after starting up the truck using
PIN code the Start switch.
access Up to 10 PIN codes can be assigned to 3 different pre-defined user levels
(ECO/PRO/Emergency). Contact service to assign the codes.
The two pedals on the sides are the accelerator pedals for forward and
Dual
backward acceleration. The brake pedal is placed in the middle. The dual
pedal
pedal system has swinging pedals, which means that pushing one pedal down
system
lifts up the other one.
Electronic
The electronic friction lock pedal is pressed down to lock the front wheels to
friction
provide simultaneous traction. The electronic friction lock can be activated
lock
when the truck speed is slow and the steering angle is limited.
pedal
Silent
Silent pump reduces noise and vibration during operation.
pump

12.2 Accessory rack

Figure 226: Accessory rack

Accessory rack allows you to attach accessories to the overhead guard.

To install the accessory rack:

1. Attach the accessory rack to the overhead guard frame with two screws.

12.3 A4 paper holder

Figure 227: A4 paper holder

You can attach A4 and A5 sized documents to the A4 size paper holder for reading and writing.

To install the A4 paper holder:

1. Install the accessory rack, see 12.2 Accessory rack.

2. Install the mounting piece to the list bracket.

3. Install the paper shield to the list bracket.

4. Install the paper holder, paper shield and the paper fastener together with the mounting
piece and a screw.

5. Install the first fastener piece to the mounting piece.

6. Install the second fastener piece on top of the first piece and attach the mounting pieces with
screws.

7. Install the fastener piece to the second fastener piece. Turn the handle to open the ball
joints.

8. Install the paper A4 paper holder to the front bar of the overhead guard with clamps and
tighten with screws.

To remove the A4 paper holder:

1. Remove the clamps that attach the mounting bracket of the A4 paper holder to the front bar
of the overhead guard.

2. Remove the A4 paper holder.

12.4 Computer holder

Figure 228: Computer holder

To install the computer holder:

1. Install the accessory rack, see 12.2 Accessory rack.

2. Install the first fastener piece to the mounting bracket.

3. Install the second fastener piece on top of the first piece and attach the mounting pieces with
screws.

4. Install the fastener piece to the second fastener piece. Turn the handle to open the ball
joints.

5. Install the computer holder to the accessory rack with clamps and tighten with screws.

Figure 229: Computer wire routing

To remove the computer holder:

1. Remove the clamps that attach the mounting bracket of the computer holder to the
accessory rack.

2. Remove the computer holder.

12.5 Scanner holder

Figure 230: Scanner holder

To install the scanner holder:

1. Install the accessory rack, see 12.2 Accessory rack.

2. Install the first fastener piece to the mounting bracket.

3. Install the second fastener piece on top of the first piece and attach the mounting pieces with
screws.

4. Install the fastener piece to the second fastener piece. Turn the handle to open the ball
joints.

5. Install the scanner holder to the accessory rack with clamps and tighten with screws.

To remove the scanner holder:

1. Remove the clamps that attach the mounting bracket of the scanner holder to the accessory
rack.

2. Remove the scanner holder.

12.6 Holder arm

Figure 231: Holder arm

To install the holder arm:

1. Install the accessory rack, see 12.2 Accessory rack.

2. Install the first fastener piece to the mounting bracket.

3. Install the second fastener piece on top of the first piece and attach the mounting pieces with
screws.

4. Install the fastener piece to the second fastener piece. Turn the handle to open the ball
joints.

5. Install the holder arm to the accessory rack with clamps and tighten with screws.

To remove the holder arm:

1. Remove the clamps that attach the mounting bracket of the holder arm to the accessory
rack.

2. Remove the holder arm.

12.7 Reverse drive handle with horn button

Figure 232: Reverse drive handle with horn button

To install the reverse drive handle:

1. Install the grommet to the battery cover.

2. Install the handle to the battery cover.

3. Guide the wire into the overhead guard through the grommet.

12.8 Smart backup alarm

Figure 233: Smart backup alarm

The smart backup alarm warns people around the truck when the truck reverses. The sound
level of the alarm can be adjusted in the range of 82-102 dB.

NOTE: You need to insert an additional relay and connect the smart backup alarm wiring to
XH50/ connector.

To install the smart backup alarm:

1. Install a corner bracket to the smart backup alarm with 2 screws and nuts.

2. Install the corner bracket with the smart backup alarm to the attachment plate on the truck
frame with 2 nuts.

3. Connect the wiring to XH50/ connector.

4. Insert a relay to slot K8 in the options panel.

12.9 Rear combination and tail lights kit

Figure 234: Rear combination and tail lights kit overview

1. Front lights 2. Brake lights

The rear combination and tail lights kit includes the following:

DC/DC converter

Wiring, switches, fuses and relays

Lever for operating the lights

Front light unit (12 V LED, except turn signals):

Position lights

Turn signals

Tail light unit (12 V LED, except turn signals):

Tail lights

Turn signals

Brake lights

Figure 235: Rear combination and tail lights kit wire routing

1. Fuse 23F1 5. Relay K5

2. Fuse 24F1 6. Relay K6
3. Fuse 25F1 7. Relay K7
4. Relay K4 8. Contactor K17

Refer to Figure 235 when you install the rear combination and tail lights kit.

12.9.1 Turn signals

When the turn signals are used, a turn signal icon blinks on the truck display. This icon also
blinks when the emergency lights are on.

