Repair Manual 7536388-040: OSE120, OSE120P, OSE250, OSE250P

Repair manual 7536388-040
OSE120, OSE120P, OSE250, OSE250P.
www.toyota-forklifts.eu
Document revisions:
Publishing Order Amendments

date number
2014-09-01 7536388-040 Chapter 4: Operations & connection sequence - Updated
Chapter 5: Parameter – Updated
Chapter 8: Error codes – Updated
Chapter 9: Chassis - Threaded inserts in side guides
Chapter 12: Brakes and wheels - New tightening torques brakes
Chapter 14: Electric system - Restarting the Li-ion battery
Chapter 16: Mast: Updated
Chapter 17: Options - Updated text T.W.I.S
Chapter 19: Wiring diagram – Updated
2015-10-01 7536388-040 Chapter 5: Parameters - Steering calibration updated
Chapter 6: Installing - PIN code for resetting after collision
Chapter 10: Motors - 10.3.4 updated
Chapter 21: Tools - updated
2016-12-01 7536388-040 Chapter 5: Parameter - Added parameter 8
Chapter 7: Maintenance – Updated
Chapter 8: Troubleshooting - Added error code 5.182
Chapter 12: Brakes and wheels - Updated
Chapter 13: Steering system - Updated
Chapter 16: Mast – Updated
Chapter 19: Wiring chart – Updated
This manual contains information on the following trucks:
T-Code Model Serial number

887 OSE250 6192050-
OSE250P
888 OSE120 6192021-
OSE120P
© TMHE T Code(s): 887, 888

Repair manual: Model(s): OSE120, OSE120P, OSE250, OSE250P
Publication Number: 7536388-040 Date: 2016-12-01 Applies from serial number: 6192021-
1. Contents
2. General introduction...................................................................................... 2–1
2.1 How to use this manual ............................................................................... 2–1
2.2 Warning symbols ......................................................................................... 2–2
2.3 Pictograms................................................................................................... 2–3
2.3.1 Screws/Nuts ................................................................................... 2–3
2.4 Abbreviations used in this manual ............................................................... 2–3
3. General safety rules....................................................................................... 3–1
3.1 Work safety.................................................................................................. 3–1
3.2 Electrical system.......................................................................................... 3–3
3.3 Safe lifting.................................................................................................... 3–4
3.4 Truck modifications...................................................................................... 3–5
4. Operation and connection sequences ......................................................... 4–1
Symbols on keypad and display 4–1
4.1 Battery is connected .................................................................................... 4–2
4.2 Logging in .................................................................................................... 4–2
4.3 Basic conditions for driving.......................................................................... 4–2
4.4 Driving in fork direction ................................................................................ 4–3
4.5 Driving in the drive wheel direction .............................................................. 4–3
4.6 Braking in neutral......................................................................................... 4–4
4.7 Reverse braking .......................................................................................... 4–4
4.8 Brake operation via controls ........................................................................ 4–4
4.9 Steering ....................................................................................................... 4–5
4.10 Fork lifting up ............................................................................................. 4–5
4.11 Fork lifting down ........................................................................................ 4–6
4.12 Platform up ................................................................................................ 4–6
4.13 Platform down............................................................................................ 4–6
5. Parameters, menu navigation and calibration ............................................ 5–1
5.1 General........................................................................................................ 5–1
Symbols on keypad and display 5–1
5.1.1 Menu navigation ............................................................................ 5–2
5.1.2 Display hour counter values ........................................................... 5–3
5.1.3 Show part numbers for software/hardware .................................... 5–4
5.2 Parameter settings ...................................................................................... 5–5
5.2.1 Copying the truck’s configurations ................................................. 5–5
5.2.2 Setting operator/service parameters without using PC/PDA .......... 5–6
5.2.3 Operator parameters ...................................................................... 5–7
Overview 5–7
Factory preset operator parameters 5–8
Description of operator parameters 5–9
5.2.4 Service parameters ...................................................................... 5–10
Overview 5–10
Description of service parameters 5–11
Verifying parameter settings for freely ventilated batteries
(lead-acid batteries) 5–14
5.2.5 Factory parameters ...................................................................... 5–17
Factory parameters # 1003 to 1042 - configurable optional
functions 5–24
5.3 Calibration ................................................................................................. 5–36
5.3.1 Steering servo calibration ............................................................. 5–36
5.3.2 Hydraulic calibration ..................................................................... 5–37
© TMHE 1– 1 T Code(s): 887, 888

6. Installation and commissioning ................................................................... 6–1

6.1 Transporting the truck.................................................................................. 6–1
6.2 Transporting the mast.................................................................................. 6–1
6.3 Safe lifting.................................................................................................... 6–2
6.4 Battery installation ....................................................................................... 6–3
6.4.1 Safety for battery handling ............................................................. 6–3
6.4.2 Installing the battery ....................................................................... 6–3
Battery indicator 6–4
6.5 Using PIN codes.......................................................................................... 6–5
6.5.1 General........................................................................................... 6–5
6.5.2 Programming PIN codes ................................................................ 6–5
6.5.3 PIN code defaults ........................................................................... 6–7
6.6 Setting parameters ...................................................................................... 6–8
6.6.1 Setting collision sensor parameters (option) .................................. 6–8
Collision sensor parameters 105 and 106 6–9
PIN code programming for truck reset 6–9
6.6.2 Setting battery parameters ........................................................... 6–10
6.7 Function check .......................................................................................... 6–11
7. Maintenance ................................................................................................... 7–1
7.1 Introduction.................................................................................................. 7–1
7.2 Maintenance instructions............................................................................. 7–1
7.2.1 Cleaning and washing .................................................................... 7–1
7.2.2 High-pressure washers .................................................................. 7–1
7.2.3 Degreasing agents ......................................................................... 7–2
7.2.4 Cleaning the exterior ...................................................................... 7–2
7.2.5 Cleaning the chain.......................................................................... 7–2
7.2.6 Cleaning the motor compartment ................................................... 7–2
7.2.7 Electric components ....................................................................... 7–2
7.3 Checking normal truck function ................................................................... 7–4
7.4 Safety checks .............................................................................................. 7–5
7.5 First service ................................................................................................. 7–8
7.6 Maintenance schedule................................................................................. 7–9
7.6.1 Maintenance service every 500 operating hours/6 months.......... 7–10
7.6.2 Maintenance service every 1000 operating hours/12 months ...... 7–14
7.6.3 Maintenance service every 3000 operating hours/36 months ...... 7–19
8. Troubleshooting............................................................................................. 8–1
8.1 Towing a defective truck.............................................................................. 8–1
Tow using a tow truck and tow wagon: 8–1
8.2 Auxiliary functions........................................................................................ 8–2
8.2.1 Emergency driving mode................................................................ 8–2
8.2.2 Error code history ........................................................................... 8–3
8.3 Error code system ....................................................................................... 8–4
8.4 Error codes .................................................................................................. 8–5
8.5 Built-in test function for the tiller arm ......................................................... 8–33
8.5.1 Display test................................................................................... 8–33
8.5.2 Speed control ............................................................................... 8–33
8.5.3 Controls for lifting/lowering ........................................................... 8–33
8.5.4 Sensilift......................................................................................... 8–34
8.5.5 Keypad ......................................................................................... 8–34
8.6 Built-in test function ................................................................................... 8–35
8.7 Digital input/output status .......................................................................... 8–37
8.7.1 Test mode “2” – ............................................................................ 8–37
8.7.2 Test mode “8” – Expansion unit SEU (option). ............................. 8–39
© TMHE 1– 2 T Code(s): 887, 888

