Service Manual

AC Power Pallet

22.07.2005

Revision Level:3
 Table of Contents
1. Introduction ........................................................................................ 1
1.1. Purpose and target users ............................................................ 1
1.2. Structure ...................................................................................... 1
1.3. Acquiring spare parts .................................................................. 2
1.4. Waste disposal ............................................................................ 2
1.5. Further information ...................................................................... 2
2. Operating the truck ............................................................................ 5
2.1. Safety guidelines for use ............................................................. 5
2.2. Operating environment ................................................................ 7
2.3. Control devices ............................................................................ 9
2.4. Driving the truck ........................................................................ 13
2.5. Load handling ............................................................................ 16
2.6. Charging the batteries ............................................................... 16
2.7. Transportation and storage ........................................................ 18
3. Regular maintenance ...................................................................... 21
3.1. Safety guidelines and preparation ............................................. 21
3.2. Maintenance guidelines ............................................................. 23
3.3. Periodic maintenance procedures ............................................. 25
3.4. Daily maintenance ..................................................................... 27
3.5. Weekly maintenance ................................................................. 37
3.6. Monthly maintenance ................................................................ 41
3.7. Semi-annual maintenance (after 600 hours of operation) ......... 42
3.8. Annual maintenance (after 1,200 hours of operation) ............... 54
3.9. Lubricant and fluid recommendations ....................................... 61
4. Electrical operation and maintenance ............................................. 63
4.1. Electrical operation .................................................................... 63
4.2. Console ..................................................................................... 71
4.3. Traction controller ...................................................................... 74
4.4. Electrical maintenance and repairs ........................................... 95
5. Hydraulic operation and maintenance ........................................... 105
5.1. Hydraulic operation .................................................................. 105
5.2. Hydraulic maintenance and repairs ......................................... 108
6. Mechanical maintenance ............................................................... 113
6.1. Replacing wheels .................................................................... 113
6.2. Replacing the tiller arm gas spring .......................................... 116
6.3. Lever system maintenance ...................................................... 117

ii i
1. Introduction
This service manual provides information on maintaining and
repairing the 1,300, 1,600 and 2,000 kg capacity models of the
pedestrian power pallet truck. The manual aims to provide
information necessary for keeping the truck fully operational for
its entire service life.

1.1. Purpose and target users

This service manual is intended as a reference source for the
professionals responsible for maintaining these trucks. The
maintenance and repair instructions in this manual are presented
with the assumption that the reader is familiar with the operation
and maintenance of powered trucks. Do not attempt any
procedure described in this manual or elsewhere unless you
have the authority, expertise and qualifications for the task.
Always adhere to all local regulations that apply to the work being
done.

The information in this manual covers the common procedures

necessary for keeping a truck in working order. The manual does
not cover nor does it attempt to cover every eventuality that may
arise when servicing trucks. Every effort has been made to
ensure that the information given in this manual is correct and
current. The information can, however, be incorrect, outdated or
otherwise not suitable to the truck model or task. Make sure that
you have all the latest information regarding the truck model and
the maintenance task. This includes, but is not limited to, the
most up-to-date schematic diagrams and special procedure
instructions. Contact your supplier or technical support for
information on obtaining the latest documentation.

1.2. Structure
This manual is divided into five main chapters. Chapter 2
Operating the truck is based on the user’s manual. The chapter
is intended as a reference source for the maintenance
professional to study the use of the truck model being serviced.

Chapter 3 Regular maintenance presents the regular

maintenance procedures of the truck. This chapter also gives
the general guidelines for safety and maintenance.

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 Chapter 4 Electrical operation and maintenance examines the
electrical aspects of the truck. It covers the electrical operation
of the truck, and gives information on using the console to
troubleshoot problems and to modify controller parameters. It
also gives information on irregular electrical maintenance tasks.

Chapter 5 Hydraulic operation and maintenance examines the

hydraulic operation of the truck and provides instructions for
hydraulic maintenance tasks.

Chapter 6 Mechanical maintenance provides instructions for

common mechanical maintenance procedures.

1.3. Acquiring spare parts

When you need spare parts, contact your supplier. Always use
original manufacturer-approved spare parts. To ensure that you
receive the correct items, have the following information ready
when ordering spare parts:

1. Truck type

2. Serial number of the truck

3. Ordering numbers for the spare parts

4. Spare part product names

5. Required quantity of parts

1.4. Waste disposal

When performing maintenance tasks with or on trucks, adhere
to all local regulations governing the proper disposal of produced
waste. Be especially careful when handling and disposing of
hazardous waste, such as hydraulic and transmission fluids,
lubricants and batteries. Reuse and recycle materials when
possible.

1.5. Further information

Contact your supplier or technical support when you require
information on using, maintaining and repairing the truck. Before
attempting any maintenance procedure, make sure that you have

2
the correct and most current version of all the necessary
documentation.

3
2. Operating the truck
This chapter presents instructions on operating the truck. The
content is based on the user’s manual. The chapter does not
contain the entire material of the user’s manual and should not
be used as such. It is intended as a reference source for
maintenance personnel, so that a separate user’s manual is not
required. The chapter covers, among other topics, usage safety,
the recommended usage environment, the truck’s controls,
handling loads and charging the batteries.

2.1. Safety guidelines for use

This section presents safety guidelines for operating the truck in
normal circumstances. Please refer to Section 3.1 Safety
guidelines and preparation and Section 3.2 Maintenance
guidelines for information on safety and preparation for
maintenance tasks.

The trucks have been designed and built to operate in an indoor

environment. They are intended for handling and transporting
goods and materials preferably on pallets. Do not use the truck
for any other than the intended purpose. Follow the operating
instructions in this section or in the user’s manual. A truck may
cause danger to persons or materials if operated incorrectly. Do
not attempt to use a truck before you have familiarised yourself
with its operating instructions.

The trucks covered in this manual conform to the EN 1726-1

standard, which ensures their safety according to the EU machine
directive 98/37/EC. The trucks also conform to the EN 12895
standard, ensuring their safety according to the electromagnetic
compatibility (EMC) directive 89/336/EEG. The trucks are
designed for light and heavy industry use (EN 50081-1 and EN
50082-2).

The most important safety guidelines are mentioned in this

manual. Regulations vary from country to country, and you are
expected to be familiar with the regulations and standards valid
in your area.

2.1.1. Instructions for site supervision

• Familiarise yourself with the truck’s operating instructions.

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 • Train the truck’s operators in the use, safety and regular
maintenance of the truck.

• Control that the operating and maintenance instructions, and

safety regulations are followed.

2.1.2. Occupational safety

• Keep the truck clean and in good working order. Carry out
the daily and weekly maintenance checks according to the
maintenance schedule and instructions to avoid faults and
operational errors.

• If you notice any faults or deficiencies that may effect the safe
operation of the truck, take the truck out of operation
immediately until the faults or deficiencies have been fixed.

• Do not repair the truck without permission from the site

supervisor.

• In the event of a malfunction, switch off the truck’s power and

notify the site supervisor.

• When using the truck, you are responsible for both your safety
and the safety of your environment.

• Immediately notify the site supervisor of an accident or injury.

In such a case, leave the truck at the location of the accident.

• Do not use the truck for a purpose or in an environment for

which it is not intended. The truck must be specifically
equipped for use in a cold environment.

2.1.3. Requirements for the truck operator

• At least 18 years old.

• Sufficient physical (e.g. good hearing and sight) and mental

abilities for operating the truck without risks.

• Appropriately trained, and familiar with the appropriate

operating, safety and maintenance instructions.

• Has permission from the site supervisor to operate the truck.

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 • Knows and masters the driving and operational features of
the truck.

2.1.4. Emergency procedures

If the truck or a load falls over or down on a ramp, release your
grip from the tiller and warn people near you. If the truck
malfunctions, release the tiller arm to the upright position or push
it down completely. This disables the driving circuitry. In case of
a malfunction, always power down the truck either normally or
by pressing the emergency stop button on the main panel, if
possible.

2.1.5. Noise
During use, the truck may subject the user to a noise level of 76
dB (A).

2.1.6. Work in dangerous environments

Trucks used for working in areas susceptible to fire, explosion
or other hazards must be specially equipped. A standard truck
is not suitable for work in hazardous environments. Contact your
supplier for specially designed and equipped trucks suitable for
hazardous environments.

2.1.7. Repairs and structural modifications

Do not modify the truck without the manufacturer's express
permission. Do not add, remove, weld or bend any parts, as the
modifications could affect the operation of the truck, weaken its
construction and cause a safety hazard.

2.2. Operating environment

Use the truck in dry, indoor facilities with hard, even and level
floors. You can operate the truck continuously in temperatures
between +5°C and +25°C, and for short periods in temperatures
between 0°C and +45°C. If you require a truck to operate in
temperatures below 0°C, contact your supplier to obtain a truck
outfitted with optional cold store equipment. Such a truck can be
used in temperatures down to –35°C.

7
 Never use the truck:

• To transport or lift people

• In environments with a fire hazard

• In environments with an explosion hazard

• At premises with insufficient floor load capacity

• If it is damaged

• As a mounting surface

• To tow another truck

• Under the influence of intoxicating substances

2.2.1. Free space

Make sure that the truck has sufficient moving space with respect
to overhead structures and other obstructions. Before driving
through aisles or door openings, ensure that there is enough
space for the truck, the load and yourself. Reduce your driving
speed in confined spaces.
NOTE Always drive at a safe distance from the edge of loading
platforms or bridges.

2.2.2. Bearing capacity of the floor

Make sure that the combined weight of the truck and the load
does not exceed the bearing capacity of the floor or driving
surface.

2.2.3. Using elevators

Obtain permission from the site supervisor to use an elevator to
transport the truck between floors. Make sure that the combined
weight of the truck, the load and any persons present does not
exceed the maximum load capacity of the elevator. Always drive
the truck into elevators and any other narrow spaces with the
load in front.

8
NOTE Make sure that there are no people in the elevator when
driving the truck in or out. The parking brake of the truck
must be on before the elevator moves. Release the tiller
arm to the upright position to deactivate the drive and
engage the parking brake.

2.2.4. Working on ramps

Obtain permission from the site supervisor to drive the truck on
a slope or ramp. When the truck is loaded, travel with the load
pointing uphill. Without a load, you can travel with the forks
pointing downhill.
NOTE Do not turn the tiller arm abruptly on a ramp, as the truck
might overturn.

2.2.5. Working on loading bridges

Always check the bearing capacity and the security of the bridge
before loading or unloading. If you need to drive the truck into a
vehicle, ensure that the vehicle cannot move during this
procedure. Do not drive too near the edge of a loading bridge
because there is always a risk of the truck overturning.

2.3. Control devices

The truck has control devices in two locations: the main control
panel and the tiller arm head assembly. The main panel houses
the main key switch, the charging safety socket and plug, and
different operational indicators. The tiller arm head assembly
houses the controls needed to drive and use the truck.

2.3.1. Main control panel

The main control panel is located on top of the main truck
chassis.

9
 Figure 2.1. Main control panel

2.3.1.1. Charger plug and safety socket (1)

The charger plug is used to charge the truck’s battery from a
normal electrical mains supply with the internal charger. During
normal operation, the charger plug is in the safety socket. The
truck cannot be driven if the plug is removed from the socket.
Refer to Section 2.6 Charging the batteries for more information
on charging the truck’s battery.

2.3.1.2. Main key switch and emergency stop button (2)

The main key switch is used to control power from the battery to
the truck’s electrical system. The switch is equipped with a key
that can be removed to prevent unauthorised use. To remove
the key, press it down, turn it counterclockwise and pull it out.
When the key is in place, the truck’s power can be turned on by
lifting the key to the up position. Press the key to the down
position to turn off the truck’s power.

The key switch also functions as an emergency stop button. In

an emergency, press the key downwards to remove electrical
power from the truck.

2.3.1.3. Status LED (3)

The status LED gives an indication of the current state of the
truck. When the truck is powered up, normally the status LED is
constantly illuminated. If the status LED flashes, this may indicate
an internal fault.

10
 The status LED indicates the possible fault with a distinct
repeating flashing sequence. For example, four flashes and a
pause indicates a low battery. The error indication may also be
due to incorrect operation. Switch off the truck's power and turn
it back on with the tiller arm in the upright position and without
giving the truck any commands through its controls while it starts
up. If the status LED continues to flash, power down the truck
and contact local maintenance staff.

2.3.1.4. Display unit (4)

The display unit shows the accumulated operating time of the
truck in hours. It also displays the battery charge level. If an
internal fault has occurred, the display unit also shows the error
code.

2.3.2. Tiller arm head controls

The tiller arm head assembly contains the controls used for
driving the truck and controlling the forks.

Figure 2.2. Tiller arm controls

2.3.2.1. Safety button (1)

The safety button is located at the far end of the tiller arm. Its
purpose is to prevent the operator from being crushed between
the truck and an object. The safety button is functional when the

11
 truck is being driven in the direction of the tiller arm. It is inactive
in the other direction.

When the safety button is pressed while the truck is being driven
in the direction of the forks, the truck immediately stops and
reverses its movement for a short period. The intensity of this
function depends on the speed of the truck.
WARNING! The operation of the safety button is verified as part of
the daily maintenance checks, which must be performed
each day before using the truck. Never use a truck with
a faulty safety button. Never use the safety button to
manoeuvre the truck.

2.3.2.2. Lifting and lowering controls (2)

Use these controls to lift and lower the truck’s fork carriage. You
can use the controls on either side of the tiller arm.

2.3.2.3. Horn button (3)

Press this button to activate the truck’s horn.

2.3.2.4. Steering (4)

The truck is steered by moving the tiller arm from side to side.
The drive wheel is directly connected to the tiller arm and turns
with it. The tiller arm can be turned 100 degrees in both directions
from the centre position.

The vertical position of the tiller arm affects driving: The truck
can only be driven when the tiller arm is in the driving position,
which is the area between the two extremes. The truck’s traction
is disabled when the arm is in the upright or the bottom position.
The restriction can be removed by pressing the brake release
button.

2.3.2.5. Accelerator controls (5)

The two winged rotating wheels control the direction and
acceleration of the truck. The movement direction is determined
by the direction in which the controls are displaced from the
neutral position. The amount of displacement determines the
truck’s speed in the given direction. The accelerator control is
also used to reduce the truck’s speed by either releasing it to the
neutral position or by turning it in the opposite direction to
movement.

12
2.3.2.6. Brake release button (option)
The brake release button is located on the top of the tiller arm
head. The brake release can be used to remove the driving
restriction when the tiller arm is in the upright or the bottom
position. This can be useful in confined spaces. The brake
release is intended to be used in special situations and should
not be used constantly.

2.4. Driving the truck

Before attempting to drive a truck, make sure that the daily
maintenance checks have been carried out.

To power up the truck:

• Ensure that the charging plug is in the safety socket.

• Ensure that the tiller arm is in the upright position.

• Ensure that no controls or buttons are depressed.

• If the key is not in place, insert it into the key switch and turn
it clockwise.

• Lift the key upwards to turn on the main power of the truck.

If, after the above procedure, the status LED is constantly

illuminated, the truck is powered up and ready to be used. If the
truck is equipped with a display unit, it activates and shows the
accumulated operating time in hours and the charge level of the
battery. Before starting to use the truck, check that the battery
level is sufficient.

2.4.1. Driving instructions

Always use care when driving a truck. Even without a load, the
truck is heavy and can cause damage or injury if driven
carelessly. Adjust your driving speed to the conditions. Reduce
speed when operating in confined spaces or when transporting
heavy or unstable loads.