Figure 236: Turn signal icon

12.9.2 Brake lights

The brake lights are activated when you push the brake pedal.

Figure 237: Brake light system

1. Brake light 3. Fuse box

2. Brake pedal

To install the brake lights:

1. Attach the lights to the top rear of the truck.

2. Connect the wiring. See 12.9 Rear combination and tail lights kit.

To remove the brake light, do the steps in a reverse order.

12.9.3 Front lights

To install the front lights:

1. Install the front light to the front light support plate.

2. Make sure that you guide the wire through the hole in the plate.

3. Install the front light with front light support to the front plate of the overhead guard.

4. Guide the cable through the opening.

5. Connect the wiring. See Figure 235.

Repeat the steps for the other front light.

12.10 Amber strobe

Figure 238: Amber strobe under the overhead guard

Figure 239: Amber strobe wire routing

The amber strobe option is a warning light that can be activated with a switch. The light has an
input voltage of 12-80 Vdc and a flash rate of 85 flashes per minute.

12.10.1 Install the amber strobe under the overhead guard

1. Install the amber strobe with 2 screws and guide the wire through the hole in the plastic
cover under the overhead guard plate.

2. Connect the wiring. See the correct wiring in 12.10 Amber strobe.

To remove the amber strobe, do the steps in a reverse order.

12.11 Autolight sensor

Figure 240: Autolight sensor

The autolight sensor is a sensor that automatically switches on the working lights when the
lighting of the working environment is inadequate. If the truck is not used in a certain time, a
timer will switch OFF the automated working lights. The time can be adjusted between 1-99
minutes. The automatic working lights function can be set ON and OFF. The sensitivity of the
sensor can be adjusted with a parameter.

Table 99: Automatic working lights sensor

TYPE PHOTODIODE

Spectral response range 320...1,100 nm

12.11.1 Install the autolight sensor

Figure 241: Measurements of the automatic working light sensor

To install the automatic working light sensor:

1. Install the working light sensor to the mounting plate of the working light.

2. Connect the wiring.

To remove the automatic working light sensor, do the steps in a reverse order.

Figure 242: Automatic working light sensor wiring

12.12 Blue point light

CAUTION
Laser beam hazard

Bright Light Radiance - Risk Group 2. This product can emit possibly hazardous optical
radiation that can be harmful to the eye. Do not look directly at the operating light.

Figure 243: Blue point lights wire routing

1. Relay K7 4. Relay K6 (truck without DC/DC

2. Relay K6 converter)
3. Relay K7 (truck without DC/DC
converter)

12.12.1 Blue point front light

The blue point front light is used to help people notice a moving truck and decrease the risk of
collisions between people and trucks. The blue point front light directs a focused beam of blue
light to the ground in front of the truck. The blue point front light is connected in parallel with the
front light.

Figure 244: Blue point front light

12.12.1.1 Install the blue point front light

1. Install the blue point front light to the plate in front with screws.

2. Connect the wiring.

12.12.2 Blue point rear light

The blue point rear light is used to help people notice a moving truck and decrease the risk of
collisions between people and trucks. The blue point rear light directs a focused beam of blue
light to the ground behind the truck. The blue point rear light is connected in parallel with the
rear light.

The blue point rear light can be installed under the overhead guard with a separate mounting
plate, see 12.12.2.1 Install the blue point rear light under the overhead guard.

12.12.2.1 Install the blue point rear light under the overhead guard

Figure 245: Blue point rear light

1. Install the blue point rear light to the mounting plate.

2. Install the blue point rear light and the mounting plate to the bar under the overhead guard.

3. Guide the wire through the hole.

4. Connect the wiring. See the correct wiring in Figure 243.

12.12.3 Remove the blue point lights

To remove the blue point lights, do the installation steps in a reverse order.

12.13 Working lights

Additional working lights can be installed on the mast and the rear of the truck for increased
visibility and operation safety. The rear light is mounted on the cabin or overhead guard.

Figure 246: Overhead guard working lights

Figure 247: Front working lights wire routing

Figure 248: Rear working light wire routing

12.13.1 Install the working lights

Front lights
1. Install the light to the mounting plate with screws.

2. Install the front light to the mast with screws.

3. Connect the wiring.

4. Repeat steps 1-3 for the second front light.

Rear light
1. Install the rear light to the rear of the cabin or the overhead guard with screws.

2. Remove the rear light cover.

3. Connect the wiring.

4. Install the rear light cover and guide the wiring.

12.14 Red stripe

Red stripe lights are safety lights that are installed on the side of the overhead guard. These
lights focus a red line to the ground to indicate the truck's moving area.

Figure 249: Red stripe

Figure 250: Red stripe wire routing

1. Relay K6

12.14.1 Install the red stripe safety lights

1. Install the light to the plate on the overhead guard with screws.

2. Connect the wiring.

12.15 USB connector

Figure 251: USB connector

You can use the USB connector to connect various electronic devices to your truck, such as
mobile phone charger.

NOTE: If USB connector has not been installed at the factory, drill a 28 mm hole in the front
panel and install the wiring.

1. Install the USB connector to the front panel.

2. Connect the wiring.

To remove the USB connector, do the steps in a reverse order.

12.16 Plastic storage locker

Figure 252: Plastic storage locker

You can store small items like pens, papers and a tape dispenser in a storage locker.