9. Chassis – C0000............................................................................................. 9–1

9.1 Details dampened floor................................................................................ 9–1
9.2 Adjust dampened floor................................................................................. 9–3
9.3 Platform with operator lift – C9130 .............................................................. 9–4
9.3.1 Adjusting the side guides ............................................................... 9–4
9.3.2 Adjusting the outer side guides ...................................................... 9–5
9.3.3 Removing the platform with operator lift......................................... 9–6
9.3.4 Reinstalling the platform with operator lift .................................... 9–11
9.4 Automatic height adjustment – C9390....................................................... 9–15
9.5 Signs, warnings, adhesive labels – C0850 ................................................ 9–16
10. Motors - C1700 ........................................................................................... 10–1
10.1 Pump motor - C1710 ............................................................................... 10–1
10.1.1 General....................................................................................... 10–1
10.1.2 Replacing the pump motor ......................................................... 10–2
10.2 Steering motor - C1730 (steering servo assembly) ................................. 10–4
10.2.1 General....................................................................................... 10–4
10.2.2 Replacing the steering servo assembly...................................... 10–6
10.2.3 Gear replacement....................................................................... 10–7
10.3 Drive motor - C1760 ................................................................................ 10–8
10.3.1 General....................................................................................... 10–8
10.3.2 Tightening torque - Drive motor.................................................. 10–8
10.3.3 Component overview – Drive motor ........................................... 10–9
10.3.4 Removing the drive motor ........................................................ 10–10
10.3.5 Fitting the drive motor............................................................... 10–12
10.3.6 Replacing the temperature sensor ........................................... 10–14
10.3.7 Replacing the RPM sensor....................................................... 10–15
10.3.8 Replacing the speed sensor toothed wheel ............................. 10–16
10.3.9 Disassembly ............................................................................. 10–17
10.3.10 Cleaning ................................................................................. 10–19
10.3.11 Replacing the upper bearing .................................................. 10–20
10.3.12 Replacing the lower bearing ................................................... 10–21
10.3.13 Assembly ................................................................................ 10–22
11. Drive gear - C2000...................................................................................... 11–1
11.1 General .................................................................................................... 11–1
11.2 Component overview – drive gear ........................................................... 11–2
11.3 Service and repairs with the drive gear in the truck................................. 11–3
11.3.1 Checking and changing the oil ................................................... 11–4
11.3.2 Replacing studs .......................................................................... 11–5
11.4 Repairs with transmission removed......................................................... 11–6
11.4.1 Removing/fitting the drive gear................................................... 11–6
11.4.2 Replacing the drive shaft seal .................................................... 11–8
11.4.3 Sealing the upper cover ............................................................. 11–9
11.4.4 Replacing the primary gear ...................................................... 11–10
12. Brake system/Wheels C3000..................................................................... 12–1
12.1 General .................................................................................................... 12–1
12.2 Parking brake - C3370............................................................................. 12–1
12.2.1 Checking the parking brake air gap............................................ 12–1
12.2.2 Removing/fitting the parking brake............................................. 12–2
12.2.3 Cleaning the parking brake ........................................................ 12–4
12.2.4 Releasing the parking brake....................................................... 12–4
© TMHE 1– 3 T Code(s): 887, 888

12.3 Drive wheel - C3530 ................................................................................ 12–5

12.3.1 Component overview.................................................................. 12–5
12.3.2 Replacing the drive wheel .......................................................... 12–5
12.4 Castor wheel – C3540 ............................................................................. 12–6
12.4.1 Component overview - Castor wheel ......................................... 12–6
12.4.2 Castor wheel maintenance and inspection................................. 12–7
Check 12–7
12.4.3 Adjusting castor wheel height..................................................... 12–7
Adjustment 12–7
12.4.4 Replacing the castor wheel ........................................................ 12–8
Method for replacing the complete wheel 12–8
Method for replacing the wheel bearing 12–9
12.5 Fork wheels – C3550............................................................................. 12–10
12.5.1 Removing/fitting for wheel OSE250, OSE250P (bogie) ........... 12–10
12.6 Wheel wear............................................................................................ 12–11
13. Steering system - C4000............................................................................ 13–1
13.1 General .................................................................................................... 13–1
13.2 Component overview ............................................................................... 13–2
13.3 Steering unit - C4110............................................................................... 13–3
13.3.1 Calibration .................................................................................. 13–3
13.3.2 Disassembling/assembling the steering unit handle .................. 13–4
Disassembly 13–5
Assembly 13–6
13.3.3 Disassembly/Assembly Replacing the potentiometer [R2] ......... 13–9
13.3.4 Replacing the inductive brake sensor [S10] ............................. 13–12
13.3.5 Replacing the damper .............................................................. 13–15
13.3.6 Checking and replacing the lateral movement line
(Ergo version) ...................................................................................... 13–17
13.3.7 Replacing buttons in the tiller arm handle ................................ 13–19
Signal button/switch 13–19
Lift/lower button 13–19
Push button 13–20
13.4 Reference sensor - C4350 .................................................................... 13–21
13.4.1 Replacing steering reference sensor [S65] .............................. 13–21
13.5 Steering bearing - C4380 ...................................................................... 13–22
13.5.1 Replacing the steering bearing................................................. 13–22
14. Electrical system - C5000 .......................................................................... 14–1
14.1 Battery - C5110 ....................................................................................... 14–1
14.1.1 Replacing the battery ................................................................. 14–1
Battery installation/replacement using a battery changing table. 14–1
Battery installation/replacement using a lifting device 14–2
14.1.2 Charging the battery ................................................................... 14–3
14.1.3 Performance limitations due to battery status ............................ 14–4
14.2 Li-ion battery (Hoppecke) ........................................................................ 14–5
14.2.1 Resetting/restarting the battery .................................................. 14–5
14.3 Inspecting the battery .............................................................................. 14–5
14.4 Contactor - C5190 ................................................................................... 14–6
14.4.1 Replacing the contactor [Q10].................................................... 14–6
14.5 ACT/ACC regulators - C5460 .................................................................. 14–7
14.5.1 General....................................................................................... 14–7
14.5.2 Replacing the transistor regulator .............................................. 14–8
14.5.3 Replacing the transistor regulator cooling fan .......................... 14–10
© TMHE 1– 4 T Code(s): 887, 888