To start driving the truck:

• Power up the truck, check that the status LED is constantly

illuminated and that the battery charge level is sufficient.

13
 • Take hold of the tiller arm handles and lower the tiller arm to
the driving position.

• Ensure that there are no obstructions.

• Turn the accelerator carefully in the desired direction.

The truck should start to slowly move in the selected direction.

Turn the accelerator further to increase the truck’s speed. Reduce
the deflection to reduce the speed and release the accelerator
to the neutral position to stop.

If you wish to reduce speed more rapidly, turn the accelerator

control to request movement in the opposite direction. If you keep
the accelerator held after the truck has stopped, it begins to move
in the requested direction at the set speed.

Use the tiller arm to steer the truck. When driving the truck in the
direction of the tiller arm, walk beside it and hold the tiller arm
handle with one hand. When driving in the opposite direction,
walk behind the truck and keep both hands on the tiller arm
handles.

2.4.2. Safety guidelines for driving

Before operating the truck, ensure that you have the appropriate
training and skills. If you have little prior experience with this type
of truck, take time to practise driving and operating it in a safe
environment before actually using the truck.

Keep the following guidelines in mind when driving a truck:

• Always adjust your driving speed to the situation. Consider

the load, visibility, the environment, other persons and any
obstructions.

• Reduce your speed in confined spaces, near edges, at

intersections, on ramps, on rough or slippery surfaces and
when driving near other persons.

• Accelerate and decelerate smoothly to avoid the load slipping

or tipping.

• Use smooth motions while steering the truck, especially when

it is loaded to reduce the risk of the load or truck overturning.

14
 • When possible, keep both hands on the tiller arm handles.

• Be especially careful when driving on slanted or uneven

surfaces.

• Do not drive over objects.

• Be careful when driving with a load that reduces your visibility.

Use an assistant if necessary.

• Always drive at a speed that enables you to stop the truck

safely.

2.4.3. Stopping and parking the truck

The speed of the truck is electrically controlled through the motor.
In addition to acceleration, the motor is used to reduce the truck’s
speed.

To slow down the speed of the truck while it is being driven,

reduce the deflection of the accelerator by moving it back towards
the neutral position. The truck's speed decreases until it travels
at the speed that corresponds to the accelerator’s deflection.
Return the accelerator control to the neutral position to decelerate
completely and bring the truck to a standstill. To reduce the speed
more rapidly, turn the accelerator against the direction of
movement to request traction in the opposite direction.

When you wish to park the truck or otherwise leave it stationary,

stop it first and then release the tiller arm to the upright resting
position.The truck has an electrical parking brake, which engages
automatically when the truck comes to a standstill and when the
accelerator is not deflected. Releasing the tiller arm to the upright
position also disables the drive.

The electrical parking brake remains engaged when the truck’s

power is turned off. You should always turn off the truck’s power
when leaving the truck standing or unattended for any length of
time.

When the truck is not being used, it should be parked in a

reserved parking place. Lower the fork carriage and release the
tiller arm to the upright position. Turn off the truck by pressing
down the key switch. For additional security, remove the key
from the key switch. Ensure that the truck cannot move by itself
or be accessed by unauthorised persons.

15
NOTE Never park the truck or leave materials in front of fire exits,
fire extinguishers, etc. Do not park on a slanted surface.

2.5. Load handling

The truck has been designed for transporting materials on pallets.
When transporting a load, keep in mind the following guidelines:

• Always secure a load before transporting it.

• Always drive the truck with the forks as low as possible.

• Accelerate, decelerate and steer carefully.

• Never place any part of your body between the structures of

the truck and the fork carriage.

• Be especially careful when transporting a load that is wider

than the truck.

• Only handle undamaged loads.

• Place the load so that its weight rests as evenly as possible

on the forks.

• On slopes and ramps, place yourself above the load.

• Do not overload the truck.

• Verify the truck’s lifting capacity from the identification plate,

which is fixed to the underside of the tiller arm.

WARNING! Do not exceed the truck's maximum loading capacity

under any circumstances.

2.6. Charging the batteries

The truck is equipped with rechargeable batteries that should be
fully recharged before the truck is taken into use each day.
Charging the batteries should be the responsibility of a trained
professional. Lead-acid batteries contain a corrosive acid solution
and can contain a considerable amount of stored electrical
energy. Therefore, the responsible person or persons should be
qualified and take appropriate precautions. See Section 3.1
Safety guidelines and preparation and Section 3.2 Maintenance
guidelines for information on safety and preparation for
maintenance tasks. See Chapter 3 Regular maintenance for

16
information on regular battery maintenance procedures and
Section 4.4.1 Battery maintenance for more information on battery
maintenance.

Adhere to the following guidelines when working with

batteries:

• Do not handle a naked flame or smoke near batteries, as

batteries can emit explosive gases.

• Do not place conductive tools or other objects on top of the

batteries to avoid short-circuiting.

• Before charging wet lead-acid batteries, make sure that the

cell caps are firmly fastened to prevent the corrosive battery
solution from splashing.

• Wear protective gear appropriate for handling batteries, which

contain a corrosive acid solution.

• Make sure that the area where batteries are charged is well
ventilated to rapidly dissipate any produced explosive gases.

• Always charge a battery before storing it or if it is not used

for a long period. Storing a battery in a low-charge state can
permanently damage it.

The battery can be charged either with an external or an internal

battery charger. If an external battery charger is used, follow the
instructions given by the manufacturer or supplier of the charging
device. When using an external battery charger, ensure that it
is suitable for the battery type.

A truck with an internal charger can be charged from a normal

wall socket. To charge a truck with an internal battery charger:

1. Park the truck in a reserved charging place.

2. Turn off the truck’s power from the main key switch.

3. Unplug the charging plug from the safety socket.

4. Connect the plug to a suitable mains socket.

The charging indicator on the truck’s control panel indicates the

progress of charging. The indicator flashes red at the beginning
of charging. It changes to yellow to indicate 80% battery charge.

17
 When the indicator turns to green, the truck’s batteries are fully
charged and the charger can be unplugged. Even if the charger
is not unplugged after charging is completed, it stops charging
automatically.

A fault in the internal charger is indicated by the charging

indicator as follows:

• Flashing green: Timeout alarm

The charging duration exceeds the preset maximum value.

Verify that the battery has the correct capacity.

• Flashing between red and yellow: Battery current alarm

Loss of output power control. Indicates a fault in the control

logic.

• Flashing between red and green: Battery voltage alarm

Loss of output power control. Indicates a fault in the control

logic.

• Flashing red, yellow and green in sequence: Temperature

alarm

Internal components have overheated. Verify fan operation.

• Flashing between yellow and green: Configuration alarm

An unavailable configuration has been selected. Verify

selector position.

2.7. Transportation and storage

Lift the truck only from a marked lifting point. Make sure that the
capacity of the lifting device is sufficient. Only tow the truck with
the drive wheel lifted from the surface.

18
Figure 2.3. Lifting point label

If the truck is not used for a long period, it should be stored in a

cool (above 0°C) and dry place. Make sure that the storage
surface is even and support the truck so that weight is taken off
the drive wheel. Fully charge the truck’s battery before storage
and recharge it every 2 to 3 months of storage to prevent
damage. Also check the level of battery fluid regularly and add
fluid if necessary. If the truck is stored for over a year, change
its hydraulic fluid annually.

If the truck has been stored for several months, perform the
procedures described for semi-annual maintenance (Section 3.7
Semi-annual maintenance (after 600 hours of operation)) before
returning it to use. For shorter storage periods, normal daily
maintenance checks are sufficient before returning the truck to
use.

19
3. Regular maintenance
Regular maintenance is the best way of keeping a truck fully
operational and safe for the users. The procedures described in
this chapter should be carried out according to the schedule
outlined in Section 3.3 Periodic maintenance procedures.

Even though daily maintenance checks can be carried out without

special training, this manual assumes that the reader is a
professional trained in the service of trucks. Therefore, the
presented maintenance and repair instructions should be followed
only by professional service personnel.

3.1. Safety guidelines and preparation

Do not attempt any maintenance or repair procedure unless you
are authorised and qualified to carry it out. To service trucks you
must be qualified to work on both electrical and hydraulic
systems. Before planning maintenance actions on a truck, ensure
that you are sufficiently familiar with the operation and use of the
truck type and model. Make sure that you have the most current
version of this service manual, as well as all the necessary and
most current versions of schematic diagrams, charts and any
other information needed for the maintenance tasks.

Perform maintenance and repair tasks only in a suitable

environment. The service area must be safe for the servicing
personnel, as well as for any other persons in its vicinity. The
area must also be safe and suitable for performing electrical,
hydraulic and mechanical maintenance procedures. The area
must be kept clean. Any fluid stains, waste and unnecessary
equipment must be cleared from the service area before and
during maintenance. Make sure that the service area is well
ventilated.

To uphold personal working safety, make sure that you are

appropriately prepared to perform servicing. Ensure that you
have the appropriate clothing for the tasks. This includes
protective clothing, footwear and gloves, as well as other
protective equipment required by the task, such as eyewear, a
mask and hearing protection. Take the appropriate precautions
when handling harmful, corrosive or toxic chemicals. Never use
bare hands or other parts of your body to test for leaks etc.
Remove personal jewellery to reduce the risk of causing short

21
 circuits. When working on trucks with any panels open, adhere
to all regulations governing electrical and hydraulic maintenance.

When performing maintenance procedures on or near batteries,

take special care to protect yourself and your environment. The
battery fluid in battery cells is a corrosive acid solution, which
will burn if it comes into contact with bare skin or eyes. Never
handle a naked flame or smoke a cigarette near batteries. Be
careful with conductive tools near batteries, especially if any
battery contacts are exposed. Always disconnect the battery
from the truck before removing it.

Do not attempt a maintenance procedure unless you have all

the necessary tools and equipment required by the task. Use
only spare parts approved by the manufacturer. Use only the
correct fluids and lubricants. Refer to Section 3.9 Lubricant and
fluid recommendations for the recommended lubricants and
fluids.

Use jacks of suitable design and sufficient capacity to lift the

truck. Remember balance when lifting with a jack: position the
jack so that the truck’s weight rests evenly on the supports and
there is no risk of it overturning. Always secure the truck after
lifting it with a jack. Do not work underneath a truck that is
supported only by jacks.

Always turn off the main power of the truck and release hydraulic
pressure before opening any covers. If any cover is open, turn
on the main power or use the hydraulic system only if it is
necessary for accomplishing the maintenance task. Disconnect
the main battery connector unless electrical power is required.
Take extreme care when working near electrical components.
Even if the main power is switched off, there may be considerable
electrical charges in truck components, such as in the batteries
and in power capacitors.

Note that some components become hot during operation. Allow

the truck to cool down after use before opening any covers.
Especially the components of the electrical and the hydraulic
system can heat up considerably during operation.

When larger repairs are involved, for example, when welding,

the battery should be disconnected or removed. When welding
is necessary, remove any paint or other finishing over a radius

22
 of at least 100 mm from the welding point to reduce the possibility
of toxic gases being produced.

Adhere to all local (national and site-specific) regulations and

recommendations governing the working area and the
maintenance procedures that you are performing. This includes
regulations on personnel safety, the handling of materials,
environmental safety and disposal of waste.

Do not perform a maintenance procedure, if you are uncertain

of how it should be carried out. Do not modify the truck in any
way that might reduce its structural integrity or affect its safe use.
If you have doubts or concerns about a procedure described in
this manual, contact the local product representative or the
manufacturer’s technical support.

Return a truck to normal use only after all regular and other
necessary maintenance procedures have been completely carried
out and the truck is deemed to be in full working order.

3.2. Maintenance guidelines

Reserve a sufficiently large area for servicing the truck. The area
should be large enough for you to be able to test all of the truck’s
normal operating functions, such as driving and lifting.

Determine the model of the truck under maintenance from the

identification plate that is located on the underside of the tiller
arm (when viewed from the driving position). The identification
plate should be easily readable when the tiller arm is in the
upright position. The three truck models covered by this manual
are distinguished by their nominal lifting capacity. The
identification plate indicates the capacity of the truck as 1,300,
1,600 or 2,000 kg. The truck models differ slightly in both regular
and irregular maintenance and repair procedures. Most of the
regular maintenance is identical for the three models, and the
differences are indicated where necessary.

23
 Figure 3.1. Identification plate

All the truck models have two main covers that can be opened:
the main cover and the top cover. In addition, the 1,600 and
2,000 kg capacity trucks have a separate battery compartment
cover on top of the truck between the top cover and the forks.
This battery compartment cover is hinged and can be opened
by lifting it. The main and top panels are held in place by screws
on both sides of the truck chassis. The two topmost screws on
either side hold the top cover, while the two lower screws on
either side hold the main cover in place.

Figure 3.2. Main cover fixing screws

To open the main or the top cover on any truck model, loosen
the fixing screws enough for the cover to be removed, but do not
remove the screws entirely. The screws move a fixing bracket,
which holds the cover in place.

24
 All of the covers on a truck should be closed when its functions
are tested. Open the covers only when it is necessary for
accomplishing the maintenance or repair task.

Some maintenance and repair tasks require the truck to be lifted.

Only suitable lifting equipment should be used to lift a truck. Use
only marked lifting points. When this is not possible, make sure
that you choose lifting points that can securely support the weight
of the truck without being damaged. Remember to secure a lifted
truck so that it does not pose a risk to personnel safety.

3.3. Periodic maintenance procedures

The periodic maintenance procedures are grouped based on the
intervals after which they must be performed. This section lists
the procedures for your convenience. If faults or damage are
encountered during any of the periodic maintenance procedures,
the maintenance process should be halted and the fault or
damage fixed. After the truck has been repaired, the maintenance
process should be restarted from the beginning. Always begin
with the daily maintenance checks before using the truck after
any repairs or modifications.

The regular maintenance schedule:

Daily maintenance

• Check the operation of the main key switch and the

emergency stop.

• Check that the battery is charged.

• Visually check the truck for any apparent damage.

• Check the condition of the wheels.

• Check the fastening of the two batteries on 1,300 kg capacity

trucks and that the battery is securely in place on 1,600 and
2,000 kg capacity trucks.

• Check the level of battery fluid in each battery cell (does not
apply to 1,300 kg capacity trucks).

• Check the transmission for leaks.

• Visually check the condition of hydraulic tubing and couplings.

25
 • Test the operation and condition of the tiller arm.

• Test the operation of the safety button.

• Test the driving functions: controlling direction and speed,

steering, the tiller arm position sensors, and the horn.

• Test the operation of the parking brake.

• Test the operation of the lifting hydraulics and controls.

Weekly maintenance

• Check that all fixing hardware and tube couplings are secure.

• Check and clean the batteries and battery cabling.

• Check the amount of fluid in the hydraulic system.

• Check the condition of identification plates and labelling.

• Clean the truck if necessary.

Monthly maintenance

• Lubricate the drive unit bearings on 2,000 kg capacity trucks

(does not apply to 1,300 or 1,600 kg capacity trucks).

Semi-annual maintenance (after 600 hours of operation)

• Complete all the daily and weekly maintenance tasks.

• Check the electrical connections and cabling.

• Check the angle and condition of the forks.

• Check the wear of the brake pad.

• Check the fastening of the transmission and the drive unit on

2,000 kg capacity trucks (does not apply to 1,300 or 1,600
kg capacity trucks).