12.16.1 Install the plastic storage locker

1. Install the plastic storage locker with three screws.

12.17 Load weight indicator and overload notification

CAUTION
Risk of accident

Exceeding the maximum loading capacity of the truck can result in an accident. The
truck can tip over, overheat, or lose braking or steering performance. Do not exceed the
maximum loading capacity of the truck under any circumstances. Always follow the
maximum values for load weight and load center information on the capacity plate.

NOTE: The load weight indicator and overload notification are only informative. Always
follow the maximum values for load weight and load center information on the capacity plate.
Do not overload the truck.

NOTE: The overload notification requires the optional tilt angle sensor.

The load weight is displayed on the center information area on the truck display. The accuracy
of the scale is +/-50 kg (+/- 110 lbs).

The load weight indicator includes an overload notification function. The overload icon appears
on the left side of the truck display when the load exceeds the configured weight limit. The
overload notification uses the information provided by the pressure sensor, mast height sensor
and an optional tilt angle sensor.

The tilt of the mast and height of the lifting carriage affect the weight limit that triggers the
overload notification. Each of the following situations have a different weight limit:

The mast is not tilted or it is tilted backward.

The mast is tilted forward.

The mast is tilted forward and the forks are lifted above the free lift area.

There is a one second delay after activating the lifting function before the overload icon is
displayed. After the first second, a moving average filtering is applied to prevent unintentional
notifications.

Figure 253: Load weight indicator and overload notification

1. Overload icon 2. Load weight indicator

12.18 Operator's seat options and accessories

The following accessories are available for the operator’s seat:

Seat armrest

Backrest extension

Swivel seat

12.18.1 Seat armrest

Figure 254: Seat armrest

Seat armrest provides additional comfort when the truck is operated for long periods at a time.
You can adjust the height and angle of the armrest and fold it to any position.

12.18.1.1 Install the seat armrest

To install the seat armrest on the MSG65 seat:

1. Use a screwdriver or other small tool as a lever to push the pins of the rivets out.

2. Remove the rivets with pliers.

3. Remove the plastic cover of the seat belt.

4. Loosen the nut of the seat belt.

5. Install the seat armrest.

6. Attach the seat armrest to the operator’s seat using a nut.

7. Tighten the nut of the seat belt.

8. Install the plastic cover.

9. Install the rivets.

10. Hit the heads of the rivet pins down, for example with a screwdriver handle.

12.18.1.2 Adjust the height of the seat armrest

1. Remove the round cover from the side of the operator’s seat.

NOTE: The round cover often breaks when you remove it, so you must have a new
plastic rivet or a pop rivet to lock the armrest in its correct position.

2. Remove the nut under the round cover.

3. Adjust the height of the armrest.

4. When the armrest is at the desired height, insert and tighten the nut back to its correct
position, or use a new plastic rivet or pop-rivet.

5. Put the round cover back to its correct position.

To adjust the angle of the seat armrest:

Turn the adjustment knob towards the plus (+) sign to lift the front part of the armrest.

Turn the adjustment knob towards the minus (-) sign to lower the front part of the armrest.

12.18.2 Backrest extension (MSG65)

Figure 255: Backrest extension

The backrest extension prevents injuries caused by the poor posture of the truck operator. The
height of the backrest can be adapted to the body height. It is adjustable in 13 steps from 475
mm to 645 mm.

12.18.2.1 Install the mounting bracket of the backrest extension

To install the mounting bracket of the backrest extension:

1. Install the springs to the mounting bracket.

2. Install the mounting bracket to the operator’s seat with 3 pop rivets.

12.18.2.2 Adjust the backrest extension

To adjust the backrest extension, lift or lower the backrest extension and leave it in a locked
position. To remove the backrest extension, lift it all the way up.

12.18.3 Swivel seat

Figure 256: Swivel seat

To install the swivel seat:

1. Install the base plate with four screws.

2. Install the three shim plates.

3. Install the seat with four screws.

12.19 Battery sideway exchange system

The truck can be equipped with a battery tray or roller bed for the sideway exchange.

The rollers make it easier to pull the battery onto a power pallet truck and to push a new battery
into the truck. The tray slides in and out of the battery compartment on rollers when pulled from
the front bracket. You can use the battery sideway exchange tools to replace the battery. See
12.19.2 Battery sideway exchange tools.

Figure 257: Battery sideway exchange chassis

Figure 258: Battery tray and battery roller bed

1. Battery roller bed 2. Battery tray

12.19.1 Requirements for power pallet trucks used to move batteries of

counterbalance trucks

The pallet truck types that can be used to move batteries of counterbalance trucks are listed in
Table 100.

Note that there are separate columns for the 625 Ah battery and 750 Ah battery.

NOTE: The fork width of the pallet truck must be 540 mm (21 in.) and length of forks can be
up to 1450 mm (57 in.).

Table 100: Requirements for power pallet trucks used to move batteries of counterbalance
trucks

CAPACITY

Battery size 500-625 Ah 625-750 Ah

Electric pallet truck 1.6 t / 1.8 t / 2.0 t 1.6 t / 1.8 t / 2.0 t

12.19.2 Battery sideway exchange tools

Figure 259: Battery sideway exchange tools

1. Battery sideway exchange tool 2. Battery stand

The battery sideway exchange tool is used to remove and install the battery. The battery stand
is used to support the battery when the battery is removed from the truck.