15. Hydraulic system – C6000......................................................................... 15–1

15.1 General .................................................................................................... 15–1
15.2 Hydraulic cleanliness ............................................................................... 15–1
15.2.1 Cleaning ..................................................................................... 15–1
15.2.2 Packaging................................................................................... 15–1
15.2.3 Handling ..................................................................................... 15–2
15.2.4 Storage....................................................................................... 15–2
15.2.5 Work procedures ........................................................................ 15–2
15.3 Component overview - Hydraulic system ................................................ 15–3
15.3.1 Overview OSE250...................................................................... 15–3
15.3.2 Overview OSE120, OSE120P, OSE250P .................................. 15–4
15.4 Operating pressure .................................................................................. 15–5
15.5 Pressure limiting valve............................................................................. 15–5
15.6 Hose rupture valve .................................................................................. 15–5
15.7 Pressure sensor ...................................................................................... 15–5
15.8 Hydraulic unit - C6100 ............................................................................. 15–6
15.8.1 Overview .................................................................................... 15–6
Overview OSE250 15–6
Description OSE250P, OSE120, OSE120P 15–7
15.8.2 Tightening torque for hydraulic unit ............................................ 15–8
Tightening torques OSE250 15–8
Tightening torques OSE250P, OSE120, OSE120P 15–9
15.8.3 Emptying the hydraulic tank ..................................................... 15–10
15.8.4 Filling the tank .......................................................................... 15–10
15.9 Removing/installing the hydraulic unit ................................................... 15–11
15.9.1 Replacing valves ...................................................................... 15–13
15.10 Adjusting the pressure limiting valve ................................................... 15–14
15.10.1 Adjustment OSE250 ............................................................... 15–14
15.10.2 Adjustment OSE250P, OSE120, OSE120P ........................... 15–15
15.11 Hydraulic calibration ............................................................................ 15–17
15.12 Hydraulic system, bleeding.................................................................. 15–18
15.13 Hydraulic couplings C6230.................................................................. 15–19
15.13.1 Tightening torques for hydraulic connections ......................... 15–19
Tapered coupling with O-ring 15–19
Tredo seal 15–19
Pipe coupling 15–20
Coupling set in aluminium 15–20
Coupling set in steel 15–21
15.13.2 Quick change connector......................................................... 15–22
Overview 15–22
Assembling the quick change connector 15–22
Dismantling the quick change connector 15–23
15.14 Main lift - C6610 .................................................................................. 15–24
15.14.1 Component overview.............................................................. 15–24
15.14.2 Removing the lift cylinder OSE120, OSE120P....................... 15–25
15.14.3 Installing the lift cylinder OSE120, OSE120P......................... 15–27
15.14.4 Removing lift cylinder OSE250............................................... 15–28
15.14.5 Installing the lifting cylinder OSE250 ...................................... 15–28
16. Mast/Lift system - C7000 ........................................................................... 16–1
16.1 Main lifting chain system C7120 .............................................................. 16–1
16.1.1 Adjustment ................................................................................. 16–1
© TMHE 1– 5 T Code(s): 887, 888

16.1.2 Checking the chain ..................................................................... 16–1

Noise 16–1
Surface rust 16–1
Rusty links 16–1
Stiff links 16–2
Bolt rotation 16–2
Loose bolts 16–2
Outline wear 16–3
Stretching 16–4
Damage 16–5
Damaged plates 16–5
Damaged bolts 16–5
Dirty chain 16–5
16.1.3 Cleaning ..................................................................................... 16–5
16.1.4 Lubrication.................................................................................. 16–6
16.2 Fork carriage – C0380 ............................................................................. 16–7
16.2.1 General - Fork carriage .............................................................. 16–7
Checking 16–7
Fork height OSE250/250P 16–7
16.2.2 Component parts OSE250, OSE250P ....................................... 16–8
16.2.3 Component parts OSE250, OSE250P ..................................... 16–10
16.2.4 Front linkage on older machines .............................................. 16–12
16.2.5 Install fork carriage OSE250, OSE250P .................................. 16–13
16.2.6 Roller replacement ................................................................... 16–14
16.2.7 Removing the fork carriage OSE250, OSE250P...................... 16–15
16.3 Fork carriage – 7420 ............................................................................. 16–17
16.3.1 General - Fork carriage ............................................................ 16–17
Inspection 16–17
Fork height OSE250/250P 16–17
16.3.2 Removing the fork carriage ...................................................... 16–18
16.3.3 Install the fork carriage in the mast .......................................... 16–20
16.3.4 Replacing the mast rollers ........................................................ 16–21
16.3.5 Checking fork carriage lateral clearance .................................. 16–22
17. Options - C9000.......................................................................................... 17–1
17.1 Spider expansion unit .............................................................................. 17–1
17.2 Component overview, T.W.I.S. (Toyota Wireless Information System)... 17–2
17.2.1 Overview OSE120...................................................................... 17–3
17.2.2 Component list ........................................................................... 17–3
17.2.3 Overview OSE120P ................................................................... 17–4
17.2.4 Component list T.W.I.S .............................................................. 17–4
17.2.5 Overview OSE250/250P ............................................................ 17–5
17.2.6 Component list T.W.I.S .............................................................. 17–5
17.3 E-bar ........................................................................................................ 17–6
17.3.1 Overview .................................................................................... 17–6
17.3.2 Component list E-bar.................................................................. 17–7
17.3.3 Replacement/installation method ............................................... 17–8
17.3.4 E-bar accessories....................................................................... 17–8
18. Instructions for disposal ........................................................................... 18–1
18.1 General .................................................................................................... 18–1
18.2 Marking of plastics ................................................................................... 18–1
18.2.1 General marking of products and packaging.............................. 18–1
© TMHE 1– 6 T Code(s): 887, 888