• Check the amount of transmission fluid on 2,000 kg capacity

trucks (does not apply to 1,300 or 1,600 kg capacity trucks).

Annual maintenance (after 1,200 hours of operation)

• Change the hydraulic fluid.

26
 • Change the transmission fluid on 2,000 kg capacity trucks
(does not apply to 1,300 or 1,600 kg capacity trucks).

3.4. Daily maintenance

The daily maintenance procedures are vital for keeping a truck
fully operational. They should always be carried out thoroughly
each day before using the truck. Daily truck maintenance can
be the responsibility of a person that does not have professional
training. In this manual, it is assumed that the daily maintenance
procedures presented below are carried out by a maintenance
professional.

If any damage or other problems that affect the use or safety of

the truck are encountered during daily maintenance, the truck
must not be used until it is fully operational.

3.4.1. Checking the operation of the main key switch and

the emergency stop
Before starting any other maintenance tasks, check that the main
key switch and the emergency stop button operate properly. If
the key switch is faulty or the emergency stop function does not
operate, remove the truck from use use immediately. Return the
truck to use only after it is fully operational. Refer to Chapter 2
Operating the truck for information on the truck’s controls.

Begin by turning the main key switch on. The truck should power
up and indicate standby mode by illuminating the indicator LED.
If the truck is equipped with an hour meter, the meter should
activate and indicate the accumulated operating hours and the
level of battery charge. Turn the main key switch off to test that
the truck shuts down.

27
 Figure 3.3. Control panel

The emergency stop button is integrated into the main key switch.
To test the emergency stop button, first switch the truck on
normally. With the truck active press the emergency stop button
to check that it deactivates the truck immediately. To reactivate
the truck, lift the button into the operating position.

3.4.2. Checking the battery charge

It is assumed that the truck’s battery is fully charged each day
before daily maintenance and use. The battery can be charged
with an external or internal charger. If an external charger is
used, you should follow the instructions issued by the
manufacturer or supplier of the charger.

If the internal battery charger is used, follow the instructions in

Section 2.6 Charging the batteries. An internal charger is
equipped with a charging progress indicator on the truck’s control
panel. Ensure that the indicator indicates a fully charged battery
before taking the truck into use.

If the truck is equipped with an hour meter, the meter shows the
approximate level of battery charge when the truck’s main power
is switched on. After charging, this indicator should read full
battery charge.

If the battery does not seem to charge properly, does not hold a
charge or presents other problems, refer to the battery

28
 maintenance section in Chapter 4 Electrical operation and
maintenance for more information.

3.4.3. Checking the truck for external damage

Visually check the truck for any apparent problems or external
damage. If damage is apparent, its extent should be checked
and any necessary repairs made before continuing with regular
maintenance. If the damage in any way affects the use or safety
of the truck, the truck must be taken out of use until it is fully
operational.

3.4.4. Checking the condition of the wheels

The truck has three wheel types: drive, load and castor. The
drive wheel is located immediately under the tiller arm anchoring
point and supports a considerable portion of the truck’s weight.
It is attached to the drive motor via the transmission to propel
the truck, and it is turned with the tiller arm to steer the truck.

Figure 3.4. Drive wheel

The load wheels are located near the ends of the forks. Their
main purpose is to support the weight of the load. Depending on

29
 the truck model, there is either a single or a double load wheel
in each fork.

Figure 3.5. Load wheels

The side-supporting castor wheels are located under the main

chassis on either side of the drive wheel. They support the truck
when it is driven and prevent it from tilting, as there is only one
drive wheel. The castor wheels turn automatically to follow the
direction of travel. They are equipped with suspension springs.

30
 Figure 3.6. Castor wheel

Remove the main cover to gain better access to the wheels.

Check all the wheels on a truck for damage and wear.The wheels
should wear evenly, and there should be no flats or holes in the
wear surface. The wheels should also turn smoothly on their
axles and there should not be play in the bearings. Even wear
can be tested by driving the truck on a smooth surface to test
that all the wheels turn and the truck rides smoothly. If a wheel
or a bearing has sustained damage that affects use or if its
surface has worn completely, it should be replaced. Refer to
Chapter 6 Mechanical maintenance for information on replacing
and servicing wheels.

3.4.5. Checking that the batteries are securely fastened

The fastening of the batteries depends on the truck model. The
1,300 kg capacity truck does not have a separate battery
compartment. Its two service-free batteries are located within
the main chassis, on both sides. These batteries are held in place
by straps. Open the main cover to perform this check. Check
that the straps are tight and that both batteries are securely held
in place.

31
 Figure 3.7. Battery arrangement on 1,300 kg capacity trucks

Trucks with a capacity of 1,600 and 2,000 kg have a separate

battery compartment between the main chassis and the forks.
On the 1,600 kg capacity truck, the battery assembly sits in its
well and is kept in place by its own weight. The implementation
is similar on the 2,000 kg capacity truck, but the battery assembly
is also held in place with a fixing bracket. Open the battery
compartment cover to check the battery assembly. In both cases,
check that the battery assembly sits evenly at the bottom of the
battery well. Check that the bracket is securely fixed on the 2,000
kg capacity truck.

32
 Figure 3.8. Battery arrangement on 1,600 and 2,000 kg capacity
trucks

3.4.6. Checking the level of battery fluid in each cell

NOTE This check applies only to the 1,600 and 2,000 kg capacity
trucks with wet batteries. The 1,300 kg capacity truck has
service-free batteries. Make sure that the battery is fully
charged before checking the level of battery fluid.

Take appropriate precautions when handling batteries and battery

fluid. Battery fluid is a corrosive acid solution and can cause
burns if it comes into direct contact with bare skin. Use only
approved fluid to fill the battery cells. Refer to Section 3.9
Lubricant and fluid recommendations for fluid recommendations.

Open the battery compartment cover to access the battery cells.

Follow the instructions issued by the battery or battery cell
manufacturer for maintaining battery cells in good condition. Use
care not to contaminate the solution with impurities. Do not overfill
the cells and close the caps firmly to avoid leakage.

33
3.4.7. Checking the transmission for leaks
Visually check that there are no apparent fluid leaks in the
transmission assembly. Open the main cover to perform this
check. The transmission of 1,300 and 1,600 kg capacity trucks
is service free and has been filled with grease to last its entire
operating life. The transmission of 2,000 kg capacity trucks is
fluid-filled and serviceable. It has a filling cap at the top, a
checking cap on its side and a draining cap on the underside.
Check that these caps are firmly fastened. Never use your hands
to check for leaks. The amount of transmission fluid is checked
during semi-annual maintenance (see Section 3.7.6 Checking
the amount of transmission fluid (2,000 kg capacity trucks only)).

3.4.8. Checking the condition of hydraulic tubing and

couplings
Visually check the condition of all accessible hydraulic lines and
couplings. Open the main cover to perform this check. The
location of hydraulic components differs between truck models,
but you should check that all the accessible couplings and tubing
in the hydraulic system are in good condition. There should be
no evidence of leaks or damage. Follow the hydraulic system
from the tank and pump assembly to all couplings.

The operation of the hydraulic system is tested during daily

maintenance (see Section 3.4.13 Testing the lifting hydraulics
and controls). The amount of hydraulic fluid in the system is
checked during weekly maintenance (see Section 3.5.3 Checking
the amount of hydraulic fluid). The hydraulic fluid in the system
is changed annually (see Section 3.8.1 Changing the hydraulic
fluid). If you find any problems or damage in the hydraulic system,
the truck must be taken out of use until it is fully operational.
Refer to Chapter 5 Hydraulic operation and maintenance for
information on hydraulic maintenance.

3.4.9. Testing the operation and condition of the tiller arm

When the truck is not being used, the tiller arm must rest in the
upright position. Check that the arm moves smoothly between
the top and bottom positions. Check that the gas spring in the
tiller arm returns the arm from any position to the upright position.
Check that the tiller arm is securely fastened at its base. Check
for any unwanted play in the moving parts. Note that the position
of the tiller arm affects driving (see Section 3.4.11 Testing the

34
 speed control unit, steering and the horn). If the tiller arm does
not function properly or if it has sustained damage, the truck must
be taken out of use until it is fully operational. Refer to Chapter 6
Mechanical maintenance for information on mechanical
maintenance.

3.4.10. Testing the safety button

WARNING! Never use a truck with a faulty safety button!

Check the operation of the safety button immediately after the

main power switch is turned on. Test the operation of the safety
button before continuing with the other operational tests.

Close all the covers before you switch on the main power. For
the remaining daily maintenance tests, you have to switch on
the truck’s main power. Refer to Chapter 2 Operating the truck
for information on the truck’s controls.

The safety button is located at the far end of the tiller arm. Its
purpose is to prevent the user from being crushed between the
truck and a solid object. The safety button works only when
moving in the direction of the tiller arm. If the button is pressed
while moving, the truck should stop immediately and reverse its
direction for a short time. The intensity of the reversing action is
proportional to the movement speed.

Figure 3.9. Safety button

35
 Check the operation of the safety button by pressing it while
driving the truck slowly in the direction of the tiller arm. If the
safety button does not function properly, halt the maintenance
process immediately and take the truck out of use until the safety
button is fully operational.

3.4.11.Testing the speed control unit, steering and the horn

Continue with this test only if the safety button of the truck is
operational. Refer to Chapter 2 Operating the truck for information
on the truck’s controls and driving.

1. Begin by taking hold of the tiller arm and lowering it from the
upright position to the driving position. Do not lower it to the
bottom position.

2. Use the accelerator on either side of the tiller arm to test the
speed control. Move the accelerator gently in the forward
direction. The truck should accelerate smoothly while the
controller is moved. Reduce the speed from the accelerator
and the truck should respond smoothly.

3. Test the reverse direction similarly. Accelerate in the forward

direction once again and test reverse braking by moving the
accelerator opposite to the direction of the movement. The
truck should first decelerate and then begin to move in the
opposite direction until the accelerator is released.

4. Test that the position sensor of the tiller arm operates by

attempting to drive when the arm is in the upright and in the
bottom position. The truck should not respond to the
accelerator when the tiller arm is in these extreme positions.

5. Repeat the test by moving the tiller arm to the driving

position, driving the truck slowly and both pressing the arm
down to the bottom position and releasing it to the upright
position. In both cases, the truck should stop.

6. Drive the truck both forward and backward, and test the
steering by moving the tiller arm from side to side. Steering
should be smooth throughout the available arc in both
directions.

7. Test the horn by pressing the horn button on the tiller arm.

36
 If any problems are encountered during this test, take the truck
out of use until it is fully operational.

3.4.12. Testing the parking brake

The trucks are equipped with an automatic parking brake. The
brake should be active when the main power is off and also when
the main power is on unless the accelerator is moved to issue a
driving command. Test the parking brake by trying to move the
truck. When the brake is active, the truck should not move
forward or backward. The parking brake only affects the drive
wheel so that the other wheels are still free to turn. The tiller arm
can also be freely moved from side to side while the parking
brake is active.

3.4.13. Testing the lifting hydraulics and controls

Test the operation of the lifting hydraulics by lifting and lowering
the forks. Refer to Chapter 2 Operating the truck for information
on the truck’s controls. The forks should rise smoothly from the
lowest position to the highest position. The forks should stop
smoothly when reaching the upper position. If the forks hit the
upper position at full speed, there may be a problem in the
system. Refer to Chapter 6 Mechanical maintenance for
information on mechanical maintenance.

3.5. Weekly maintenance

Like daily maintenance, weekly maintenance is important for
keeping the truck in full working order. Weekly maintenance
should be scheduled for a certain day of the week, so that the
maintenance interval does not fluctuate. When weekly
maintenance is due, complete all of the daily maintenance
procedures first before continuing with the weekly maintenance
procedures.

Before beginning, ensure that the main power of the truck is

turned off. Open the main and top covers of the truck before
commencing with the weekly maintenance procedures. Refer to
Section 3.2 Maintenance guidelines for information on how to
open the truck’s covers.

Should the weekly maintenance procedures reveal anything that

affects the use or safety of the truck, the truck must immediately
be taken out of use until it is restored to full working order.

37
3.5.1. Checking that fixing hardware and tube couplings
are secure
Check that all accessible fixing hardware is securely fastened,
and that there is no play between parts that should be firmly
fixed. Check that all the couplings in the hydraulic system are
tight.

3.5.2. Checking and cleaning the batteries and battery

cabling
The batteries of the 1,300 kg capacity truck are located in the
main chassis, so you have to open the main cover to access
them. The batteries of the 1,600 and 2,000 kg capacity trucks
are located in the battery compartment between the main chassis
and the forks. Open the battery compartment cover to access
the batteries.

Visually check the condition of the two batteries on 1,300 kg

capacity trucks. Visually check the condition of the battery cells
on 1,600 and 2,000 kg capacity trucks. Check that all the battery
cabling (both to the main poles and between cells) is securely
fixed and in good condition, with all the insulators intact.

Over time, grime accumulates onto the batteries. Clean batteries

weekly with a non-conductive and non-abrasive dry cloth. Never
use water or any other cleaning agent when cleaning batteries
or battery cells. Take precautions for handling lead-acid batteries,
which contain a corrosive acid solution. Take care to not
short-circuit a battery or cell connection.

3.5.3. Checking the amount of hydraulic fluid

Check the amount of fluid in the hydraulic system. Before
checking the amount, ensure that there is no pressure in the
system, that is, that the forks are resting in the lowest position.
The location of the hydraulic tank differs between truck models,
but it is visible when the main cover is open. On 1,300 kg capacity
truck models, the tank is installed horizontally, and it should be
half full.

38
Figure 3.10. Hydraulic tank location (1,300 kg capacity truck
model)

On 1,600 kg and 2,000 kg capacity truck models, the tank is

installed vertically, and it should be filled to three-quarters (¾)
of the capacity when measured from the bottom of the tank to
the bottom edge of the filling tube.

39
 Figure 3.11. Hydraulic tank location (1,600 and 2,000 kg capacity
truck models)

If the level of fluid in the tank is below the above amounts, you
must add hydraulic fluid to the system. Refer to Section 3.9
Lubricant and fluid recommendations for fluid recommendations.
When adding hydraulic fluid to the system, use only new and
clean fluid, and uphold cleanliness during the operation so that
contaminants are not introduced into the hydraulic system. Take
appropriate precautions when handling hydraulic fluid, as it is
harmful.

3.5.4. Checking the condition of identification plates and

labelling
The main identification plate of the truck is located on the
underside of the tiller arm. Check that it is firmly in place,
undamaged and fully legible. If the plate is missing or cannot be
read, a new one must be fitted. In addition to the identification
plate, check that other labelling and markings, such as lifting
points or any warnings, are in place and intact.

40
3.5.5. Cleaning the truck
Clean the truck at least once a week. Keeping the truck clean
upholds safety and helps to maintain it in good working condition.
If the truck is kept clean, it is also easier to notice possible
damage or wear.

When cleaning the truck, take care not to let water or other fluids
enter the main chassis or battery compartment. Never use a
pressure washer to clean the truck. Use a dry and clean cloth
when possible and use solvents only when necessary. If solvents
are necessary, make sure that the chemicals will not harm the
surface or component that is being cleaned.

3.6. Monthly maintenance

There is only one monthly maintenance procedure, which affects
2,000 kg capacity trucks.

3.6.1. Lubricating the drive unit bearings (2,000 kg capacity

trucks only)
The bearings of the drive unit must be lubricated monthly. Open
the main cover of the truck to gain access to the bearing. The
bearing assembly to be lubricated sits above the drive motor and
transmission assembly. The lubrication nipple should be used
to lubricate the bearings.