12.19.2.1 Install the battery sideway exchange tool

Figure 260: Battery sideway exchange installation

To install the battery sideway exchange tool to a power pallet truck:

1. Make holes through a jig to the forks of the power pallet truck.

2. Install the battery sideway exchange tool to the holes you made to the forks.

12.19.2.2 Disassemble the battery locking mechanism

1. Remove the countersunk screw.

2. Remove the stopper.

3. Remove the tightening part.

4. Remove the knob.

5. Pull out the lock.

To assemble the battery locking mechanism, do the steps in a reverse order.

NOTE: If a wide battery is used, you must disassemble the battery locking mechanism and
turn the lock 180 degrees so that the battery fits in.

Figure 261: Battery lock options

1. Lock for small battery 2. Lock for large battery

12.20 Wide view mirror

Figure 262: Wide view mirror

The wide view mirror gives the truck operator a panoramic back view and thus enhances the
safety of the truck operation.

12.20.1 Install the wide view mirror

1. Install the mounting bracket to the overhead guard with screws.

2. Install the wide view mirror to the mounting bracket with a screw.

To remove the wide view mirror, do the steps in a reverse order.

12.21 Rear view mirror

Figure 263: Rear view mirror

The parabolic rear view mirror gives the operator visibility towards the right-hand side of the
truck without having to turn their head. The rear view mirror comes with an extra mounting
bracket.

12.21.1 Install the rear view mirror

1. Install the mounting bracket to the overhead guard with screws.

2. Install the rear view mirror to the mounting bracket with a nut.

To remove the rear view mirror, do the steps in a reverse order.

12.22 Side-view mirrors

The truck can be equipped with side-view mirrors on both sides of the overhead guard.

Figure 264: Side-view mirrors

12.22.1 Install the side-view mirrors

1. Remove the plastic cover.

2. Install the mounting bracket of the mirror to the overhead guard with screws.

3. Insert the plastic cover.

12.23 Hydraulic accumulator

Figure 265: Hydraulic accumulator overview

1. Protection plate 6. Accumulator

2. Bracket 7. Nut
3. Fitting 8. Connector
4. Adjustment valve 9. Hydraulic hose
5. Elbow connector 10. Hose connector

The hydraulic accumulator acts as a shock absorber of the lifting device when the truck is used
on rough surfaces outdoors.

12.23.1 Install the hydraulic accumulator

1. Install the protection plate to the bracket.

2. Install the hydraulic hose with connectors to the adjustment valve.

3. Connect the adjustment valve and the hydraulic accumulator to the bracket.

4. If you have installed the front lights, remove the screws and nuts from the front light support
plate.

5. Slide the accumulator into its place and connect with screws.

6. Connect the hydraulic hose connector.

After you have installed the hydraulic accumulator, tighten all connections according to the
tightening torques shown in Figure 266.

Figure 266: Hydraulic accumulator tightening torques

12.23.2 Adjust the hydraulic accumulator

Adjust the hydraulic accumulator based on the load and the environment where the truck is
operated in.

1. Turn the adjustment screw on the adjustment valve for approximately 5 turns. Start with the
valve in a fully closed position.

2. If necessary, open or close the adjusment screw for up to 2 turns based on the load and the
operating environment of the truck.

12.24 Front cover

A protective rubber cover can be mounted to the front of the truck. This reduces the amount of
dust and debris that enters the underside of the truck.

Figure 267: Rubber front cover

12.24.1 Install the rubber front cover

1. Install the mounting brackets.

2. Install the rubber cover to the mounting brackets.

3. Install the rubber covers to the truck.

12.25 Sun guard

Figure 268: Sun guard

12.26 Reading light

Figure 269: Reading light wire routing

12.26.1 Install the reading light

1. Route the wire and make the appopriate electric connections. See Figure 269.

2. Install the mounting plate.

3. Secure the reading light to the mounting plate with screws.

4. Connect the cable.

12.27 Cabin fan

Figure 270: Cabin fan wire routing

12.27.1 Install the cabin fan

1. Install the clamp and the cabin fan to the truck with two screws.

2. Connect the cabin fan connector.

12.28 Fender extensions

Figure 271: Fender extensions

1. Install each fender extension with 4 screws.

12.29 Tilt angle sensor / display status indication

Figure 272: Tilt angle sensor

The tilt display informs the truck operator of the tilt angle through the truck display. The tilt angle
is measured via an analogue angle sensor.

The tilt angle minimum, maximum and centre positions must all have individual values. The
values are set through the TruckTool software. The tilt angle is shown to the truck operator
through the truck display. For a complete list of symbols that indicate the status and functionality
of the truck, see DSbug 1.

The tilt angle symbols are shown on the top right corner of the truck display.

Figure 273: Tilt angle symbol on the truck display

12.29.1 Install the tilt angle sensor

1. Install the locking piece to the threaded rod.

2. Install the first joint piece to the threaded rod.

3. Install the second joint piece to the first joint piece.

4. Install the threaded rod with the joint pieces to the tilt angle sensor.

5. Install the locking piece.

6. Install the tilt angle sensor to the mounting plate with 2 screws.

7. Install the tilt angle sensor to the plate in the front part of the truck.

8. Adjust the threaded rod.

For instructions on how to calibrate the tilt angle sensor, see the instructions of TruckTool.