18.2.2 Marking according to the manufacturer’s standards .................. 18–2

Abbreviations 18–2
Marking examples 18–2
18.3 Pressure vessels ..................................................................................... 18–3
18.3.1 Gas struts ................................................................................... 18–3
18.4 Sorting categories.................................................................................... 18–4
19. Electrical components and electrical diagram........................................ 19–1
19.1 Electric components ................................................................................ 19–1
19.1.1 Electric component overview...................................................... 19–5
19.2 Electrical wiring diagrams ..................................................................... 19–10
19.2.1 List of symbols.......................................................................... 19–10
19.2.2 Wiring diagram 250P - Overview.............................................. 19–11
19.2.3 Wiring diagram 250P ................................................................ 19–12
19.2.4 Wiring diagram 120P - Overview.............................................. 19–23
19.2.5 Wiring diagram 120P ................................................................ 19–24
19.2.6 Wiring diagram 120 - Overview ................................................ 19–38
19.2.7 Wiring diagram 120 .................................................................. 19–39
19.2.8 Wiring diagram 250 - Overview ................................................ 19–52
19.2.9 Wiring diagram 250 .................................................................. 19–53
20. Hydraulics schematics ............................................................................. 20–1
20.1 Schematics OSE120P ............................................................................. 20–1
20.2 Schematics OSE120 ............................................................................... 20–3
20.3 Schematics OSE250P ............................................................................. 20–4
20.4 Schematics OSE250 ............................................................................... 20–6
21. Tools............................................................................................................ 21–1
21.1 Super Seal connectors ............................................................................ 21–1
21.2 AMP connectors ...................................................................................... 21–2
21.3 AMP connectors, Multilock series 040..................................................... 21–3
21.4 Molex connectors .................................................................................... 21–4
21.5 CPC contacts........................................................................................... 21–5
21.6 MQS contacts .......................................................................................... 21–6
21.7 Grease guns ............................................................................................ 21–8
21.8 Other tools ............................................................................................... 21–9
22. Service data and grease specifications ................................................... 22–1
22.1 General tightening torques ...................................................................... 22–1
22.1.1 Galvanised, non-oiled screws .................................................... 22–1
22.1.2 Untreated, oiled screws.............................................................. 22–1
22.2 Lubrication chart ...................................................................................... 22–2
22.3 Oil and grease specification .................................................................... 22–3
23. Technical data ............................................................................................ 23–1
23.1 Basic data ................................................................................................ 23–1
23.1.1 Speed limitation .......................................................................... 23–4
© TMHE 1– 7 T Code(s): 887, 888

© TMHE 1– 8 T Code(s): 887, 888

2. General introduction
2.1 How to use this manual
The repair manual is divided into chapters containing the following
information:
• Operation and connection sequences – This chapter provides a basic
description of the main functions of the truck
• Parameters – This chapter describes steering system parameters and the
calibration procedure
• Installation and commissioning – This chapter describes the work that is
necessary for commissioning of the truck
• Maintenance – This chapter includes a general diagram for regular
maintenance followed by detailed descriptions of required maintenance
procedures
• Troubleshooting – The troubleshooting chapter describes the error codes
that are displayed when the truck is partially or completely disabled. It also
describes the cause of the problem together with suggested remedies.
• Remedies – This chapter describes the various truck systems, e.g. the
hydraulic system and includes descriptions of system parts and the
necessary service procedures. The various descriptions are divided
according to the C code system of the truck manufacturer.
• Appendices - The appendices include:
Instructions for disposal
Information about electrical components and wiring diagrams
Hydraulics diagram
List of required tools
Information about general tightening torques
Oil and grease specifications
Technical data
© TMHE 2– 1 T Code(s): 887, 888

2.2 Warning symbols

The following warning symbols are used throughout the service manual:
DANGER!
DANGER! means there is a risk of accident potentially leading to death or
serious injury and material loss or damage. This is always indicated by the
warning symbol.
WARNING!
WARNING! means that there is a risk of damage to components that are
sensitive to electrostatic discharge.
Heed applicable ESD safety precautions.
NOTE:
Note: means there is a risk of material loss or damage if the instructions are
not followed. Also used to call attention to various points.
© TMHE 2– 2 T Code(s): 887, 888

2.3 Pictograms
2.3.1 Screws/Nuts
Wherever possible, pictograms have been used to describe certain work
operations.
Pictograms are primarily used for operations that require loosening or
tightening of screws:
×n
s mm
The pictograms contain information about the screw head type and have
arrows that show if the screw should be loosened or tightened.
The text below the pictograms provide additional information, such as:
‘s’: spanner size, ‘n’: number of screws and, where required, ‘T’: the
recommended tightening torque.
2.4 Abbreviations used in this manual
Abbreviatio
Unit
n
ICH Integrated Controller Handle (main control unit)
ACT AC Traction (travel control)
ACC AC Combi (combi-control)
EPS Electronic Power Steering (steering servo)
CAN Controller Area Network
SEU Spider Expansion Unit
NVM Non-Volatile Memory
— End of section —
© TMHE 2– 3 T Code(s): 887, 888

© TMHE 2– 4 T Code(s): 887, 888

3. General safety rules

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

To make work safer and prevent accidents, always keep the following in
mind:
• Keep the maintenance work site clean. Oil and water on the floor will make
it slippery.
• Use the correct working posture. Service work often involves sitting on
your knees or bending over forwards. Try sitting on a toolbox, for example,
to relieve the strain on your knees and back.
• Loose items and jewellery can get caught in moving parts of the truck. So
never wear loose articles or jewellery while working on the truck.
• Exercise caution and always follow applicable local regulations when
working at high heights.
• Use the correct tools for the work you are carrying out.
• Keep all tools well maintained.
• Make sure that all safety equipment including guards and covers are
properly secured and that they work as intended before starting the repair
work. If a guard or cover must be removed in order to perform the repair
work, extra care must be taken, and when the repair work is finished the
guard or cover must be refitted.
• Relieve the system pressure slowly before starting work on the truck’s
hydraulic system.
• Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hands.
• Drive unit oil and the hydraulic system oil may be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Allow the truck to cool down before changing the oil.
• Only fill the hydraulic system with new and clean oil.
DANGER!
Risk of damage to the hydraulic system.
If the oil is contaminated, the hydraulic components will suffer damage.
Always use new and clean oil in the hydraulic system.
• Store and transport changed oil according to applicable local directions.
• Do not flush solvents, etc. down the drain unless they are intended to be
disposed of in this way.
Follow local disposal regulations.
© TMHE 3– 1 T Code(s): 887, 888

• Disconnect the battery prior to performing any welding work on the truck.
NOTE:
The battery could be damaged.
When welding with an electric welding unit, welding current may enter the
battery.
The battery must be disconnected.
• Prior to welding or grinding on painted surfaces, be sure to remove the
paint at least 100 mm around the welding/grinding area by using
sandblasting equipment or paint remover.
DANGER!
Harmful gasses.
Heated paint gives off harmful gases.
Remove paint 100 mm around the welding/grinding location.
© TMHE 3– 2 T Code(s): 887, 888