41
 Figure 3.12. Lubrication nipple location

Use a grease gun to press the lubricant into the bearing

assembly. Refer to Section 3.9 Lubricant and fluid
recommendations for lubricant recommendations. After
lubrication, move the tiller arm from side to side to distribute the
lubricant evenly in the bearing assembly.

3.7. Semi-annual maintenance (after 600 hours of

operation)
Semi-annual maintenance should be carried out either after half
a year or after 600 hours of use, whichever is sooner. If the truck
is equipped with an operating time meter, semi-annual
maintenance is easy to schedule. If not, the operating time can
be read using the console (refer to Chapter 4 Electrical operation
and maintenance for more information on using the console).
The semi-annual maintenance procedures should be carried out
only by a trained professional.

3.7.1. Daily and weekly maintenance procedures

Before beginning the semi-annual maintenance procedures, both
the daily and weekly maintenance procedures must be carried
out as explained above.

Before continuing to the semi-annual maintenance procedures,

ensure that the power to the truck is turned off. The procedures

42
 described below require that you first remove the main and top
covers of the truck.

3.7.2. Checking the electrical connections and cabling

Visually check that all the main electrical connections and cabling
of the truck from the battery to the drive and pump motors are
in good working order. Take appropriate precautions for
performing electrical maintenance.

1. Begin by checking that the main battery connection is firmly

in place.

Figure 3.13. Main battery connection (1,300 kg capacity

truck model)

43
 Figure 3.14. Main battery connection (1,600 and 2,000 kg
capacity truck models)

2. Follow the main cabling from the battery connection to the

main fuses. Visually check the condition of the cabling for
any damage. One fuse routes power to the drive motor while
the other routes power to the pump motor.

3. Check that all the connections to and from the fuses are
secure and that the cable ends are in good working order.

44
 Figure 3.15. Main fuses

4. Follow the power cable to the traction controller. Visually

check that the cable is in good working order.

5. Check that all the traction controller connections are secure

and that the cable ends are in good working order.

Figure 3.16. Traction controller

45
 6. Follow the three phases cables from the traction controller
to the drive motor while checking the condition of the cables.

Figure 3.17. Traction motor connections

7. Return to the main fuses and follow the power cable to the
pump contactor. Visually check that the cable is in good
working order.

8. Check that the contactor connections are secure and in good

working order.

46
 Figure 3.18. Pump contactor

9. Follow the cabling from the pump contactor to the pump

motor and check the condition of the cables.

Figure 3.19. Pump motor connection

10. Check the security and condition of the main minus

connection and all the cabling attached to it.

47
 Figure 3.20. Universal minus connection

After these main connections have been checked, continue by

visually checking the condition of the remaining accessible
electrical cabling and connections. Pay special attention to
binding points and eyelets, as well as other locations where
cables or cable groups are or may come under stress during
use.

3.7.3. Checking the angle and condition of the forks

As the forks are the working part of a truck, they wear and may
become damaged during use. It is necessary to monitor their
condition regularly. Ordinary wear, such as that of the paint or
surface, is acceptable, but any actual damage or deformation of
the forks must be fixed before the truck is returned to use.

Verify that the forks are straight and parallel to each other. Check
that they do not droop, and that they are at right angles to the
main chassis both vertically and horizontally. Also check that
they do not hang between the supporting points, that is, the main
chassis and the load wheels. A hang of up to 10 mm is
acceptable.

48
 Figure 3.21. Checking the forks

3.7.4. Checking, cleaning and adjusting the brake

Check the brake for wear and clean it. The brake on 1,300 and
1,600 kg capacity trucks cannot be adjusted, and the brake pad
must be replaced when it has worn. The air gap in the brake of
the 2,000 kg capacity truck can be adjusted to compensate for
the wear of the brake pad.

Open the main cover to perform these maintenance procedures.

Turn the tiller arm so that you can access the brake. Remember
to uphold a clean working environment when working with the
brake so that you do not inadvertently introduce dirt into the brake
mechanism.

3.7.4.1. 1,300 and 1,600 kg capacity trucks

Check the wear of the brake pad and clean the brake. Perform
the following procedure to service the brake.

1. Open the three screws that fix the brake to the drive unit.
Use a 7 mm wrench.

49
 Figure 3.22. Brake fixing screws

2. Detach the brake unit carefully.

3. Detach the brake pad and measure its thickness. The

thickness of a new brake pad is 7.6 mm. Replace the pad
when it has worn to a thickness of under 7.4 mm.

Figure 3.23. Checking the brake pad thickness

50
 4. After checking/replacing the brake pad, clean the brake unit
from any accumulated dust with pressurised air. Follow work
safety procedures when using pressurised air and use a low
pressure.

5. After the above procedures, reattach the brake unit to the

drive unit.

3.7.4.2. 2,000 kg capacity trucks

Check the wear of the brake pad by measuring the air gap. If the
air gap is within acceptable limits, only cleaning the brake with
pressurised air is necessary.

To service the brake:

1. Remove the rubber gasket over the brake air gap.

Figure 3.24. Removing the rubber gasket

2. Use a feeler gauge to measure the air gap of the brake.

Measure the air gap at three points near each fixing screw.
The air gap should be between 0.2 and 0.55 mm and equal
at each point.The air gap increases as the brake pad wears.
If the air gap is within limits and equal at each point, continue
directly to Step 5. Otherwise, continue to Step 3.

51
 3. To adjust the air gap, loosen the three fixing screws with a
7 mm wrench and adjust the gap with the adjustment nuts
in the brake. Retighten the fixing screws and measure that
the air gap is within limits and equal at each point. Repeat
this procedure if necessary to set the air gap as near 0.2
mm as possible to allow for wear. If the adjustment is
successful, continue directly to Step 5, otherwise continue
to Step 4.

Figure 3.25. Adjusting the air gap

4. If the brake pad has worn so much that the air gap can no
longer be adjusted, the pad should be replaced. If the pad
must be replaced, open the brake completely, remove the
old brake pad and replace it with a new brake pad. The
thickness of a new brake pad should be 8.5 mm.
Reassemble the brake after replacing the brake pad and
return to Step 3.

5. After the brake has been checked and possibly serviced, it

must be cleaned. Use pressurised air to remove any
accumulated dust from the brake. Follow work safety
procedures when using pressurised air and always use a
low pressure.

6. After the above steps, reattach the rubber gasket. Carefully

position the gasket so that its skirt falls into the grooves on
both sides to seal the enclosure.

52
3.7.5. Checking the fastening of the transmission and the
drive unit (2,000 kg capacity trucks only)
Check that the drive unit fixing bolts and the main transmission
bolts are securely fastened.

Figure 3.26. Main transmission bolts

Figure 3.27. Drive unit fixing bolts

53
3.7.6. Checking the amount of transmission fluid (2,000 kg
capacity trucks only)
For this check, access the checking hole on the side of the
transmission unit. If you need to lift the truck to perform the check,
make sure that it remains level while performing this check.
Remember cleanliness and follow fluid safety procedures.

To check the fluid level, open the cap of the checking hole with
a 5 mm Allen key. If the fluid level is clearly lower than the edge
of the checking hole, you must add transmission fluid. For more
information on adding transmission fluid, refer to Section 3.8.2
Changing the transmission fluid (2,000 kg capacity trucks only).
Refer to Section 3.9 Lubricant and fluid recommendations for
fluid recommendations.

Figure 3.28. Location of the checking hole

3.8. Annual maintenance (after 1,200 hours of

operation)
Annual maintenance should be carried out either after a year or
after 1,200 hours of use, whichever is sooner. If the truck is
equipped with an operating time meter, annual maintenance is
easy to schedule. If not, the operating time can be read using
the console. Refer to Chapter 4 Electrical operation and
maintenance for more information on using the console. The

54
 annual maintenance procedures should be carried out only by
a trained professional.

3.8.1. Changing the hydraulic fluid

The hydraulic fluid must be changed once a year on all truck
models. The location of the hydraulic system components differs
between truck models. Follow the given instructions based on
the truck model. Note that the filling cap functions as a breather
for the tank, so do not overtighten it or overfill the tank to avoid
leakage. Refer to Section 3.9 Lubricant and fluid
recommendations for fluid recommendations. Remember
cleanliness and follow the precautions for handling harmful fluids.

3.8.1.1. 1,300 kg capacity trucks

Remove the main and top covers of the truck. The hydraulic
pump and tank assembly is located in the upper left part of the
main chassis when viewed from the front. The assembly is
installed horizontally.

To drain the fluid from the tank, use a draining apparatus. Make
sure that all the tools and tubing you use are clean so that no
dirt is introduced into the hydraulic system. After draining the
tank completely, fill it to half (½) its volume with new hydraulic
fluid.

55
 Figure 3.29. Draining the hydraulic tank (1,300 kg capacity truck
model)

3.8.1.2. 1,600 kg capacity trucks

Remove the main and top covers of the truck. The hydraulic
pump and tank assembly is installed vertically. The filling tube
of the tank has a right angle, so the tank must be removed to
drain the old fluid. Remove the hydraulic tank according to the
following steps.

1. The hydraulic pump and tank assembly is fixed to a bracket,

which is fixed to the bottom of the main chassis. Locate the
bolts that fix the bracket to the chassis and open them.

2. After opening the bolts, turn the assembly out of the chassis
to gain access to it.

3. Open the four screws that hold the entire assembly together
using a 4 mm Allen key. Be careful when handling the
assembly with the screws removed.

56
 Figure 3.30. Removing the hydraulic tank (1,600 kg capacity
truck model)

4. Carefully remove the tank and pour out the old hydraulic
fluid.

5. Reattach the tank to the rest of the assembly and refix the
four fixing screws.

6. Reattach the entire assembly to the main chassis.

7. Open the filling cap and fill the tank with new hydraulic fluid
to three-quarters (¾) of its capacity when measured from
the bottom of the tank to the filling tube.

3.8.1.3. 2,000 kg capacity trucks

On 2,000 kg capacity trucks, you have to remove the battery
pack to gain access to the fixing screws that hold the hydraulic
pump and tank assembly. Except for the hydraulic pump and
tank assembly being fixed directly to the back plate of the main
chassis, the process is similar to the 1,600 kg capacity truck
model.

57
 Take the utmost care and suitable precautions when lifting the
battery assembly from the truck. Protect any unshielded contacts
against short-circuiting. Use a non-conductive belt for hoisting
the battery assembly. The battery assembly can be lifted with a
crane or another truck.

Figure 3.31. Removing the battery pack (2,000 kg capacity truck

model)

After the battery assembly has been removed, you can access
the fixing screws for the hydraulic pump and tank assembly.
Follow the procedure given for the 1,600 kg capacity truck for
draining and refilling the tank. After the pump and tank assembly
has been reattached, replace the battery assembly.

3.8.2. Changing the transmission fluid (2,000 kg capacity

trucks only)
Change the transmission fluid once a year on 2,000 kg capacity
trucks. The transmission has three orifices: the filling hole (1) at
the top, the checking hole (2) on the side, and the draining hole
(3) on the underside.

58
 Figure 3.32. Location of filling (1), checking (2) and draining (3)
orifices

The filling cap is opened with a 12 mm wrench, while the checking

and draining hole caps require a 5 mm Allen key. Take
precautions for handling transmission fluid and keep the servicing
area clean.

To change the transmission fluid:

1. Lift the truck with a suitable jack or other safe method and
secure it to a level position. Always secure the truck so that
it is safe to work under.
NOTE Never work under a truck that is supported only by jacks.

2. After the truck has been lifted and levelled, place a suitable
container under the transmission draining hole. There is
approximately 0.6 litres of fluid in the transmission.

3. Open the draining hole cap using a 5 mm Allen key.

59
 Figure 3.33. Opening the draining cap

4. Open the filling hole cap using a 12 mm wrench and let the
transmission fluid drain completely.

Figure 3.34. Opening the filling cap

5. Close the draining hole cap.

6. Open the checking hole cap using a 5 mm Allen key.

60
 Figure 3.35. Location of the checking hole

7. Using a funnel, pour new transmission fluid carefully into

the filling hole until it reaches the level of the checking hole.
Refer to Section 3.9 Lubricant and fluid recommendations
for fluid recommendations.

8. Close the checking and filling hole caps.

3.9. Lubricant and fluid recommendations

Take the appropriate precautions when handling lubricants and
fluids during maintenance. Many of the used fluids are harmful
or even toxic, and some solutions are corrosive. Always use
protective clothing, eyewear and gloves when handling harmful
fluids. Refer and conform to all local safety guidelines governing
these fluids and lubricants. Before use, always familiarise yourself
with a substance by reading the instructions and precautions for
use from the container or associated documentation. Never
handle an open flame or smoke a cigarette in or near the area
where these substances are handled.

3.9.1. General lubricant

Use grease that conforms to NLGI grade No. 2 requirements as
the general lubricant for moving parts in trucks. If the truck is
used in cold environments, such as cold store applications, use
NLGI No. 1 or No. 0.

61
3.9.2. Battery fluid
Use fluid intended for lead-acid batteries as the battery fluid for
trucks with serviceable batteries. Never use any other fluid to fill
the battery cells.

3.9.3. Hydraulic fluid

Normally use fluid of the ISO VG 32 viscosity class as the
hydraulic fluid. Use fluid of the ISO VG 15 viscosity class in cold
environments.

3.9.4. Transmission fluid

The transmissions of 1,300 and 1,600 kg capacity trucks are
grease filled at the factory and do not require service. Use
transmission fluid of grade EP 80 or 90 as the transmission fluid
for 2,000 kg capacity trucks.

62
4. Electrical operation and maintenance
This chapter examines the electrical aspects of the truck. The
chapter begins with a description of the truck's electrical
operation. It continues by introducing the console and presents
its use in reading and modifying controller parameters. The
chapter concludes with electrical maintenance and repair
instructions not covered in Chapter 3 Regular maintenance.

Refer to Section 3.1 Safety guidelines and preparation and

Section 3.2 Maintenance guidelines for information on safety
and preparation for maintenance tasks. Refer to Chapter 2
Operating the truck for operating instructions.

4.1. Electrical operation

This section presents the truck's primary electrical functions.
Ensure that you have the correct version of the electrical
schematics for the truck model under maintenance. Contact your
supplier or technical support for information on obtaining
up-to-date documentation for your truck.

The section assumes that you are using the standard model of
the truck. This chapter only addresses the primary electrical
functions. To troubleshoot a particular component, you need to
locate it on the electrical schematic diagram to understand how
it is connected to the entire system. Keep a copy of the electrical
schematic diagram at hand while reading this chapter.

63
4.1.1. Using the schematic diagram

Figure 4.1. A sample page from the electrical schematic diagram

of the pedestrian power pallet truck (TS980803)

NOTE Always acquire the correct version of the electrical

schematics before proceeding with electrical maintenance.

The electrical schematic diagram is divided into zones, which

are presented along the top edge of each page. Use these zones

64
 as a navigating aid to locate components. For example, the text
may refer to a component in a certain zone of a certain page of
the schematics.

4.1.2. Power source

The electrical power source differs between truck models. Trucks
with a nominal lifting capacity of 1,300 kg use two 12-volt
batteries. These batteries are either AGM type batteries with a
maximum capacity of 35 Ah or GEL type batteries with a
maximum capacity of 48 Ah. The batteries are presented in zone
11 of page 1 of the electrical schematic diagram. They are
marked G1 and G2 and are connected in series to provide the
system with the required 24 volts.