12.30 Hook-on sideshift

Figure 274: Hook-on sideshift assembly

1. Lifting carriage 3. Hook-on sideshift frame

2. Mounting hook 4. Sideshift cylinder

13 TECHNICAL SPECIFICATIONS
Technical specifications available on request.

14 LABELS

Figure 275: Type plate

Figure 276: Capacity plate

Figure 277: Battery label

Figure 278: Lithium-ion battery decal

Figure 279: UL plate type E

Figure 280: UL plate type EE

Figure 281: UL EE classified decal

Figure 282: Quality check label

Figure 283: Emergency exit decal

Figure 284: Manual pocket decal

Figure 285: Manufacturer authorized tires decal

Figure 286: Crush point warning decal

Figure 287: Mast warning decal

Figure 288: Open battery cover decal

Figure 289: Back-up alarm decal

Figure 290: Overhead guard decal

Figure 291: Load backrest decal

Figure 292: No passengers warning decal

Figure 293: In case of tipover warning decals

Figure 294: Safety notice decal

Figure 295: Blue light radiance decal

Figure 296: Operator restraint system decal

Figure 297: High voltage decal

Figure 298: Mast lifting point decal

Figure 299: Oil cap decal

Figure 300: Safe operation decal

15 TRUCK DISPLAY LANGUAGES

The following truck display languages are available:

Bulgarian – Български

Croatian – Hrvatski

Czech – Čeština

Danish – Dansk

Dutch – Nederlands

English

Estonian – Eesti

Finnish – Suomi

French – Français

German – Deutsch

Greek – Ελληνικά

Hungarian – Magyar

Italian – Italiano

Latvian – Latviešu

Lithuanian – Lietuvių

Norwegian – Norsk

Polish – Polski

Portuguese – Português

Romanian – Română

Russian – Русский

Slovak – Slovenčina

Slovene – Slovenščina

Spanish – Español

Swedish – Svenska

Turkish – Türkçe

16 MAINTENANCE CHECK LIST

MANDATORY ACTION
Only adequately trained truck operators and service personnel are allowed to carry out
the daily and weekly check-ups.

Only trained service personnel are allowed to carry out other maintenance operations.

The terms of warranty prescribe the appropriate maintenance of the truck. Use original
spare parts.

Figure 301: Maintenance decal

Table 101: Maintenance check list

Legend: C = Check, R = Repair, Clean or Change, G = Grease
1000 H OR
BEFORE MONTHLY
EVERY
DAILY USE USE
YEAR
(OPERATOR) (OWNER)
(SERVICE)

Safety

Test the functionality of the seat switch C

Backup alarm (if applicable) C

Electronic friction lock pedal (if applicable) C

Battery cover lock C

Warning decals and plates C

Emergency switch C

Examine the condition and test the

C C
functionality of the seat belt

Check the functionality of the service brake

C C C
and the parking brake

See the instructions of the manufacturer

Test the functionality of the fire extinguisher
or supplier

Test the functionality of the rear combination

C
and tail lights (if applicable)

Test the functionality of the option warning

C
lights and buzzer/alarm

Examine the static discharge strip C

Battery

Battery water level, see 7.1.5 Battery

C C C
maintenance.

Clean the battery if necessary C

Battery compartment, restraint, cable and

C C C
connector, see 7.1.5 Battery maintenance.

Battery cell voltage and specific gravity, see

C C
7.1.5 Battery maintenance.

Battery automatic watering system, see 7.1.5

C C
Battery maintenance.

Charger, see 7 Battery maintenance. C

Examine the condition of the battery connector

and clean the battery connector on the truck
side. Pay special attention to the voltage C
selector pin and the holes of the connector.
See 7.1.5 Battery maintenance.

Measure the insulation resistance of the

C
battery

Electrics

Key switch C

Travel controls C C C

Steering wheel functions C C C

Horn C C C

Test the functionality of the armrest lever

C
switches

Test the functionality of the lights C

Truck display C

Test the functionality of all sensors C

Examine the magnets of the magnetic

switches and clean any dust or metallic C
particles

Cable torque of the motor C

Controller power cable torque C

Cables and wiring C

Test the functionality of the regenerative brake C

Examine the tightening torques of the

C
controller power cable terminal bolts

Examine the tightening torques of the power

C
cable terminal bolts in all motors

Examine and clear the alarm history C

Measure the insulation resistance of the truck C

Wheels

Damage and wear in the wheels C C

Examine the mounting of the front and rear

C C
wheels

Measure the pressure of the pneumatic

C
wheels

Drive unit

Drive axle leakage check C C C

Fastening of the drive axle C

Damage of the drive axle C

R (First
oil
Level of the transmission oil, see 11.3 Oils and
change
lubricants.
after 150
hours)

Lubrication (see the correct lubrication points) G

C
(Replace
Oil level of the service brake tank
at 2000
hours)

Rear axle

Apply grease to the lubrication points of the

C
rear axle, see 11.3 Oils and lubricants.

Examine the operating condition of the

C
bearings, check for looseness of the bearings

Examine the welds for cracks C

Examine the mounting of the rear axle C

Examine the condition of the rubber spring C

Hydraulics

Leakage check C C C

Replacement of the hydraulic oil return filter R

Cleaning of the hydraulic oil suction filter Only when necessary

Oil level C C

Operation of the hydraulics C C C

Relief valves C

Change hydraulic oil and add hydraulic oil

Every 2,000 hours or 2 years.
additive. See 11.3 Oils and lubricants.

Hoses and cylinders C

Lubricate the pump axle splines Every 2 years.