3.2 Electrical system

When working on the electrical system of the truck, remember the following:
• Never wear loose items or jewellery when working with the truck.
DANGER!
Short-circuiting/Burn injury.
Short circuits and burn injuries can occur if metal objects come into contact
with live electrical connections when working on the truck's electrical
system.
Remove wristwatches, rings and other metal objects beforehand.
• Always use insulated tools when working on the electrical system.
• Always disconnect the battery before opening any covers to drive units or
the electrical system.
• Always disconnect the battery prior to welding work using an electric
welding unit. The welding current may damage the battery.
• Always disconnect the battery when carrying out maintenance or repair
work on the truck unless otherwise stated in this repair manual.
• Clean electric motors using a rag or a vacuum cleaner.
• Clean electrical panels, electronic cards, contactors, contacts, magnetic
valves, etc. with a dampened cloth and a cleaning agent that will not
damage the part.
NOTE:
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the logic cards.
© TMHE 3– 3 T Code(s): 887, 888

3.3 Safe lifting

All lifting must be carried out on a level, non-slip and stable surface. Asphalt
surfaces should be avoided if possible.
To prevent the truck moving while it is being lifted, it must not be lifted with
anyone on the platform or with the tiller arm in the lowered position.
If the drive wheel, which is braked, is being lifted the other wheels must be
chocked to stop the truck from moving.
Select the lifting point so that the lift is as easy as possible, for example lifting
one corner at a time. If the truck has marked lifting points on the lower part of
the chassis, these must be used to ensure balanced lifting.
Make sure the surface where the jack is placed is clean and free of oil and
grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. If the lever is too short, more
exertion than is necessary will be required. If the lever is too long, there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing since a poorly supported truck could fall down.
Never work under a truck that is not supported by trestles and secured by a
lifting device.
Support the truck:
• as close to the lifted part of the chassis as possible in order to reduce the
falling height if the truck should collapse
• so the truck cannot move.
Never support the jack on trestles to achieve a higher lift.
Never work under a raised truck without it being properly supported on
trestles.
© TMHE 3– 4 T Code(s): 887, 888

3.4 Truck modifications

Any modification of the truck must be approved beforehand. No modification
of truck may be performed that may influence the capacity, stability and safety
of the truck without prior written approval from the manufacturer, its
representative or successor.
In the case of the manufacturer no longer being in business and there being
no successor, the user of the truck may arrange for modifications on the
precondition that the user:
• makes sure that an engineer with expert knowledge of industrial trucks
and their safety designs, tests and implements the modification,
• files all documentation of the designs, tests and implementation of the
modification,
• approves and makes the applicable changes to the capacity plate,
adhesive labels, markings and operator’s manual and
• affixes a permanent and well visible sign to the truck stating how the truck
has been modified, together with the date of the modification and the
name and address of the company that carried out the modification work.
© TMHE 3– 5 T Code(s): 887, 888

© TMHE 3– 6 T Code(s): 887, 888

4. Operation and connection sequences

This section provides a basic description of the main functions of the truck.
The terms below are used in the description of the truck’s main functions.
• Event – Use of one of the truck's main functions is referred to as an event.
• Prior event – Indicates an event which must have taken place immediately
before the current event in order for the latter to be performed correctly.
• Action(s) – An action that the driver must perform in order for an event to
happen.
• Influencing elements – Conditions that must be fulfilled in order for an
event to happen. Certain parameter settings may also affect the outcome
of the event.
• Resulting conditions – Describe the key events that can be checked in
order to confirm a function.
Note that resulting conditions indicate what is assumed to occur when there
is no error state.
Text within square brackets [ ] refer to the electrical component names in the
truck's electrical diagram.
{High} means ˜ 24 V and {low} means ˜ 0 V unless otherwise specified.
Symbols on keypad and display
Symbol Description
ON button
This button is used to start the truck
and confirm entered settings during
PIN code management
OFF button
Error code
Battery charge as a percentage
Parameter
Hour counter
© TMHE 4– 1 T Code(s): 887, 888

4.1 Battery is connected
Event Connection of battery

Preceding event -
Action(s) Connect battery [X1, G1]

Main power fuse OK [F1]
Influencing
Current circuit fuses [F50, F51, F52, F53]
elements
Resulting
Login possible.
conditions
4.2 Logging in
Event PIN code login

Preceding event Battery is connected
Log in with PIN code and press the ON button
Action(s)
[A17]
Emergency stop not actuated [S21]
Influencing elements Drive position sensor deactivated [S10]
Input [T1:INP TILL. ARM IN DRIV. POS] is {low}
Battery indicator lamp lights. The main display
[A6] shows the hour meter for four seconds,
Resulting conditions followed by battery status (% of full charge)
The mechanical brake [Q1] must remain actuated
[T1:OUT.BRAKE RELEASE] {high}
4.3 Basic conditions for driving
Event Steering unit lowered to drive position

Preceding event Switched on (PIN code login)
Action(s) Lower the steering unit

Presence check [S19]
Influencing elements
Drive position sensor [S10]
Drive position sensor activated [S10].
Input [T1:INP TILL. ARM IN DRIV. POS] goes {high}
Resulting conditions
Output [T1:OUT.MAIN CONTACTOR] goes {low}
Main contactor closed [Q10]
© TMHE 4– 2 T Code(s): 887, 888

4.4 Driving in fork direction
Event Driving, fork direction

Preceding event Steering unit moved to drive position
Action(s) Move the speed control [L1] in the fork direction.

Hall element in speed control [A2:S300-308]
Load cell [B10]
Influencing elements Load > 500 mm [S12]
Platform sensor > 500 mm [S103]
Steering angle
Parameter settings
[T1:OUT.BRAKE RELEASE] goes {low}
Brake coil [Q1] is energised, mechanical brake is
Resulting conditions released
Pulsed current is fed to the drive motor in
proportion to the position of the speed control
4.5 Driving in the drive wheel direction
Event Driving, drive wheel direction

Preceding event Steering unit moved to drive position
Action(s) Move the speed control [L1] in the drive wheel direction.
Drive direction selector’s Hall element [A2:S310-318]
Load > 500 mm [S12]
Influencing
Platform sensor > 500 mm [S103],
elements Load cell [B10]
Steering angle
Parameter settings
[T1:OUT.BRAKE RELEASE] goes {low}
Brake coil [Q1] is energised, mechanical brake is
Resulting
released
conditions
Pulsed current is fed to the drive motor in proportion to
the speed control’s movement
© TMHE 4– 3 T Code(s): 887, 888

4.6 Braking in neutral
Event Neutral braking

Driving, fork direction
Preceding event or
Driving, drive wheel direction
Allow the speed control [L1] to return to the neutral
Action(s)
position.
Influencing
Load cell [B10]
elements Parameter settings
The drive motor [M1] functions as a generator and
converts the kinetic energy of the truck into electrical
energy via the transistor regulator [T1]. This reduces the
Resulting
velocity of the truck.
conditions The excess energy is fed back to the battery [G1].
The mechanical brake engages when the truck stops
completely. [T1:OUT.BRAKE RELEASE] goes {high}
4.7 Reverse braking
Event Reverse braking