The more powerful truck models with nominal lifting capacities

of 1,600 and 2,000 kg have wet lead-acid batteries, which consist
of 12 cells and supply a nominal voltage of 24 volts. The batteries
have a maximum capacity of 270 Ah on the 1,600 kg capacity
truck model and 345 Ah on the 2,000 kg capacity truck model.
The batteries reside in a separate compartment and are
connected to the system via the XG1 battery connector. The
battery is presented as G1 in zone 13 on page 1 of the electrical
schematic diagram.

4.1.3. Key switch

The main key switch S1 controls the electrical power supply to
the entire system. It also functions as the emergency stop button.
The main key switch is activated by pulling it up, which closes
the switch. If the system needs to be powered down at any time,
the key switch can be pressed. This opens the S1 switch
connection. The switch is located in zone 13 on page 1 of the
electrical schematic diagram.

When the main key switch closes the contact, electrical power
is supplied to the system through the main fuses 1F1 and 2F1.
Fuse 1F1 supplies the battery positive voltage B+ to the traction
controller. The fuse is rated at 70 A on 1,300 and 1,600 kg
capacity trucks, and 100 A on 2,000 kg capacity trucks. Fuse
2F1 supplies B+ to the pump motor contactor K1. The fuse is
rated at 70 A on all the truck models. Refer to the electrical
schematic diagram for the location of the main fuses in zones
13 and 15 on page 1.

65
 After the main fuse 1F1, the B+ supply is fed to the main positive
input terminal of the traction controller. The positive power feed
is internally connected to the auxiliary fuse A1F1 in the traction
controller. Fuse A1F1 is rated at 5 A. Refer to zone 20 on page
1 of the electrical schematic diagram. On 2,000 kg capacity
trucks, the main positive electrical power feed is also connected
to pin 1 of connector X1 of the traction controller. The battery
negative pole B- is connected directly to the negative input
terminal of the traction controller.

The pump motor contactor K1, which is fed through the main
fuse 2F1, is controlled by the traction controller. In the schematic
diagram, the K1 contacts are presented in zone 15 on page 1.
The coil controlling the K1 contacts is presented in zone 23 on
page 1. The coil is connected to pins 5 and 10 of connector X3
of the traction controller. Pin X3:5 is the positive supply and pin
X3:10 is the digital output for the pump motor contactor. The
contactor coil is powered as long as the battery voltage is high
enough. Lifting is disabled when the battery voltage drops under
the level set with the Level low batt. parameter of the traction
controller. Refer to Section 4.2 Console for information on reading
and modifying the parameters of the traction controller.

4.1.4. Traction
The movement of the truck is controlled by the traction controller.
Before the truck can be driven, the battery must be connected,
the main key switch must be closed (in the up position) and the
system must have passed the self-test procedure.

When the truck is powered on and in standby mode, it can be

driven by moving the accelerator at the end of the tiller arm
towards the forward or backward direction. The accelerator is
presented in zones 23 to 26 on page 1 of the electrical schematic
diagram. Refer to Chapter 2 Operating the truck for more
information on driving the truck.

The accelerator unit receives its 24-volt electrical supply from

pin 1 of connector X6. The negative connection is supplied
through pin 7 of connector X6. As the accelerator is moved in
either direction, it indicates the direction to the traction controller
via pins 2 and 3 of connector X6. It also provides a varying
voltage to pin 6 of connector X6. The voltage varies between
approximately 0.3 and 5 V, and depends on the position of the

66
 accelerator control. The voltage increases as the accelerator is
moved to either extreme.
NOTE If the accelerator needs to be replaced for any reason,
the sensor values should be reread using the console.
Refer to Section 4.3.2.38 Parameter 251: Program throttle
for information on the Program throttle parameter.

When the voltage at pin 6 of connector X6 of the traction

controller rises above 0.3 V, the controller first checks the
directional inputs (pins 2 and 3 of connector X6) for a direction
indication. The controller also checks for any internal errors.
Before the controller engages the traction motor, it releases the
1Y1 electrical parking brake.

The brake is controlled through pins 1 and 5 of connector X4.

The parking brake is active when it receives no power, that is,
also when the truck is powered down. To release the brake, the
traction controller applies 24 V to pin 1 of connector X4 for one
second and then reduces the voltage to 60% to hold the brake
open. Refer to zone 18 on page 1 of the electrical schematic
diagram.

After the parking brake is released, the traction controller begins

to feed the three-phase alternating current to drive the M1 traction
motor. The AC traction motor is connected to the U, V and W
outputs of the traction controller. Refer to zones 17 to 19 on page
1 of the electrical schematic diagram.

Figure 4.2. Traction motor connections

67
 The truck is powered by a DC battery. The direct current is
converted in the traction controller to three-phase alternating
current to drive the AC traction motor. This process is known as
inverting. The three motor inputs are driven out of phase to create
a voltage drop between the phases. The order of the phases,
that is, which phase is leading and which phases follow,
determines the rotating direction of the motor.

The rotating speed of the motor is relational to the width and

frequency of the pulse. The greater the pulse width, the longer
current flows through the motor. The actual current passing
through the motor is more sinusoidal than pulsed due to the
characteristics of an inductor. The pulse width varies depending
on feedback from the traction speed encoder bearing B3. If the
motor revolves faster than the speed reference, the pulse width
is decreased and vice versa.

Motor speed feedback allows the control system to maintain an

exact speed, regardless of the load on the truck. The feedback
process continues until the request to move ends. In other words,
until you release the accelerator or an alarm occurs, which forces
the traction controller to cease operation and to engage the brake.
If there are no alarms when the accelerator is released, the
traction controller reverses the motor phasing to slow it down (by
attempting to reverse its rotating direction). The parking brake
is engaged once the motor has stopped revolving, which the
traction controller senses via the traction speed encoder.
NOTE The maximum forward and backward travel speeds of the
truck can be modified with the console. The maximum
permitted speed of a pedestrian truck is 6 km/h. Refer to
Section 4.2 Console for more information on using the
console to adjust parameters.

The traction speed encoder is connected to the traction controller

at pins 3, 4, 7 and 8 of connector X4. Pin 7 supplies the encoder
with 15 volts while pin 8 supplies the negative connection. Pin 3
is encoder channel A and pin 4 is encoder channel B.

The traction controller determines the rotating speed of the motor

by counting the pulses produced by the encoder over a certain
period.The faster the motor turns, the more pulses are generated
during the monitoring period. The rotating direction of the traction
motor is determined by comparing the signals of the two
channels. The motor’s turning direction causes the signal of one
channel to lead while the other lags.

68
NOTE The operation of the traction speed encoder can be tested
using the console. Refer to Section 4.2 Console for more
information on using the console.

4.1.5. Braking
The truck is normally slowed down with the traction motor. When
the truck is being driven in one direction, reducing the deflection
of the accelerator control causes the system to reduce the speed
reference to the traction motor, which actively reduces the speed.
The operator can slow down the truck more rapidly by turning
the accelerator in the opposite direction to the movement. This
causes the traction controller to instruct the traction motor to
reverse its movement and therefore to rapidly reduce its turning
speed. If the accelerator is held in this position after the truck
has stopped, it begins to move in the given direction at the
requested speed.

In practice, when the accelerator is turned opposite to the

direction of movement, the traction controller switches the order
of the two of the three motor input phases (U, V and W). This
action forces the traction motor to reverse its rotating direction.
This will initially slow down the motor and then begin to turn it in
the opposite direction.
NOTE Braking characteristics can be adjusted with the Reverse
braking parameter. Refer to Section 4.2 Console and
Section 4.3.2 Parameters for more information on setting
truck parameters with the console.

When the movement of the truck is slowed down with the motor,
the motor acts as a generator and produces electrical power.
This power is used to recharge the truck’s battery. This is known
as regenerative or inverse braking. In this situation, the motor
produces AC voltage from each of its phases. This AC voltage
is rectified to a direct positive and negative voltage. As long as
the resultant DC voltage is higher than the battery voltage, the
battery is charged.

The truck is equipped with an electrical brake, but this is normally

not used to control the truck’s speed. The Stop mode tiller
parameter controls the function of the electrical brake. In the
default mode, the electrical brake is engaged only after the truck's
movement has stopped. This reduces the wear on the electrical
brake. The electrical brake can be used to slow down the truck,
but this is not recommended.

69
4.1.6. Safety button
The truck is by regulations obligated to have a safety button to
protect the operator. The safety button is situated at the far end
of the tiller arm. Its purpose is to stop and reverse the direction
of the truck’s movement to minimise the risk of the operator being
crushed between the truck and an obstacle.

The safety button works only when the truck is driven in the
direction of the tiller arm. When the button is pressed, the truck
automatically stops and reverses its movement for a short period.
The sharpness of the response is controlled by parameter 142
and also by the original speed. The response is greater at faster
driving speeds. Refer to Section 4.2 Console for more information
on setting the truck’s parameters with the console.

The safety button S2 is located in zone 23 on page 1 of the

electrical schematic diagram. When it is pressed, it opens the
connection and removes the 24-volt electrical supply from pin 4
of connector X6.This causes the controller to connect the reverse
direction. The reversing acceleration is set with parameter 142.

4.1.7. Lifting and lowering the forks

The forks are lifted hydraulically. The operator requests lifting or
lowering by using the micro switches in the tiller arm head. Lifting
is requested with switch S4 and lowering with switch S5. Refer
to zones 28 and 29 on page 1 of the electrical schematic diagram.

When the operator requests lifting, switch S4 is closed, which

sends the 24-volt signal to pin 8 of connector X6 of the traction
controller. Before the traction controller reacts to the request, the
battery voltage must be above a designated level. The traction
controller energises the K1 contactor coil through pin 5 of
connector X3. K1 closes and feeds the battery voltage to the
pump motor. The pump motor engages and turns the pump to
draw hydraulic fluid from the tank and send it to the lifting cylinder.
The pump motor runs until the lifting request is removed or the
forks reach the top position. When the top position is reached,
the lifting limit switch (S7) opens, which deactivates the pump
motor.

When the operator requests lowering, switch S5 is closed, which

sends the 24-volt signal to pin 9 of connector X6. The traction
controller then controls the magnetic valve through pin 4 of

70
 connector X3. Refer to Chapter 5 Hydraulic operation and
maintenance for information on the hydraulic operation of the
power pallet truck.

4.2. Console
The handheld console provides a user interface to the controllers
used in trucks. The console can be used to verify the operation
of the truck, read and modify controller parameter values, monitor
the inputs and outputs of a controller, and display the error code
when a fault has occurred. The console used in conjunction with
these trucks is the BPK part number (RL)469054. Contact your
supplier for information on obtaining a handheld console.

Figure 4.3. Handheld console, model BPK ((RL)469054)

4.2.1. Connecting the console

Before connecting the console, make sure that the truck’s main
key switch is turned off. The console is connected to connector
X7 of a controller. To access the connector, remove the main
cover of the truck. Refer to Chapter 3 Regular maintenance for
information on removing the truck’s covers. The connector may
already be reserved by a peripheral device, such as a display
unit. If so, simply disconnect the peripheral device to connect
the console, and reconnect the peripheral device after
disconnecting the console.

To connect the console:

71
 1. Turn off the truck’s main key switch.

2. Open the main cover and locate the controller.

3. Disconnect a possible peripheral device (e.g. the display

unit) from controller connector X7.

4. Connect the connection cable of the handheld console to

connector X7 on the controller.

4.2.2. Navigating the parameter list

After the console is connected to the controller, the truck’s main
key switch can be turned on. As the console goes through its
start-up procedure, it first displays its own software version. After
the start-up sequence, the console displays the serial number
and software version of the controller to which it is connected.

The handheld console has six keys on its face: four arrow keys,
an Esc key and an Enter key. Use the up and down arrows to
scroll through the available parameters.

Press the down arrow from the first display to scroll to the first
available parameter. The console displays “Searching next
parameter” for a short period, then the name and number of the
parameter, before displaying the name and value of the
parameter.

Some controller parameters are diagnostic parameters and

cannot be modified by the user. When you reach a modifiable
parameter, press the left or right arrow key to enter editing mode.
After the cursor has appeared, move it to the correct position
with the left and right arrow keys and modify the selected value
with the up and down arrow keys.

When in editing mode, if a value is changed and no keys are

pressed for one second, the new value is temporarily in use but
has not been stored into the system. The Enter key must be
pressed to store the value in the controller memory and to exit
editing mode. If you wish to discard any changes and return to
the previous stored value, press the Esc key to exit editing mode
without storing the new value.

72
4.2.3. Accessing additional functions
The handheld console provides additional functions, which can
be accessed by pressing the left and right arrow keys
simultaneously.This opens a submenu with the following choices:

List of errors

This function displays a chronological list of the last eight

controller faults that have occurred. The eight slots are reserved
for different fault codes. If the same fault has occurred several
times, it is displayed only once.

Write (BPK->dACi) and Read (dACi->BPK)

These commands are used to upload and download parameter

sets to a controller. This can be useful, for example, when the
controller must be replaced and settings must be moved to the
new controller, or when several controllers are to be programmed
with the same parameter set.

The Read (dACi->BPK) command is used to read and store the

parameter values of a connected controller into the BPK handheld
console. The handheld console has memory space to store up
to eight parameter sets. When using this command, you are
asked to select one of the available storage locations.

The Write (BPK->dACi) command is used to overwrite the

parameter set of a connected controller. Once this function is
selected, the console asks you to select one of the eight possible
parameter sets to be downloaded to the controller. Be careful
with this command, as it overwrites the entire parameter set of
the connected controller.

Search device

When the connected controller is on a communication bus that

contains other controllers, this function can be used to search
for the device addresses of the controllers on the bus.

Select address

When the connected controller is on a communication bus that

contains other controllers, this function can be used to connect
the console to a different controller on the same bus.

73
 Select language

Use this function to select one of the two available console user
interface languages: English or German.

4.3. Traction controller

The traction controller is an important part of the truck’s electrical
system. Depending on the truck model, it controls some or nearly
all the electrical functions, such as driving, braking, lifting and
lowering the forks, and the safety functions. The main task of the
traction controller is to act as an inverter and convert the DC
battery voltage to AC electrical power to drive the AC electrical
motor.

4.3.1. Connections
As the electrical schematic diagram shows, the traction controller
is connected to several electrical components of the truck. The
traction controller A1 is presented in zones 20 to 22 on page 1
of the electrical schematic diagram. There are different models
of the controller for different truck models. They, however, all
function similarly. If the controller has to be replaced, contact
your supplier or technical support for information on obtaining
up-to-date documentation and parts for your truck.

Figure 4.4. Traction controller

74
 The traction controller has two main DC voltage inputs from the
battery. It has three main AC voltage outputs to the three phases
of the traction motor. In addition to these connections, the
controller has several connectors for peripheral devices. The
different connectors of the traction controller are listed below.
Refer to the given sections of the electrical schematic diagram
to locate the connectors. The actual physical location of the
connectors on the traction controller varies by model, but is
marked on its casing.
NOTE The operation of the traction controller connections can
be tested with the console. For more information, refer to
Section 4.2 Console and Section 4.3.2 Parameters.

4.3.1.1. Connector X1 (zone 20, page 1)

X1, pin 1: The battery voltage is applied to this input in order to
power on the controller. The input is protected by a 5 A fuse,
which can be reached from outside the controller housing. This
input provides the voltage supply for the other peripheral
components.