Mast

Mounting of the mast C

Visual inspection of the wear level of the mast

C
rollers and contact surface

Examine the welding in the mast for cracks C

Examine the welding of the outer masts and

C
cylinder support for cracking

Chain setting, adjustment if necessary C C C

Chain wear measurement and replacement if

C
over the 2% limit

Chain anchors and locking pins check C

Chain lubrication (clean and lubricate). See

G
11.3.3 Mast chains.

Tightness of the hydraulic connections, hoses

C C
and pipes, possible leaks and damages

Tightness of the cylinders and piston rods,

C
possible leaks and damages

Mounting of any attachments and load

C
carrying components

Examine the fork base for wear and cracking C

Examine the welding of the cylinder and masts

C
for cracking

Examine the rollers, roller pins and welds for

C
cracking and damage

Lubrication of the mast channel and roller

G
surfaces

Apply grease to the lubrication points of the tilt

G
cylinder

Examine the mechanical limits of the lift and tilt

C
function for cracking and damage.

Functionality of the lift sensors in the mast,

C
possible damages

Test lift function and check lifting and lowering

C
speeds

Test lift with rated load, and with a customer

C
specific load if necessary

Maintain the additional equipment according to the instructions of the manufacturers

Lifting carriage

Examine the lifting carriage welding for

C
cracking

Examine the mounting, wear and damage of

C
the forks and the load handling device

Fork thickness and locking C

Load backrest C C C

Test the functionality of the load handling

C C C
equipment (if applicable)

Lubrication if applicable (see the correct

G
lubrication points)

Cabin

Examine the level of the windshield washer

C
fluid. Add fluid if it is necessary.

Examine the operator door. Make sure that the

door closes properly with both latches
engaged. If necessary, adjust the position of C C
the locking pin. See 8.13.1.6 Adjust the
operator door lock.

General

Cleaning C C C

Examine the welding in the truck frame for

C
cracking and damage

Examine the operator's compartment C C C

Examine the overhead guard for deformation,

C C C
cracking and damage

Examine the gas springs C C C

Make sure that the type and capacity plates

C C C
are in the correct position and not damaged.

Make sure that all warning and instruction

decals and plates are in the correct position C C C
and not damaged.

Examine the covers, see 6.2 Truck covers. C C C

Examine the fastening of the steering wheel C

Test the functionality of the battery door and

C
battery cover mounting

Examine the functionality and mounting of the

C
armrest

Examine the mounting and functionality of the

C
seat and seat belt

Options (CSM)