Preceding event or
The speed control [L1] is moved to the opposite driving
Action(s)
direction.
Influencing elements Load cell [B10]
Parameter settings
The drive motor [M1] functions as a generator and
converts the kinetic energy of the truck into electrical
energy via the transistor regulator [T1]. This reduces
the velocity of the truck.
Resulting conditions The excess energy is fed back to the battery [G1].
The mechanical brake engages when the truck stops
completely. [T1:OUT.BRAKE RELEASE] goes
{high}
4.8 Brake operation via controls
Event Mechanical braking

Preceding event or
Action(s) Move tiller unit handle to upper position
© TMHE 4– 4 T Code(s): 887, 888

Event Mechanical braking

Influencing Drive position sensor is deactivated [S10]
elements
Input [T1:INP TILL. ARM IN DRIV. POS] goes {low}
Resulting Brake reduction until the truck is stationary
conditions Brake coil [Q1] is deactivated, mechanical brake is
engaged [T1:OUT.BRAKE RELEASE] goes {high}
4.9 Steering
Event Steering
Action(s) Steering unit is moved to the left or right

Steering angle potentiometer [R2]
Reference sensor [S65, A5:INP.REFERENCE SWITCH]
Influencing
Presence sensor [S19, T1:INP.OPERATOR ON
elements PLATFORM]
Parameter settings
Resulting Steering servo motor positions the drive wheel according
conditions to steering unit movement [A5, M6]
4.10 Fork lifting up
Event Fork lifting

Action(s) Press the fork lift button [A2:S320]

Main contactor [Q10].
Pump contactor [Q30] (OSE250)
Fuse [F1].
Fork lift button [A2:S320]
Battery status OK (>20% charge left)
Lift height limit S31 [A1:INP.LIFT LIMIT] not activated
[T1:OUT. P-] goes {low}.
Valve [Q22] opens (OSE120P, OSE250P)
Resulting conditions [T1:OUT.PUMP CONTACTOR] goes {low} (OSE250)
Pump contactor [Q30] is energised (OSE250)
Pump motor [M3] starts.
© TMHE 4– 5 T Code(s): 887, 888

4.11 Fork lifting down
Event Fork lowering

Preceding event Fork lifting
Action(s) Press the fork lowering button [A2:S321].

Fork lowering button [A2:S321]
Influencing elements PLATFORM]
Sensor – Forks <200 mm [S32,T1:INP FORKS
<200MM] (OSE120, OSE120P)
[T1:OUT. PROP VALVE] goes {low}, proportional valve
[Q4] opens.
Resulting conditions
[T1:OUT. FORK VALVE] goes {low}, [Q22] opens
(OSE120P, OSE250P).
4.12 Platform up
Event Platform lifting

Action(s) Press the platform lift button [A2:S322].

Platform lift button [A2:S322]
Battery status OK (>20% charge left)
PLATFORM]
Sensor for platform lift limit [S107,T1:INP. PLATFORM
LIFT LIMIT]
[T1:OUT. P-] goes {low}.
Valve [Q23] opens.
Resulting conditions [T1:OUT.PUMP CONTACTOR] goes {low} (OSE250)
Pump contactor [Q30] is energised (OSE250)
Pump motor [M3] starts.
4.13 Platform down
Event Platform lowering

Preceding event Platform lifting
Press the platform lowering button [A2:S323] or press
Action(s)
the foot switch [S214] twice
Platform lowering button [A2:S323] / foot switch [S214]
Influencing elements Presence sensor [S19, T1:INP.OPERATOR ON
PLATFORM]
[T1:OUT. PROP VALVE] goes {low}, proportional valve
Resulting conditions [Q4] opens.
[T1:OUT. PLATFORM VALVE] goes {low}, [Q23] opens.
© TMHE 4– 6 T Code(s): 887, 888

5. Parameters, menu navigation and calibration

5.1 General
A keypad and a numeric information display with coloured LED symbols are
used together with a menu-based information system as the primary
communication tool between the operator/technician and the truck.
In logged-in mode, the display is always lit and shows battery capacity in the
numeric field while the battery indicator is lit.
Symbols on keypad and display

Symbol Description
ON button
This button is used to start the truck
and confirm entered settings during
PIN code management
OFF button
Error code
Battery charge as a percentage
Parameter
Hour counter
The speed control is used for menu navigation.

To select a menu item, press and release the horn button.
Menu item "ESC" always returns you to the previous menu.
If logged in without CAN key or TruckCom, only a limited number of menus
are available.
© TMHE 5– 1 T Code(s): 887, 888

5.1.1 Menu navigation

Proceed as follows if you only want to view the different truck settings:
1. Ensure that the truck is switched off. Connect the CAN key or enter the
PIN code. Note: Do not press the ON button.
2. Press and then release the horn button. “Info“ is shown on the display.
3. Move between menus by turning the speed control several times. See
the overview below.
Log on using horn
Parameter set/ PIN code menu Service mode Escape

Info menu Emergency drive Calibrate
view “CAL” “Pin” Ser “ESC”
“InFo” “Ed” “Cal”
“PAr” Truck resets
Starts truck in
First parameter emergency drive 1st calibrate Enter PIN code Starts truck in
“1” mode. All LEDs function edit function service mode
are flashing “1”
Last parameter Last calibrate

“XXXX” function
“X”
Escape Escape
“ESC” “ESC”
Back to prev menu Back to prev menu
Part number Build in test ICH Escape

Hour meter display Error log display Shock lockout log
display “tESt” “ESC”
“H” “E” “c”
“Pn” Back to prev menu
A time “A” Software part no Display test Latest shock PIN

Latest error “1”
Total key on time “SPn” Walking 8 “1”
B time “b” Oldest error “XX” Hardware part no Oldest shock PIN
Throttle
Active time (XX max 50) “HPn” “10”
Accessible to
the operator
C time “c” Escape Escape
“ESC” Machine no “ESC”
Drive avtive time “no”
Back to prev menu Back to prev menu
D time “d” Only accessible

Hydraulic active Hardware serial no Lift/Lower with the CAN key,
time “HSn” operator
S time “S” Escape

Time to service “ESC” Sensilift
Back to prev menu
Escape
“ESC” Keyboard
Back to prev menu
Escape by
pressing horn
© TMHE 5– 2 T Code(s): 887, 888