Pins 2, 3 and 4 of connector X1 are not in use. Do not connect.

4.3.1.2. Connector X2 (zone 12, page 2)

This connector is not used in this application. Do not connect.

4.3.1.3. Connector X3 (zones 21-22, page 1)

X3, pin 1: This pin supplies the 24-volt battery voltage to the
safety socket switch S8 (zone 28, page 1). If the charging plug
is removed from its socket, traction is disabled. Lifting is still
permitted.

X3, pin 2: This pin supplies the 24-volt battery voltage to the
lifting limit switch S7 (zone 27, page 1). When the lifting limit of
the forks is reached, this switch opens and disables lifting.

X3, pin 3: The positive voltage supply for the H2 horn (zone 25,
page 1). This output is controlled by input X6:10.

X3, pin 4: The positive voltage supply for the magnetic lowering
valve 2Y1 (zone 24, page 1). This output is controlled by input
X6:9.

75
 X3, pin 5: The positive voltage supply for the K1 pump motor
contactor (zone 23, page 1). This output is controlled by input
X6:8.

X3, pin 6: The digital input for the safety socket switch S8. See
X3, pin 1.

X3, pin 7: The digital input for the lifting limit switch S7. See X3,
pin 2.

X3, pin 8: The negative connection for the horn H2.

X3, pin 9: The negative connection for the magnetic lowering

valve 2Y1.

X3, pin 10: The digital output for the K1 pump motor contactor.

4.3.1.4. Connector X4 (zone 20, page 1)

X4, pin 1: The positive 24-volt supply for the 1Y1 electrical brake
(zone 18, page 1).

X4, pins 2 and 6: Connection for the motor temperature sensor.

Not used in this application. Do not connect.

X4, pin 3: Channel A signal link from the B3 motor encoder (zone
17, page 1).

X4, pin 4: Channel B signal link from the B3 motor encoder.

X4, pin 5: Digital output for the 1Y1 electrical brake.

X4, pin 7: The 15-volt supply for the B3 motor encoder.

X4, pin 8: The 0-volt connection for the B3 motor encoder.

4.3.1.5. Connection X5 (zone 20, page 1)

X5, pin 1: The positive 24-volt supply for the H1 status LED
(zones 16-17, page 1).

X5, pin 2: The positive 24-volt supply for the B2 tiller arm position
switch (zones 17-18, page 1).

X5, pin 3: Input from the tiller arm position switch. Indicates that
the tiller arm is in the driving position.

76
 X5, pin 4: Digital output for the H1 status LED.

X5, pin 5: The 0-volt connection for the B2 tiller arm position
switch.

X5, pin 6: Input from the tiller arm position switch. Indicates that
the tiller arm is either in the upright or in the bottom position. In
these positions, traction is disabled unless the S3 brake release
switch is closed.

4.3.1.6. Connector X6 (zones 21-22, page 1)

X6, pin 1: The positive 24-volt supply for the B1 tiller arm head
module (zones 23-30, page 1).

X6, pin 2: Digital input from the accelerator for the forward
direction.

X6, pin 3: Digital input from the accelerator for the backward
direction.

X6, pin 4: Digital input from the safety button (S2) (zone 23, page
1). Switch S2 is normally closed. If S2 is opened, the 24-volt
supply is removed from this terminal and the traction controller
acts accordingly.

X6, pin 5: Digital input from the brake release switch S3 (zone
28, page 1). By pressing this switch, the operator can drive the
truck at reduced speed even when the tiller arm is in the upright
or bottom position.

X6, pin 6: The speed reference input from the accelerator.

X6, pin 7: The battery negative connection for the B1 tiller arm
head module.

X6, pin 8: Input for the lifting switch S4 (zone 28, page 1).
Controls the X3:5 output.

X6, pin 9: Input for the lowering switch S5 (zone 29, page 1).
Controls the X3:4 output.

X6, pin 10: Input for the horn switch S6 (zone 29, page 1).
Controls the X3:3 output.

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 X6, pin 11: 10-volt output, 100 mA maximum current. Not
connected.

X6, pin 12: Digital input for speed reduction. Not in use.
Connected directly to pin 1.

4.3.1.7. Connector X7 (zone 12, page 2)

This is the controller’s RS485 interface connector. If the truck is
equipped with a display unit, it is connected to connector X7.
The console connects to this connector. If a display unit is
included, it must be disconnected before the console is
connected. Refer to Section 4.2 Console for more information
on using the console.

X7, pin 1: 15-volt supply.

X7, pin 2: 0-volt connection.

X7, pin 3: RS485, signal A.

X7, pin 4: RS485, signal B.

4.3.2. Parameters
There are two main parameter types in the controller: diagnostic
and modifiable. The values of diagnostic parameters can be
viewed but cannot be changed. The parameters available for the
traction controller are presented below. Their order is determined
by the parameter number, which controls the order in which they
are listed on the handheld console.

You may notice that not every parameter is available even for
viewing. The console shows only those parameters that are
meant to be user read or modified. Other parameters exist, but
these are either not used in the current application or they have
been preset by the manufacturer.
NOTE Do not alter the value of a parameter unless you are
completely certain of the necessity of the change and
aware of how it affects the truck’s operation.

4.3.2.1. Parameter 0: Software version (diagnostic)

This parameter displays the version of the connected controller’s
internal software.

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4.3.2.2. Parameter 4: Operating hours (diagnostic)
This parameter displays the operating time of the connected
controller. The time is displayed in hours and to an accuracy of
three decimals.

4.3.2.3. Parameter 7: Serial number (diagnostic)

This parameter displays the serial number of the connected
controller.

4.3.2.4. Parameter 10: Actual speed (diagnostic)

This parameter displays the actual current speed of the truck in
km/h.

4.3.2.5. Parameter 11: Speed set value (diagnostic)

This parameter displays the speed reference value from the
accelerator in km/h.

4.3.2.6. Parameter 17: Temp. controller (diagnostic)

This parameter displays the temperature measured from the
traction controller heat sink. The temperature is displayed in
degrees Celsius (°C) and to an accuracy of one degree.

4.3.2.7. Parameter 18: Battery level (diagnostic)

This parameter displays the level of the battery charge. The level
is displayed as a value between 1 and 10, with 1 indicating a
level of 10% and 10 indicating 100%.

4.3.2.8. Parameter 30: Throttle value (diagnostic)

This parameter displays the speed reference value from the
accelerator. The value is displayed as a voltage between 0 and
5 V, and to an accuracy of one decimal. When the accelerator
is in the neutral position, the value should be close to 0 V. When
the accelerator is moved to either extreme, the value should
increase linearly close to 5 V.

79
4.3.2.9. Parameter 33: Battery voltage (diagnostic)
This parameter displays the current measured battery voltage.
The nominal voltage in this application is 24 V. The reading
decreases while the truck is operated, as electrical power is
drawn from the battery.

4.3.2.10. Parameter 46: Connector X1 (diagnostic)

This parameter displays the active pins of connector X1.

4.3.2.11. Parameter 47: Connector X2 (diagnostic)

This parameter displays the active pins of connector X2.
Connector X2 is not used is this application.

4.3.2.12. Parameter 48: Connector X3 (diagnostic)

This parameter displays the active pins of connector X3. In the
standby state, the parameter displays pins 6, 7 and 10 (A=10).
Pin 6 is the digital input of the safety socket. If the plug is
removed from the safety socket, pin 6 should disappear from the
display. When the safety socket is removed, the truck cannot be
driven, but the forks can still be lifted.

Pin 7 is the digital input of the lifting limit switch. When the forks
are lifted to the top position, the lifting limit switch (S7) opens,
and removes the 24-volt supply from digital input pin 7 of
connector X3. In this situation, the 7 should disappear from the
display. As the pump motor is disabled, the A (pin 10) should
also disappear from the display. Pin 10 is the digital output for
the pump motor contactor K1.

4.3.2.13. Parameter 49: Connector X4 (diagnostic)

This parameter displays the active pins of connector X4. The
possible displayed pins are 3, 4 and 5. Pin 3 is the channel A
input signal from the motor encoder bearing and pin 4 is the
channel B signal. Pin 5 is active when the electrical brake is
released.

You can test the encoder by driving the truck very slowly to
observe the signals from the two encoder channels. When you
start driving, pin 5 should appear to indicate that the electrical
brake has been released. Pin 5 should not be displayed when

80
 the truck is stationary, as the electrical brake should be engaged.
The sequence of pins 3 and 4 depends on the direction of travel.
They could, for example, indicate the following sequence: first
pin 3, then both pin 3 and pin 4, then only pin 4, then neither,
then pin 3 again, and so forth.

4.3.2.14. Parameter 50: Connector X5 (diagnostic)

This parameter displays the active pins of connector X5. The
possible displayed pins are 3, 4 and 6. Pin 3 indicates that the
tiller arm is in the driving position. Pin 4 indicates that the status
LED is illuminated. Pin 6 indicates that the tiller arm is either in
the upright or in the bottom position.

When the truck is powered on and no faults have occurred, the

status LED should be constantly illuminated, that is, pin 4 should
be constantly displayed. If a fault has occurred, both the status
LED and pin 4 flash in a pulse sequence that indicates the fault
type. In other words, the error code can be counted from the
sequence.

Move the tiller arm between the upright and bottom positions to
check that the tiller switch works correctly. When the tiller arm
is in the upright or bottom position, pin 6 should be displayed
and the truck should not respond to driving commands, unless
the brake release button is pressed.

4.3.2.15. Parameter 51: Connector X6 (diagnostic)

This parameter displays the active pins of connector X6. The
possible displayed pins are 2, 3, 4, 5 and 12 (C=12). Pin 2
indicates that the digital input for the forward driving direction is
active. Pin 3 indicates that the digital input for the backward
direction is active. Pin 4 indicates that the digital input of the
safety switch is active. Pin 5 indicates that the digital input of the
brake release button is active. Pin 12 indicates that the optional
digital input is active.

When the truck is driven, pin 2 or 3 is displayed to indicate the

driving direction. Pin 4 is normally displayed and disappears
when the safety switch is pressed. Pin 5 appears when the brake
release button is pressed to enable traction even when the tiller
arm is in the upright or bottom position. Pin 12 (C) is displayed
constantly, as it is an optional pin that has been hardwired to the
24-volt supply.

81
4.3.2.16. Parameter 60: Wheel diameter
This parameter is used to set the diameter of the drive wheel.
The value is displayed in millimetres.The nominal wheel diameter
is 230 mm.

4.3.2.17. Parameter 61: Gear ratio

This parameter is used to set the gear ratio of the truck’s
transmission. The factor has been preset and should not be
changed. The default value is 36.04 for 1,300 and 1,600 kg
capacity trucks, and 30.1 for 2,000 kg capacity trucks.

4.3.2.18. Parameter 67: BDI curve

This parameter is used to select the algorithm used for battery
discharge monitoring. The selection depends on the battery type.
Use the following values: 9 for 1,300 kg capacity trucks with AGM
batteries, 5 for 1,300 kg capacity trucks with GEL batteries, and
3 for 1,600 kg and 2,000 kg capacity trucks.

4.3.2.19. Parameter 68: BDI reset

This parameter sets the voltage value at which the system
displays full battery charge. The default value is 25.08 V.

4.3.2.20. Parameter 69: BDI timer

This parameter determines a time period for battery discharge
monitoring. Use the preset value. Do not change. The default
values are 150.00 s for 1,300 kg capacity trucks, and 240.00 s
for 1,600 kg and 2,000 kg capacity trucks.

4.3.2.21. Parameter 81: Lift cut-off

This parameter controls the lift cut-off function. When it is active,
that is, set to 1, lifting is disabled when the low battery warning
is triggered. The low battery warning level is set with parameter
175.

4.3.2.22. Parameter 98: Stop mode tiller

This parameter controls how the controller decelerates when the
tiller arm is removed from the driving position. There are three
choices, indicated by the number 1, 2 or 3. The default and

82
 recommended value is 2. Its advantage is that it reduces the
wear of the electrical brake. The alternatives are:

1. The motor’s power feed is cut and the brake is applied at

the same time.

2. The motor’s deceleration ramp is applied and the brake is

engaged after the truck has come to a standstill.

3. The motor’s deceleration ramp is applied and the brake

engaged at the same time.

4.3.2.23. Parameter 107: Warn. temp. contr.

This parameter sets the temperature level for the controller’s
high temperature warning. The value is entered in degrees
Celsius (°C) and can be between 50 and 79. The default value
is 70, which should not be changed.

4.3.2.24. Parameter 133: Acceleration

This parameter controls the rate at which the truck accelerates
when the accelerator is moved to request traction. Acceleration
is given in km/h/s with an accuracy of two decimals and in the
range from 0.50 to 6.00. The default value is 2.80 for 1,300 kg
capacity trucks, and 3.60 for 1,600 and 2,000 kg capacity trucks.

4.3.2.25. Parameter 134: Deceleration

This parameter controls the rate at which the truck decelerates
when the accelerator is released to request stopping.
Deceleration is given in km/h/s with an accuracy of two decimals
and in the range from 0.50 to 6.00. The default value is 2.80 for
1,300 kg capacity trucks, and 3.60 for 1,600 and 2,000 kg
capacity trucks.

4.3.2.26. Parameter 137: Smoothing curve

This parameter affects the smoothing of the motor control curves.
Its range is from 0 to 9, and the default setting is 5 for all truck
models. This value should not be changed.

83
4.3.2.27. Parameter 138: Progress. curve
This parameter affects the progression of the motor control
curves. Its range is from 0 to 100, and the default setting is 75
for all truck models. This value should not be changed.

4.3.2.28. Parameter 139: Reverse braking

This parameter controls the rate at which the truck decelerates
when the accelerator is moved to the opposite direction of
movement, that is, when performing reverse braking. The
deceleration is given in km/h/s with an accuracy of two decimals
and in the range from 0.50 to 6.00. The default value is 4.80 for
all truck models.

4.3.2.29. Parameter 142: Dec. belly & tiller

This parameter controls the rate at which the truck decelerates
when the truck is driven in the direction of the tiller arm and the
safety button is pressed. The deceleration is given in km/h/s with
an accuracy of two decimals and in the range from 0.50 to 9.00.
The default value is 9.00 for all truck models.

4.3.2.30. Parameter 175: Level low batt.

This parameter sets the battery discharge level at which the low
battery warning is triggered. The warning is triggered, if the
battery level is below the set level for over three seconds. The
parameter also sets the level at which the lift cut-off function
activates (parameter 81 controls the lift cut-off function). The
value range is from 1 to 5. The default value is 2 for 1,300 kg
capacity trucks, and 1 for 1,600 and 2,000 kg capacity trucks.

4.3.2.31. Parameter 176: Low batt. speed

This parameter sets the speed reduction when the low battery
warning is triggered. It sets the percentage of maximum speed
(set by parameters 211 and 216) that is allowed when the low
battery warning is triggered. The value range is from 10% to
100%, and the default value is 33 for all truck models.

4.3.2.32. Parameter 211: Max. speed FWD

This parameter sets the maximum speed permitted in the forward
direction. The value range is from 0.50 to 6.00 km/h. The default

84
 value is 5.80 km/h for 1,300 kg capacity trucks, and 6.00 km/h
for 1,600 and 2,000 kg capacity trucks.