Examine the functionality of the options. C

664200-EN A CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. 06/23

Moffett Truck-Mounted Forklifts Operator's Manual PDF
No ratings yet
Moffett Truck-Mounted Forklifts Operator's Manual PDF
162 pages
Crown Esr5000
100% (10)
Crown Esr5000
534 pages
Service Manual Spe160l 7SLL12.5 - 20F Sn.924454aa
No ratings yet
Service Manual Spe160l 7SLL12.5 - 20F Sn.924454aa
216 pages
Technical Information For Hyster Customer Care Centres
No ratings yet
Technical Information For Hyster Customer Care Centres
36 pages
List Fault Code
89% (9)
List Fault Code
60 pages
388 operator manual 3888011501 EN 12-2012
No ratings yet
388 operator manual 3888011501 EN 12-2012
312 pages
13 - Optimum8 Operation Manual
No ratings yet
13 - Optimum8 Operation Manual
102 pages
SXH 20 EN 2017-12 Manual Web
100% (1)
SXH 20 EN 2017-12 Manual Web
122 pages
396-03 LP op manual 3968011651EN 11-2016
No ratings yet
396-03 LP op manual 3968011651EN 11-2016
236 pages
Operating Instructions: Model: VH-WP 20B
No ratings yet
Operating Instructions: Model: VH-WP 20B
46 pages
MEC Schematics - 90412-sch
No ratings yet
MEC Schematics - 90412-sch
14 pages
FABERCOM 8 Sortie - 231110 - 145000
No ratings yet
FABERCOM 8 Sortie - 231110 - 145000
8 pages
CBD 15 Wlix
No ratings yet
CBD 15 Wlix
55 pages
NR14N-25NH_Errors
No ratings yet
NR14N-25NH_Errors
10 pages
Service Manual
No ratings yet
Service Manual
104 pages
Supersigma2 Handleiding
No ratings yet
Supersigma2 Handleiding
44 pages
Sevcon-Controller Catalog
No ratings yet
Sevcon-Controller Catalog
12 pages
Linde 661
No ratings yet
Linde 661
101 pages
Separately Excited (SX) Transistorized Dual Motor Traction Control and Series Pump Control Installation and Operation Manual
No ratings yet
Separately Excited (SX) Transistorized Dual Motor Traction Control and Series Pump Control Installation and Operation Manual
74 pages
Huolto-Ohje Haulotte Star 8-10 Eng (Osa 1) PDF
No ratings yet
Huolto-Ohje Haulotte Star 8-10 Eng (Osa 1) PDF
197 pages
PackMule SC-775-6SA Handset Manual (Sevcon)
No ratings yet
PackMule SC-775-6SA Handset Manual (Sevcon)
11 pages
Instruction Handbook - B08D-B09D - 633725 EN vB
No ratings yet
Instruction Handbook - B08D-B09D - 633725 EN vB
214 pages
Efg 213 220 201606
No ratings yet
Efg 213 220 201606
4 pages
14e04k10 Jung-Efg 425-S50 - Instructions
No ratings yet
14e04k10 Jung-Efg 425-S50 - Instructions
35 pages
Parker Vansco vmm2404 Stand Alone CANJ1939 User Manual Instruction Book
100% (1)
Parker Vansco vmm2404 Stand Alone CANJ1939 User Manual Instruction Book
82 pages
Best Motor - Zapi 120V
No ratings yet
Best Motor - Zapi 120V
104 pages
Compact Display: Edition April 2005 Rev.2.0
100% (1)
Compact Display: Edition April 2005 Rev.2.0
38 pages
1212C Manual en
100% (1)
1212C Manual en
70 pages
EKX 410/412/514/516k/516: Electric Order Picker/tri-Lateral Stacker (1,000/1,200/1,400/1,600 KG)
No ratings yet
EKX 410/412/514/516k/516: Electric Order Picker/tri-Lateral Stacker (1,000/1,200/1,400/1,600 KG)
8 pages
J MAST UNIT FOR 1400/1600kg Capasity
No ratings yet
J MAST UNIT FOR 1400/1600kg Capasity
3 pages
Efg 550
No ratings yet
Efg 550
8 pages
TCM FTB14-20 (L) - E4 FB16-20 (L) - E4 Wiring Diagram
No ratings yet
TCM FTB14-20 (L) - E4 FB16-20 (L) - E4 Wiring Diagram
28 pages
3f110 03 Electrical System
No ratings yet
3f110 03 Electrical System
68 pages
en
No ratings yet
en
184 pages
Service Manual: Compact Rough Terrain Scissors (ANSI/CSA)
No ratings yet
Service Manual: Compact Rough Terrain Scissors (ANSI/CSA)
120 pages
Product Catalogue PDF
No ratings yet
Product Catalogue PDF
142 pages
Nuovo Traigo 9FB 80 2.0-3.5 2
No ratings yet
Nuovo Traigo 9FB 80 2.0-3.5 2
6 pages
Data Sheet Efg 213 215 216k 216 218k 218 220
No ratings yet
Data Sheet Efg 213 215 216k 216 218k 218 220
4 pages
Terex Ta 50 e Oprat0r
No ratings yet
Terex Ta 50 e Oprat0r
61 pages
Fleet Manager 200 Plus. Installation Manual PDF
No ratings yet
Fleet Manager 200 Plus. Installation Manual PDF
15 pages
V Series: Three Wheel, Counterbalanced Lift Truck
No ratings yet
V Series: Three Wheel, Counterbalanced Lift Truck
126 pages
UKŁAD STEROWANIA
No ratings yet
UKŁAD STEROWANIA
118 pages
Cd4217e D160S-5
No ratings yet
Cd4217e D160S-5
916 pages
Iqan-Lx - Uk - Ed0707 - Instrução
No ratings yet
Iqan-Lx - Uk - Ed0707 - Instrução
29 pages
Controlador de Direccion 2
No ratings yet
Controlador de Direccion 2
6 pages
Service and Parts Manual Wartungs-Und Ersatzteilhandbuch Manuel de Maintenance Et de Pièces Detachées
No ratings yet
Service and Parts Manual Wartungs-Und Ersatzteilhandbuch Manuel de Maintenance Et de Pièces Detachées
229 pages
4FB-FBA 10-30 Hasta 1980 Ref.s5103
No ratings yet
4FB-FBA 10-30 Hasta 1980 Ref.s5103
459 pages
Hubtex Forklift Mq 30 Ac 2126 Operating Instructions and Spare Parts List De
No ratings yet
Hubtex Forklift Mq 30 Ac 2126 Operating Instructions and Spare Parts List De
24 pages
Manual Curtis 1222 OS15 2013-02-05
No ratings yet
Manual Curtis 1222 OS15 2013-02-05
124 pages
PM PML PLL
100% (1)