4. Press and release the horn button to select which menu to view.
Note:
Service mode - SEr
This sets the truck to a special service mode used in production. Note that
the truck cannot be driven in this mode.
5. Turn the speed control several times to move between the different
positions in the selected menu.
6. If logged in without CAN key or TruckCom, only a limited number of
menus are available and unavailable menus are not shown.
The following are not shown:
- Calibration (CAL)
- PIN code menu (Pin)
- Collision sensor log (c)
7. Switch off the truck by pressing the OFF button or return to the previous
menu by selecting "ESC".
5.1.2 Display hour counter values

3. Press the horn button to select.
4. “H” is shown on the display.
5. Press the horn button to select. The hour counter symbol is lit.
6. To cycle through the 5 different hour meter values, press the speed
control repeatedly.
7. To show an hour meter value, release the speed control when the
required hour meter symbol is shown on the display. The hour meter
value in question is shown on the display.
© TMHE 5– 3 T Code(s): 887, 888

5.1.3 Show part numbers for software/hardware

1: Ensure that the truck is switched off. Connect the CAN key or enter the
2: Press and then release the horn button. “Info“ is shown on the display.
3: Press the horn button to select.
4: Turn the speed control several times until “Pn” is shown on the display.
5: Press the horn button to select.
6: You can obtain the following information by pressing the speed control
repeatedly:
– Software part number
– Hardware part number
– Serial number
– Hardware serial number
7: To show a part number, release the speed control when the required part
number symbol is shown on the display. The part number in question is
shown on the display.
8: Switch off the truck by pressing the OFF button or return to the previous
© TMHE 5– 4 T Code(s): 887, 888

5.2 Parameter settings

The truck's control system stores a number of parameters. These parameters
are used to configure the truck for correct operation in specific settings and
for a particular application. The parameters are divided into groups:
• Operator parameters – The operator parameters are used to adapt
truck's characteristics to a specific operator or work task. Up to 10 sets of
operator parameters can be stored. Operator parameters are displayed
and changed only for a selected operator, but if a CAN service key is
connected, the parameters for all operators can be displayed and
changed. Operator parameters can be changed by the operator if the
truck's program is set up for this.
• Service parameters – Service parameters are used to adjust the
functional performance of the truck. The service parameters can be
changed once a suitable CAN service key or PDA/PC has been connected
to the truck. Please note that the service parameters can be checked
without any need for plugging in a CAN service key, however it is then not
possible to change the values.
• Factory parameters – Truck-specific parameters pre-set at the factory.
These can be changed by a service technician if special needs arise. The
parameters specify e.g. the truck model and which controls to use for the
hydraulic function.
The factory parameters are changed via PC/PDA and TruckCom and
cannot be changed via the CAN service key.
• Factory parameters, calibration – (range 1251-1500) stores the values
generated during calibration of valves, potentiometers, etc. These should
not normally be changed. The parameters can be changed once a suitable
CAN service key or PDA/PC has been connected to the truck.
All parameters can be changed via PC/PDA and TruckCom (refer to

TruckCom manual).
5.2.1 Copying the truck’s configurations

The truck contains a mother board (ICH) and a secondary board (ACT). The
secondary board functions as back-up. The function is used to transfer the
truck’s configuration between the boards, for example when replacing the
mother board. The configuration data copied are parameters, hour meters
and serial number (see TruckCom manual).
© TMHE 5– 5 T Code(s): 887, 888

5.2.2 Setting operator/service parameters without using PC/PDA

DANGER!
Risk of personal injury and material and property damage.
Changes must only be carried out by someone with good knowledge of how
the truck will be affected by changing a parameter setting.
Proceed as follows to set parameters:
1. Connect the CAN key. Press and release the horn button
Operator parameters can also be set by entering the PIN code and then
pressing and releasing the horn button. Note: Do not press the ON
button. This requires that parameter 102 is set to an odd value.
2. “Info” is shown on the display.
3. Turn the speed control several times. Stop when the display shows "Par".
The parameter symbol is lit.
4. Press and release the horn button to select.
5. Turn the speed control to move between the parameters.
They are as follows:
- Operator parameters (1-100)
- Service parameters (101-1000)
- Factory parameters (1001-)
To return to the previous menu, select "ESC", which is found between the last
parameter and the first parameter.
6. To edit a parameter, release the speed control when the required
parameter number is shown on the display. You can display the items
more quickly by holding the speed control depressed.
To change the set value, press the horn button once.
The parameter symbol will start to flash if the value can be changed.
7. Change the value by turning the speed control level.
8. Confirm the setting by pressing the horn button once more.
The parameter symbol lights continuously once again.
Note:
If you want to keep the original setting instead of saving the new setting,
press the OFF button without pressing the horn button.
9. Exit programming by pressing the OFF button or return to the previous
© TMHE 5– 6 T Code(s): 887, 888

5.2.3 Operator parameters
Overview
Note:
Changing specific truck parameters changes the truck's driving properties.
Do not change any parameter values without the necessary know-how.
Increm
Parameter Name/unit Min./Max. Std. Description
ent
Speed, Fork 30: minimum speed
1 30:100 5 80
direction, % 100: maximum speed
Speed, drive 30: minimum speed
2 30:100 5 100
wheel direction, % 100: maximum speed
10: lowest acceleration
3 Acceleration, % 10:100 5 80
100: full acceleration
40: minimum brake force
4 Neutral braking, % 40:100 5 70 100: maximum
braking force
0: stationary
Travel speed,
100: maximum speed
5 platform 0:100 10 100
See section "23.1.1 Speed
> 0.5 meters, %
limitation".
Speed -Walking at 40: minimum speed (2.4 km/h)
6 40:100 5 100
side of truck,% 100: highest speed (6 km/h)
Brake force if the operator
leaves the platform during truck
Neutral braking -
7 60:100 5 90 travel
leave truck, %
60: minimum brake force
100: maximum brake force
Speed - Remote
40: minimum speed (1.6 km/h)
8 drive (option 40:100 5 100
100: highest speed (4 km/h)
OSE250), %
Connection to logged-in operator

Operator parameters can be adjusted individually for up to ten different
operator profiles.
Note
If, for example, “01 1” is shown in the numeric field when adjusting an
operator parameter value, this is read as “parameter 1 operator profile 1”.
© TMHE 5– 7 T Code(s): 887, 888

Factory preset operator parameters

Upon delivery from the factory, the various operator profiles have different
values set for operator parameters 1, 2, 3, 4 and 6. See the table below.
The values for operator profile 1 and 4-10 are the default values.
Operator profile Parameter Factory setting PIN code
1 80
Operator profile 1, 2 100
4 -10 3 80 1, 4-9
Standard profile 4 70
6 100
1 70
2 80
Operator profile 2
3 50 2
Beginner profile
4 70
6 80
1 100
2 100
Operator profile 3
3 100 3
Advanced profile
4 100
6 100
© TMHE 5– 8 T Code(s): 887, 888