4.3.2.33. Parameter 216: Max. speed BWD

This parameter sets the maximum speed permitted in the
backward direction. The value range is from 0.50 to 6.00 km/h.
The default value is 5.80 km/h for 1,300 kg capacity trucks, and
6.00 km/h for 1,600 and 2,000 kg capacity trucks.

4.3.2.34. Parameter 221: Opt. speed limit 1

This parameter sets the optional speed reduction. It sets the
percentage of the maximum speed permitted when using the
option. The value range is from 10% to 100%, and the default
value is 100%. The option is not used in this application.

4.3.2.35. Parameter 222: Brake rel. speed

This parameter sets the speed reduction when using the brake
release function. It sets the percentage of maximum speed (set
by parameters 211 and 216) that is allowed when the low battery
warning is active. The value range is from 10% to 100%, and the
default value is 33 for all models.

4.3.2.36. Parameter 223: Tiller type

This parameter sets the type of the installed tiller arm position
switch. It has two values: “0” refers to an NO type switch and “1”
refers to an NO/NC type switch. The default value is “1”. Do not
change.

4.3.2.37. Parameter 249: Error message (diagnostic)

This parameter displays the current error code, if any. Refer to
Section 4.3.3 Fault codes for an explanation of the possible error
codes.

4.3.2.38. Parameter 251: Program throttle

This parameter is used to program the voltage range of the
accelerator potentiometer into the controller.This procedure must
be performed, if either the controller or the accelerator module
in the tiller arm head is replaced. It can also be performed, if the
truck does not seem to be responding correctly to the accelerator.

85
 To program the voltage range:

1. Scroll to the Program throttle parameter. The console

displays a value of “0”.

2. Press either the left or the right arrow key to activate the
cursor.

3. Press the upward arrow key to change the value to “1”.

4. Press the Enter key to initiate the programming procedure.

5. During the 15-second programming period:

a. Move the accelerator smoothly to the maximum forward

value.

b. Keep it held for one second.

c. Move it to the maximum backward value.

d. Keep it held for one second.

e. Return it to the neutral value.

6. If the procedure was successfully completed, the parameter

value returns to “0” automatically.

NOTE The traction motor is disabled while the programming

procedure is carried out.

4.3.3. Fault codes

When a fault occurs while the truck is operated, truck functions
are disabled and the status LED flashes to indicate a fault. The
status LED flashes in a particular sequence, depending on the
fault. The error code can be determined from the sequence. If
the truck is equipped with a display unit, it displays the numerical
error code. The error code can also be read with the console by
accessing the Error message parameter (249). This section
presents the possible error codes with explanations.

4.3.3.1. Error: Watchdog

This fault does not have a numerical error code. It can be
determined from the status LED. When the Watchdog error is

86
 triggered, the status LED flashes with the following sequence:
pulse duty cycle 1:1 and frequency 1.25 Hz.

This error signifies an internal fault in the controller. When

triggered, it disables the drive and digital outputs. The controller
is faulty and must be replaced.

4.3.3.2. Error: RAM fault

This fault does not have a numerical error code. It can be
determined from the status LED. When the RAM fault error is
triggered, the status LED flashes with the following sequence:
pulse duty cycle 1:3 and frequency 2.1 Hz.

This error signifies an internal fault in the controller. When

triggered, it disables the drive and digital outputs. The controller
is faulty and must be replaced.

4.3.3.3. Error: FLASH fault

This fault does not have a numerical error code. It can be
determined from the status LED. When the FLASH fault error is
triggered, the status LED flashes with the following sequence:
pulse duty cycle 3:1 and frequency 2.1 Hz.

This error signifies an internal fault in the controller. When

triggered, it disables the drive and digital outputs. The controller
is faulty and must be replaced.

4.3.3.4. Error 2: New software version

This fault has error code number 2. The status LED indicates
this fault by repeating the following sequence: two pulses and a
pause.

This error appears only when a new software version is being

loaded into the controller. It disables the drive and digital outputs.
Reload the software as instructed.

4.3.3.5. Error 3: Overcurrent from power stage

This fault has error code number 3. The status LED indicates
this fault by repeating the following sequence: three pulses and
a pause.

87
 When this error occurs, the drive is disabled. This error can occur
if the controller was loaded for a long period at its current limit.
The fault should not appear as long as motor speed monitoring
functions correctly. The error can also appear, if a parameter
that influences the controller current or the overcurrent shutdown
level was modified.

Check the signals from the encoder bearing while the traction
motor operates. The signals of channels A and B (pins 3 and 4
of controller connector X4) should appear in the correct
sequence. If the sequence is incorrect, check the encoder cable
and connections, and change the encoder if necessary.

If the problem is due to altered parameters, it may be resolved

by returning to a previous parameter set.

4.3.3.6. Error 4: Low battery voltage

This fault has error code number 4. The status LED indicates
this fault by repeating the following sequence: four pulses and
a pause.

This error is triggered when the measured battery voltage drops

below the level set with parameter 175 for more than three
seconds. It causes the traction speed to be reduced to the level
set with parameter 176. It also causes the lift cut-off function to
activate, if it is enabled with parameter 81. If the battery voltage
drops below the value set with parameter 173 (not accessible
with the console) for more than three seconds, the controller is
shut down.This fault can be reset only by switching the controller
supply off and on.

This error can also be triggered, if there are too great voltage
drops in the controller supply cables. Check the condition of the
battery and the controller supply cabling.

4.3.3.7. Error 5: Battery overvoltage

This fault has error code number 5. The status LED indicates
this fault by repeating the following sequence: five pulses and a
pause.

This error is triggered when the measured battery voltage

exceeds the value set with parameter 174 (not accessible with
the console) for more than three seconds. It is also triggered if

88
 the battery voltage exceeds 150% of the nominal voltage. This
fault should not occur, if the battery and the connections to the
controller are intact (assuming that parameter 174 is correctly
set). This error could also result from a damaged power stage
in the controller.

Check that the connections between the battery and the controller
are in good condition. Check the value of parameter 174, if
possible. If the cause cannot be found, change the controller.

4.3.3.8. Error 6: Motor overtemperature

This fault has error code number 6. The status LED indicates
this fault by repeating the following sequence: six pulses and a
pause.

This error should not occur, as a motor temperature sensor is

not used in this application.

4.3.3.9. Error 7: Controller overtemperature

This fault has error code number 7. The status LED indicates
this fault by repeating the following sequence: seven pulses and
a pause.

This error is triggered if the controller has overheated during

operation. This may result from the controller being overloaded
for a long period. This error can also result from a fault in the
controller’s temperature measurement function.

Check that the controller is mounted according to the instructions

so that it is able to dissipate heat efficiently. Check the controller’s
output current. It should not exceed the unit’s nominal current.
If the fault persists, the controller needs to be replaced.

4.3.3.10. Error 8: Drive signal monitoring

This fault has error code number 8. The status LED indicates
this fault by repeating the following sequence: eight pulses and
a pause.

This error indicates a fault with the accelerator. The error can be
due to an incorrect operating sequence. After the controller is
powered up, the following conditions must be true:

• Drive signals (X6:2 and X6:3) must not be present.

89
 • Speed reduction must be active.

• The brake release switch (S3) must be open. ara>

• The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Check that the drive signals are working. Access parameter 51

with the console. Test that turning the accelerator in the forward
direction provides the drive signal at pin 2 of connector X6 and
that backward direction provides the drive signal at pin 3 of
connector X6.

4.3.3.11. Error 9: Encoder bearing monitoring

This fault has error code number 9. The status LED indicates
this fault by repeating the following sequence: nine pulses and
a pause.

This error could indicate a fault in the encoder bearing or a broken

connection between the encoder and the controller.

Check the encoder signals from channels A and B at pins 3 and

4 of connector X4. Refer to Section 4.3.2.13 Parameter 49:
Connector X4 (diagnostic).

4.3.3.12. Error 10: Safety switch monitoring

This fault has error code number 10. The status LED indicates
this fault by repeating the following sequence: ten pulses and a
pause.

This error indicates a fault with the safety switch. The error can
be due to an incorrect operating sequence. After the controller
is powered up, the following conditions must be true:

• Drive signals (X6:2 and X6:3) must not be present.

• Speed reduction must be active.

• The brake release switch (S3) must be open.

90
 • The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 4 of

connector X6. Refer to Section 4.3.2.15 Parameter 51: Connector
X6 (diagnostic).

4.3.3.13. Error 11: Tiller switch monitoring after power-up

This fault has error code number 11. The status LED indicates
this fault by repeating the following sequence: eleven pulses and
a pause.

This error indicates a fault with the tiller switch. The error can be
due to an incorrect operating sequence. After the controller is
powered up, the following conditions must be true:

• Drive signals (X6:2 and X6:3) must not be present.

• Speed reduction must be active.

• The brake release switch (S3) must be open.

• The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 6 of

connector X5. Refer to Section 4.3.2.14 Parameter 50: Connector
X5 (diagnostic).

4.3.3.14. Error 12: Accelerator monitoring

This fault has error code number 12. The status LED indicates
this fault by repeating the following sequence: twelve pulses and
a pause.

91
 This error indicates a fault with the accelerator. The error can be
due to an incorrect operating sequence. After the controller is
powered up, the following conditions must be true:

• Drive signals (X6:2 and X6:3) must not be present.

• Speed reduction must be active.

• The brake release switch (S3) must be open.

• The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Use the console to check that the voltage value from the
accelerator to pin 6 of connector X6 is close to 0 V when the
accelerator is in the neutral position. The value can be checked
with parameter 30 (refer to Section 4.3.2.8 Parameter 30: Throttle
value (diagnostic)).

4.3.3.15. Error 14: EEPROM fault

This fault has error code number 14. The status LED indicates
this fault by repeating the following sequence: fourteen pulses
and a pause.

This error signifies an internal fault in the controller. The controller

is faulty and must be replaced.

4.3.3.16. Error 15: Unrealistic U/f relationship

This fault has error code number 15. The status LED indicates
this fault by repeating the following sequence: fifteen pulses and
a pause.

This error indicates that there is a problem with the parameters

that control the U/f relationship of the drive.

The error can be resolved by returning to a previous parameter

set.

92
4.3.3.17. Error 16: Unrealistic speed input transfer function
This fault has error code number 16. The status LED indicates
this fault by repeating the following sequence: sixteen pulses
and a pause.

This error indicates that there is a problem with the parameters

that control the speed input transfer function.

The error can be resolved by returning to a previous parameter

set.

4.3.3.18. Error 17: Tiller switch monitoring while system

running
This fault has error code number 17. The status LED indicates
this fault by repeating the following sequence: seventeen pulses
and a pause.

This error indicates that the two tiller switch signals are not
complementary.

Use the console to check the operation of the tiller switch (signals
X5:3 and X5:6). Refer to Section 4.3.2.14 Parameter 50:
Connector X5 (diagnostic).

4.3.3.19. Error 18: Speed reduction monitoring

This fault has error code number 18. The status LED indicates
this fault by repeating the following sequence: eighteen pulses
and a pause.

This error indicates a fault with the optional speed reduction

function. The optional function is not used in this application. The
option connection on connector X6 is bridged to the 24-volt
supply.

The error can be due to an incorrect operating sequence. After

the controller is powered up, the following conditions must be
true:

• Drive signals (X6:2 and X6:3) must not be present.

• Speed reduction must be active.

• The brake release switch (S3) must be open.

93
 • The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 12 (C) of

connector X6. Refer to Section 4.3.2.15 Parameter 51: Connector
X6 (diagnostic).

4.3.3.20. Error 19: Brake release monitoring

This fault has error code number 19. The status LED indicates
this fault by repeating the following sequence: nineteen pulses
and a pause.

This error indicates a fault with the brake release function. The
error can be due to an incorrect operating sequence. After the
controller is powered up, the following conditions must be true:

• Drive signals (X6:2 and X6:3) must not be present.

• Speed reduction must be active.

• The brake release switch (S3) must be open.

• The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Use the console to check that pressing the brake release button
provides a signal at pin 5 of connector X6. Refer to
Section 4.3.2.15 Parameter 51: Connector X6 (diagnostic).

4.3.3.21. Error 20: Safety socket monitoring

This fault has error code number 20. The status LED indicates
this fault by repeating the following sequence: twenty pulses and
a pause.

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 This error indicates a fault with the safety socket. The error can
be due to an incorrect operating sequence. After the controller
is powered up, the following conditions must be true:

• Drive signals (X6:2 and X6:3) must not be present.

• Speed reduction must be active.

• The brake release switch (S3) must be open.

• The tiller switch (B2) must not indicate driving position.

• The safety switch (S2) must be closed (i.e. not depressed).

• The safety socket (S8) must be closed.

• The speed reference signal (X6:6) must be near 0 V.

Use the console to check that there is a signal at pin 6 of

connector X3 when the safety socket is in place. Refer to
Section 4.3.2.12 Parameter 48: Connector X3 (diagnostic).

4.4. Electrical maintenance and repairs

This section provides instructions for specific maintenance
procedures. These tasks are not part of the regular maintenance
schedule.They are performed when needed. Refer to Section 3.1
Safety guidelines and preparation and Section 3.2 Maintenance
guidelines for information on safety and preparation for
maintenance tasks.

If other (than those examined below) electrical components fail,

contact your supplier or local technical support for replacement
parts and instructions. If you have a specific electrical
maintenance problem that is not answered here or in another
part of the manual, contact your supplier or technical support.

4.4.1. Battery maintenance

Before performing battery maintenance, take safety precautions
appropriate for handling lead-acid batteries and battery fluid. A
truck battery carries a considerable amount of stored electrical
energy. When handling a battery, battery assembly or battery
cell, insulate all the electrical contacts to minimise the risk of a
short circuit. Be careful with conductive tools and equipment
when working near batteries. Lead-acid batteries contain a

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 corrosive acid solution. Wear appropriate protective gear such
as protective clothing, gauntlets and eyewear. Refer to Chapter 3
Regular maintenance for information on regular battery
maintenance procedures. Contact technical support for current
information on servicing truck batteries and acquiring a new
battery or battery assembly.

There are three possible power source arrangements (see

Section 4.1.2 Power source). The 1,300 kg capacity truck has
two independent batteries. They are AGM or GEL type batteries,
which are mounted in the main chassis of the truck. Both types
are service free, and the entire battery must be replaced when
it begins to age. Refer to the instructions provided by the battery
manufacturer on using and maintaining AGM and GEL batteries.
When replacing the batteries, remember to replace them with
batteries of equal weight so that the usage safety of the truck is
not affected.

Figure 4.5. Power sources of the 1,300 kg capacity truck

The 1,600 and 2,000 kg capacity truck models have a separate

battery compartment, which holds a battery cell assembly. The
battery assembly consists of 12 wet lead-acid battery cells and
has a nominal voltage of 24 V. The truck models can
accommodate power sources with varying capacities. The
maximum battery capacity is 270 Ah for 1,600 kg capacity trucks
and 345 Ah for 2,000 kg capacity trucks. The battery assembly
is connected to the truck’s electrical system via connector XG1.

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Refer to Section 4.1 Electrical operation for more information on
the electrical connections and operation of these trucks.

Figure 4.6. Power source of a 1,600 kg capacity truck

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 Figure 4.7. Battery assembly

When you suspect that a battery cell or the entire battery

assembly is not functioning optimally, check the state of the cells
in the assembly by measuring their specific gravity. This
measurement provides more reliable information about the
condition of a cell than, for example, measuring its voltage.
Always refer to the maintenance instructions issued by the
manufacturer or supplier of the battery cell or battery assembly.
As a guideline, however, the specific gravity measurement of a
fully-charged battery cell should be 1.28 to 1.30 at 30°C. A cell
is about half-charged if it measures 1.20 and empty at 1.15 or
below.