PM PML PLL
262 pages
Jungheinrich - Gerbeur - ERC Z14 - Operating Intructions
100% (1)
Jungheinrich - Gerbeur - ERC Z14 - Operating Intructions
125 pages
Manual Yamaha YST-SW105 (Service)
No ratings yet
Manual Yamaha YST-SW105 (Service)
17 pages
Linde EMotion Inverters Datasheet en
0% (1)
Linde EMotion Inverters Datasheet en
5 pages
Eje m13 m15 Data Sheet
No ratings yet
Eje m13 m15 Data Sheet
4 pages
PS12 16 20 N PS16DN（压缩）
No ratings yet
PS12 16 20 N PS16DN（压缩）
4 pages
8 FBN 1479092131
No ratings yet
8 FBN 1479092131
7 pages
J1.60-1.80-2.00XMT: 2033452 Sheet 1 of 7 Revision 0
No ratings yet
J1.60-1.80-2.00XMT: 2033452 Sheet 1 of 7 Revision 0
35 pages
Traction Control Methods
No ratings yet
Traction Control Methods
24 pages
Service Bulletin: R: SB-07-100 (F03-006) P: D: V: S: M
No ratings yet
Service Bulletin: R: SB-07-100 (F03-006) P: D: V: S: M
13 pages
MXL-50C Omm
No ratings yet
MXL-50C Omm
200 pages
Operating instruction SM225.60B
No ratings yet
Operating instruction SM225.60B
56 pages
MX-X EN Manual
No ratings yet
MX-X EN Manual
174 pages
99790-87100-06_Operating Techniques
No ratings yet
99790-87100-06_Operating Techniques
14 pages
GE00024R00H
No ratings yet
GE00024R00H
3 pages
Up Righting Mast with the Tilting Aid
No ratings yet
Up Righting Mast with the Tilting Aid
30 pages
622076-EN-D_SERVICE_8.5x11_6-29-23
100% (1)
622076-EN-D_SERVICE_8.5x11_6-29-23
436 pages
NOR15 Heavy Duty Snap Ring for Presence Pedal
No ratings yet
NOR15 Heavy Duty Snap Ring for Presence Pedal
5 pages
99790-87100-04_Refueling
No ratings yet
99790-87100-04_Refueling
2 pages
Subject Area
No ratings yet
Subject Area
6 pages
000002-23C - The Importance of Firmware Updates
No ratings yet
000002-23C - The Importance of Firmware Updates
12 pages
AJ - 600A, 600AJ - JLG - Parts - English
No ratings yet
AJ - 600A, 600AJ - JLG - Parts - English
398 pages
EN B.1 - SERVICE - 8.5x11 - 6 29 23
No ratings yet
EN B.1 - SERVICE - 8.5x11 - 6 29 23
700 pages
CHASIS
No ratings yet
CHASIS
34 pages
Capacidades y Especificaciones
100% (1)
Capacidades y Especificaciones
21 pages
MIFLTC - RevD.es - SMV 10-65 - FLT - Forklift C-Model
No ratings yet
MIFLTC - RevD.es - SMV 10-65 - FLT - Forklift C-Model
266 pages
Design and Realization of A One-Pedal-Driving Algorithm For The TU/e Lupo EL
No ratings yet
Design and Realization of A One-Pedal-Driving Algorithm For The TU/e Lupo EL
12 pages
TGB Outback 425 - Service Manual
100% (5)
TGB Outback 425 - Service Manual
229 pages
1.8L - Engine - Motronic Multiport Fuel Injection (MFI) 132 K
No ratings yet
1.8L - Engine - Motronic Multiport Fuel Injection (MFI) 132 K
18 pages
Chapter 1 General Information
No ratings yet
Chapter 1 General Information
8 pages
Sae Technical Paper Series: Daniel Mckay, Gary Nichols and Bart Schreurs
No ratings yet
Sae Technical Paper Series: Daniel Mckay, Gary Nichols and Bart Schreurs
13 pages
3C 3D 3B 3A: Power Rating 8V 1600
No ratings yet
3C 3D 3B 3A: Power Rating 8V 1600
3 pages
Ficha Técnica Motor 1 11-16 Ss 2019
No ratings yet
Ficha Técnica Motor 1 11-16 Ss 2019
1 page
Mô hình chuyển tiếp và chiến lược điều khiển dựa trên logic mờ để cải thiện hiệu quả hệ thống truyền lực trong xe điện hybrid song song
No ratings yet
Mô hình chuyển tiếp và chiến lược điều khiển dựa trên logic mờ để cải thiện hiệu quả hệ thống truyền lực trong xe điện hybrid song song
19 pages
Equipment Rental Rates
No ratings yet
Equipment Rental Rates
2 pages
IVMS RAG Report
No ratings yet
IVMS RAG Report
7 pages
SERIES
100% (1)
SERIES
109 pages
Wave Alpha Parts Catalogue 18K71LM2
No ratings yet
Wave Alpha Parts Catalogue 18K71LM2
132 pages
Analysis For Suspension Hardpoint of Formula SAE Car Based On Correlation Theory
No ratings yet
Analysis For Suspension Hardpoint of Formula SAE Car Based On Correlation Theory
6 pages
Classic Jaguar - April-May 2019 PDF
No ratings yet
Classic Jaguar - April-May 2019 PDF
100 pages
Crown Counterbalance Trucks FC5200 Operator Manual - Compressed
No ratings yet
Crown Counterbalance Trucks FC5200 Operator Manual - Compressed
21 pages
Tailift FB15-30 DEC052-07-ENGLISH PDF
No ratings yet
Tailift FB15-30 DEC052-07-ENGLISH PDF
340 pages
NB
No ratings yet
NB
3 pages
Peugeot 406 Coupe
100% (1)
Peugeot 406 Coupe
28 pages
Marine: High Speed Propulsion Engines
No ratings yet
Marine: High Speed Propulsion Engines
44 pages
Company Profile - Latest
No ratings yet
Company Profile - Latest
4 pages
Report Sheet Spooring
No ratings yet
Report Sheet Spooring
1 page
Goodyear Datasheet
No ratings yet
Goodyear Datasheet
8 pages
Service Manual: Forklift Battery
No ratings yet
Service Manual: Forklift Battery
265 pages
Piper Seneca I Checklist
No ratings yet
Piper Seneca I Checklist
4 pages
F-15E Manual 23.06.14 - Compressed
100% (1)
F-15E Manual 23.06.14 - Compressed
546 pages
KTM Folder ADVENTURE Range MY20 - EN PDF
No ratings yet
KTM Folder ADVENTURE Range MY20 - EN PDF
48 pages
Ayp Model 7143a89 Parts List
No ratings yet
Ayp Model 7143a89 Parts List
47 pages
Kenworth T800
No ratings yet
Kenworth T800
11 pages