If a battery cell needs to be replaced, refer to the maintenance

instructions issued by the cell manufacturer. Remember to use
a cell that is identical to the original one in electrical
characteristics, size and weight. In circumstances in which
several cells are performing badly, it may be wise to replace the
entire battery assembly. It is very important that all the
characteristics, especially the weight of the new battery assembly
is identical to the original one, so that the truck’s usage safety is
not affected.The truck’s identification plate indicates the minimum
weight of the battery.

Be careful when replacing the battery assembly, as it is very

heavy. Use a sufficiently powerful crane or truck to lift the

98
 assembly from its marked lifting points. Never lift the assembly
from any other points. When preparing the assembly for lifting,
insulate the battery cell contacts to protect against short circuits.

4.4.2. Fuses
The truck's fuses do not require regular checks. They need to
be replaced only if they have blown. Never operate a truck with
a blown fuse. Replace the fuse before continuing to use the truck.
When fuses need to be changed, always replace them with
identical components. Never use a fuse of another rating than
that recommended by the manufacturer.

The standard truck has two main fuses and an auxiliary fuse in
the controller. To access the fuses, open the truck’s main cover.

Figure 4.8. Example of the two main fuses

On the electrical schematic diagram, the main fuses are marked

as 1F1 and 2F1 (zones 13 and 15 on page 1). Fuse 1F1 supplies
the positive battery feed to the traction controller. It is rated at
70 A on the 1,300 and 1,600 kg capacity trucks, and 100 A on
2,000 kg capacity trucks. Fuse 2F1 supplies the positive battery
feed to the K1 pump motor contactor. It is rated at 70 A on all
truck models.

The auxiliary controller fuse is mounted in the controller, but can

be accessed from the outside. The auxiliary fuse is marked as

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 A1F1 in the electrical schematic diagram (zone 20 on page 1).
It is rated at 5 A.

Figure 4.9. Auxiliary controller fuse

If the truck is fitted with optional cold store equipment, an

additional heater fuse is present. The heater fuse is marked as
F51 in the electrical schematic diagram (zone 14 on page 3). It
is rated at 5 A.

4.4.3. Replacing a controller

A controller in the truck may encounter an internal fault, which
cannot be fixed from the outside. In this case, it is best to replace
the entire controller. Contact your supplier or technical support
for information on obtaining up-to-date documentation and parts
for the truck. The truck cannot be used with a faulty controller.

Turn the main key switch off and disconnect the battery before
attempting any maintenance procedures on the controller. When
disconnecting the controller, remember to start by removing the
positive supply connection first and the negative connection last.
When connecting a new controller, connect the negative supply
connection first and finish with the positive connection. Pay
attention to the polarity markings on the controller, as polarity
inversion will damage it. Contact technical support for the latest
information regarding controller replacement.

100
NOTE The parameters of the replacement controller must be
reprogrammed for the application.

4.4.4. Replacing the accelerator module in the tiller arm

head
The accelerator module in the tiller arm head may require
replacement during the truck’s operating life. The tiller arm head
assembly contains the main control devices needed by the
operator to use the truck. Its main component is the accelerator.
It also houses the lifting controls, the brake release button, the
horn button and the safety button. Refer to Chapter 2 Operating
the truck for more information on the truck’s control devices.
WARNING! Disconnect the battery connector before beginning.

To replace the accelerator module:

1. Begin by locating the two fixing screws on the underside of

the head assembly and the two screws on the topside of the
assembly. Open the four screws using a 5 mm Allen key.

Figure 4.10. Main fixing screws at the back of the tiller arm
head assembly

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 Figure 4.11. Main fixing screws in front of the tiller arm head
assembly

2. After removing the screws, lift the top section upwards from
the edge containing the safety button. Be careful with the
end closer to the arm, as lifting it might stress the internal
wiring.

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 Figure 4.12. Opening the assembly

3. Disconnect the connector from the accelerator module.

4. Remove the accelerator controls from both sides of the

assembly by unscrewing them from the axle. Take care not
to lose the spring washers.

5. Loosen the two fixing screws holding the accelerator module

with a 4 mm Allen key. The screws do not have to be
removed, loosening is sufficient.

6. Remove the safety switch carefully by prying it with a

flat-head screwdriver.

7. Install the new accelerator module.

8. Replace the safety switch.

9. Tighten the accelerator module fixing screws.

10. Replace the accelerator controls to the assembly. Note the

position of the controls: one of the three wings of both

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 controls should point in the direction of the arm, that is,
downwards when the arm rests in the upright position.

11. Connect the accelerator module connector.

12. Reposition the top section of the assembly on to the bottom

section.

13. Tighten the four fixing screws.

Once the accelerator module has been replaced, it should be

tested. Begin by programming the voltage range of the
accelerator to the truck’s traction controller. For more information
on this procedure, refer to Section 4.3.2.38 Parameter 251:
Program throttle. After this procedure, thoroughly test the
operation of the tiller arm head controls before returning the truck
to normal use.

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5. Hydraulic operation and maintenance
This chapter describes the hydraulic system of the truck. The
chapter is divided into two main sections. The first section,
Hydraulic operation, presents the hydraulic operation of the truck.
The second section, Hydraulic maintenance, provides information
on maintenance and repair procedures not covered in Chapter 3
Regular maintenance.

Refer to Section 3.1 Safety guidelines and preparation and

Section 3.2 Maintenance guidelines for information on safety
and preparation for maintenance tasks. Refer to Chapter 2
Operating the truck for operating instructions.

5.1. Hydraulic operation

This section presents the hydraulic operation of the truck. Please
ensure 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.

The hydraulic schematic diagram illustrates the operation of the

hydraulic system. In the following procedures, different parts of
the hydraulic system are numbered. These numbers refer to the
figure below.

105
 Figure 5.1. Hydraulic system (TH50 1104)

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

Lifting:

1. The electrical motor (1) operates the hydraulic gear pump

(2).

2. The hydraulic fluid is pressurised.

3. The fluid pressure is maintained using a relief valve (3),

which opens at a certain pressure. In such cases, hydraulic
fluid is returned to the fluid tank. The opening pressure of
the relief valve is indicated in the hydraulic schematics.

4. The pressurised hydraulic fluid flows through the no-return

valve (5) to the lifting cylinder (6).

5. The lifting cylinder piston lifts the forks.

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Figure 5.2. Hydraulic fluid flow during lifting

Lowering

1. The solenoid valve (8) is opened with the lowering switch.

2. Hydraulic fluid flows through a 300 µ sieve (7) back to the

fluid tank.

3. As the hydraulic pressure reduces, the lifting cylinder piston

retracts and the forks are lowered.

107
 Figure 5.3. Hydraulic fluid flow during lowering

Various truck models can have different configurations of the

hydraulic system.

5.2. Hydraulic maintenance and repairs

The following sections illustrate various hydraulic maintenance
procedures not covered in Chapter 3 Regular maintenance.

5.2.1. Replacing gaskets

NOTE When the gasket of the hydraulic cylinder needs to be
replaced, the wiper and guide strips are also replaced.

To replace gaskets:

1. Pull out the piston rod from the cylinder.

2. Remove the wiper from the cylinder using suitable pliers.

3. Pull the old gasket carefully out of the cylinder.

108
NOTE Do not use sharp tools.

4. Squeeze the new gasket using round pointed pliers. The

groove in the gasket goes inside the cylinder (towards the
bottom of the cylinder).
NOTE Do not scratch the inside walls of the cylinder.

Figure 5.4. Squeezing the gasket

5. Attach the new wiper to the cylinder. The wiper prevents dirt
from entering the cylinder when the piston rod moves.

6. Insert the piston rod into the cylinder.

5.2.2. Replacing the hydraulic pump

The hydraulic pump and tank assembly is located in the left part
of the main chassis when viewed from the front. Depending on
the truck model, the assembly is installed either horizontally
(1,300 kg capacity truck model) or vertically (1,600 and 2,000 kg
capacity truck models).

To replace the hydraulic pump:

1. Remove the main and top covers of the truck.

2. The hydraulic pump and tank assembly is fixed to a bracket,

which is fixed to the main chassis. Locate the bolts that fix
the bracket to the chassis and open them.

109
NOTE On 2,000 kg capacity trucks, you have to remove the
battery pack to gain access to the fixing screws that hold
the hydraulic pump and tank assembly.

3. After opening the bolts, turn the assembly out of the chassis
to gain access to it.

4. Open the four screws that hold the entire assembly together
using a 4 mm Allen key. Be careful when handling the
assembly with the screws removed.

Figure 5.5. Removing the hydraulic tank (1,600 kg capacity

truck model)

5. Carefully remove the tank and drain out the old hydraulic
fluid.

6. Detach the hydraulic hoses from the hydraulic pump and

tank assembly.

7. Disconnect the electrical connections from the hydraulic

pump motor.

8. Replace the hydraulic pump motor.

110
9. Connect the electrical connections to the new hydraulic
pump motor.

10. Connect the hydraulic hoses to the hydraulic pump.

11. Attach the hydraulic tank to the hydraulic pump and fasten
the four fixing screws.

12. Reattach the entire assembly to the main chassis.

13. On 2,000 kg capacity trucks, reattach the battery pack.

14. Open the filling cap and fill the tank with new hydraulic fluid
to half (1,300 kg capacity truck model) or three-quarters
(1,600 and 2,000 kg capacity truck models) of its capacity
when measured from the bottom of the tank to the filling
tube.

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6. Mechanical maintenance
This chapter presents the mechanical maintenance procedures
not covered in Chapter 3 Regular maintenance. Refer to
Section 3.1 Safety guidelines and preparation and Section 3.2
Maintenance guidelines for information on safety and preparation
for maintenance tasks. Refer to Chapter 2 Operating the truck
for operating instructions.

6.1. Replacing wheels

A truck has three wheel types: drive, load and castor wheels.
Check all the wheels on a truck for damage and wear.The wheels
should wear evenly and there should be no flats or holes in the
wear surface. The wheels should also turn smoothly on their
axles and there should not be play in the bearings. Even wear
can be checked by driving the truck on a smooth surface to test
that all the wheels turn and the truck rides smoothly. If a wheel
or a bearing has sustained damage that affects use or if its
surface has worn completely, it should be replaced.

To replace a truck wheel, follow the instructions given below.

WARNING! Never work under the truck if it is supported only by a
jack.

6.1.1. Replacing the drive wheel

The drive wheel is located immediately under the tiller arm
anchoring point and supports a considerable portion of the truck’s
weight. The drive wheel is used to propel and steer the truck. It
is attached to the drive motor via the transmission. The tiller arm
is used to turn the drive wheel when steering the truck.

To replace the drive wheel:

1. Open the main and the top covers of the truck by loosening
the fixing screws enough for the cover to be removed, but
do not remove the screws entirely. The screws move a fixing
bracket, which holds the cover in place.

2. If you are working on a 2,000 kg capacity truck, skip to step

4. On 1,300 and 1,600 kg capacity trucks: Open the four
fixing screws of the bottom steel plate cover. Use a 5 mm
Allen key.

113
 Figure 6.1. Removing the bottom plate fixing screws

3. Lift the bottom steel plate cover up over the tiller arm. Make
sure that none of the control panel wires are damaged.

4. Turn the drive wheel using the tiller arm so that the fixing
screws of the wheel can be reached.

5. On 2,000 kg capacity trucks, remove the five wheel fixing

screws with a 19 mm wrench. On 1,300 and 1,600 kg
capacity trucks, remove the ten wheel fixing screws with a
5 mm Allen key. Do not remove the two countersunk screws,
as they hold the planet gear rim in place.

114
 Figure 6.2. Removing the drive wheel fixing screws on 1,300
and 1,600 kg capacity trucks

6. Lift the truck from under the chassis using a suitable jack
so that the drive wheel is lifted off the supporting surface.

7. Remove the old drive wheel.

8. Attach the new drive wheel.

9. Replace all truck covers and test the operation of the drive
unit.

6.1.2. Replacing the load wheels

The load wheels are located near the ends of the forks. Their
main purpose is to support the weight of the load. Depending on
the truck model, there is either a single or a double load wheel
in each fork.

To replace single load wheels:

1. Loosen the locking pin from the axle using a 5 mm pin punch.
The locking pin is located on the outside end of the axle.

115
 2. Raise the forks and lift the truck slightly with a jack.

3. Remove the locking pin from the axle.

4. Remove the load wheel axle.

5. Replace the load wheel and reattach the axle and the locking
pin.

To replace double load wheels:

1. Lift the truck using a jack. Place supporting brackets under

the truck.

2. Remove the axle bolt using a 8 mm Allen key on both ends

of the bolt.

3. Replace the load wheel and reattach the axle bolt.

6.1.3. Replacing the castor wheels

The side-supporting castor wheels are located under the main
chassis on either side of the drive wheel. They support the truck
when it is driven and prevent it from tilting, as there is only one
drive wheel. The castor wheels turn automatically to follow the
direction of travel. They are equipped with suspension springs.

To replace the castor wheels:

1. Lift the truck using a jack. Place supporting brackets under

the truck.

2. Remove the axle bolt using a 17/19 mm wrench on both

ends of the bolt.

3. Replace the castor wheel and reattach the axle bolt.

6.2. Replacing the tiller arm gas spring

This section gives instructions on how to replace the gas spring
of the tiller arm. The purpose of the gas spring is to return the
tiller arm automatically to the upright resting position. It is a safety
device, which must always be fully operational.

To replace the gas spring:

1. Remove the cover from the base of the tiller arm.

116
 2. Remove the ball joints from both ends of the gas spring
using a 13 mm wrench.

3. Replace the gas spring.

4. Attach the ball joints to the tiller arm.

5. Reattach the cover to the base of the tiller arm.

6. Test the operation of the tiller arm.

Figure 6.3. Replacing the tiller arm gas spring

6.3. Lever system maintenance

The lever system is present only on trucks with initial lifting
functionality. The system is composed of levers and the initial
lifting cylinder between the main chassis and the mast assembly,
and push rods under the forks. They operate to lift the mast and
fork assembly evenly when initial lifting is used. The following
procedures provide instructions for disassembling the system
for maintenance purposes.

The bushings in the initial lifting levers must be changed when

play has developed in the system.

117
WARNING! These procedures require the truck to be lifted and
supported. Take care to support the weight of the truck
and the separated components. Take care especially
when removing the levers between the main chassis and
the mast assembly.

To remove the pushrods:

1. Lift the truck.

2. Remove the locking pins from both ends of the push rods
using a 5 mm punch.

3. Remove the shafts from both ends of the push rods.

NOTE The shafts at the cylinder ends of the push rods cannot
be removed by hitting them with a punch. You have to
use an inertia hammer to pull the shaft out from the push
rod.

4. Remove the push rods.

To remove the wheel forks:

1. Remove the load wheels from the wheel forks.

2. Remove the locking pins and detach the wheel forks.

To remove the hydraulic cylinder lever:

1. Remove the push rods.

2. Remove the circlips from the cylinder axle ends.

3. Remove the axle from the cylinder. There are two washers
on each side of the cylinder attachment point.

4. Remove the lever.

To remove the upper and lower levers:

1. Remove the locking pins with a 4 mm punch.

2. Remove the axles. Depending on the lever end, gently

hammer the axles out or remove them with an extractor.

3. Remove the bushings from the axle and install new ones.

118