Description of operator parameters

#1 - Speed, fork direction
Adjusts the maximum speed of the truck in the fork direction.
#2 - Speed, drive wheel direction
Allows for adjustment of the maximum speed of the truck in the drive wheel
direction.
#3 - Acceleration
The lower the parameter value, the more time is needed to accelerate to the
maximum speed.
#4 - Neutral braking
Defines plug braking force when speed control [L1] returns to the neutral
position. The lower the value of parameter, the longer it takes to reduce
speed.
# 5 - Travel speed, platform > 0.5 m
Adjusts the truck's max. speed when the platform is lifted above 0.5 metre.
Value 0 shuts off the driving of the truck. The value 100 gives maximum travel
speed with the platform lifted above 0.5 metre. See section "23.1.1 Speed
limitation".
# 6 - Speed, walking at side
Adjusts the truck’s maximum speed when the operator is not on the platform,
i.e. when the operator walks alongside the truck.
# 7 - Neutral braking, walking at side of truck
Defines the plug brake force when the speed control [L1] returns to the
neutral position and the operator dismounts the truck and walks by the side of
the truck. The lower the value of parameter, the longer it takes to reduce
speed.
# 8 - Speed, “Remote control” (option)
“Only for OSE250”
Adjusts the maximum speed of the truck when the operator is not standing on
the platform but is using the remote drive, remote control and bracelet.
© TMHE 5– 9 T Code(s): 887, 888

5.2.4 Service parameters

Before any service parameter can be changed, the CAN service key must be
connected to the contact [X41].
Overview
Note:
Changing specific truck parameters changes the truck's driving properties.
Do not change any parameter values without the necessary know-how.
Note:
Parameter 201 must be set to a value greater than or equal to the value of
parameter 4. If a value of any parameter is changed causing the value of
parameter 201 to become smaller than that of parameter 4, then the value of
parameter 201 will automatically be reset to 100. When the parameter value is
changed, error code 2.002 is generated automatically.
Min./ Increm
Parameter Name/unit Std. Description
Max. ent
Determines the limit when the next service visit
Service interval, is required. When the next service is required, a
101 0:2000 50 0
hours code is shown on the display.
0 = Service indicator off.
Values 1 and 2 = Key
Values 3 and 4 = Keypad with 100 PIN codes
Values 5 and 6 = Keypad with DHU
102 Operator access 1:8 1 3 Values 7 and 8 = ID unit
Odd values = Open operator parameters
Even values = Operator parameters can only be
changed with a CAN key.
Start-up - Sets which value is shown on the display when
103 1:5 1 2
alternative the truck is started.
Automatic logout/
104 0:20 1 20 Value 0 gives logout after 4 hours.
min
Option. Indicates the degree of sensitivity for
Collision sensor X
105 0:100 1 0 what should be interpreted as a frontal/rear-end
level
impact.
Collision sensor Y Option. Indicates the degree of sensitivity for
106 0:100 1 0
level what should be interpreted as a side impact.
Battery
107 1:20 1 8 See table in descriptions
adjustment, Ah
0 = A special PIN code is required to reset the
truck after a collision.
Reset following a 1 = The truck can be reset using the activated
111 0:3 1 0
collision PIN codes.
2 = Deactivates acoustic signal
3 = Options 1 and 2 combined.
0 = Do not clear
Clear application
112 0:2 1 0 1 = Clear histogram at start-up
data
2 = Clear collision log at start-up
© TMHE 5 – 10 T Code(s): 887, 888

Min./ Increm
Max. ent
Determines how hard the truck should brake
when the speed control is turned fully in the
opposite direction.
Reversing
201 70:100 5 100 Note: This value must not be lower than the
braking, %
value of parameter 4. If it is lower, error code
2.002 is shown at start-up and the value is not
changed.
Maximum speed Specifies the maximum speed with raised forks,
203 0:120 1 60
with raised forks in (km/h*10)
Manoeuvring from 0 = activated
207 0:1 1 0
the side 1 = deactivated
OTP, speed Angle when the speed reduction in the drive
220 0-25º 1 25
reduction. wheel direction should begin
OTP reduction of Angle when the reduction in acceleration should
221 0-35º 1 35
the acceleration begin
OTP, speed at
4-6 km/ Minimum speed at maximum steering angle in
222 maximum steering 0.1 6
h the drive wheel direction
angle.
Platform, lowering Parameter value 100% represents the
308 30:100 5 100
speed, % maximum lowering speed.
Description of service parameters

#101 - Service intervals
This parameter determines the time value (in hours) to the next service from
0 to 2000 hours in increments of 50 hours. Whenever this value is changed,
the timer is reset and will start to count the truck activity time. On reaching the
set value, code “S - 0h” is shown on the display.
#102 – Login method and operator parameter access
Specifies which login method should be used and if the operator will have the
possibility of changing the operator parameter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad with 100 PIN codes See section "6.5 Using PIN
codes".
Values 5 and 6 = Keypad with DHU
Values 7 and 8 = ID unit
Odd values = Open operator parameters
Even values = Operator parameters can only be changed with a CAN key.
#103 - Start-up display
Sets which value is shown on the display when the truck is started.
When the truck is started, one of the truck's 5 values is shown on the hour
meter display "H" (hour meter display) for 5 seconds. After the menu has
disappeared, the battery capacity is continuously shown in the numeric field
at the same time as the battery indicator is lit.
© TMHE 5 – 11 T Code(s): 887, 888

The truck control system stores five different time values. "Value 2 -
Operating time" is the default value on the start-up display.
Hour meter values Display
Value 1 = Key time

The total time the truck has been in use
Value 2 = Operating time

Combined time during which the pump or drive motor has
been in operation.
Default display.
Value 3 = Drive motor time

The total time the drive motor has been in operation.
Value 4 = Pump motor time

Total time the pump motor has been in operation.
Value 5 = Remaining time until next service.

Parameter 101 controls the initial value.
#104 - Automatic logout

This parameter is used to set the time (minutes) until the truck is switched off
when the keypad is used. Time is counted from when the latest power
consumer is used.
Value 0 gives 4 hours.
#105 - Collision sensor X sensitivity degree
Indicates the degree of sensitivity for what should be interpreted as a side
impact. This parameter must be set during truck installation. See the chapter
“Setting collision sensor parameters (option)”
#106 - Collision sensor Y sensitivity degree
Indicates the degree of sensitivity for what should be interpreted as a frontal/
rear-end impact. This parameter must be set during truck installation. See the
chapter “Setting collision sensor parameters (option)”
# 107 - Battery size
Specifies what type of battery the truck is equipped with.
The parameter can be used to compensate for different ways of driving by:
• increasing the value to discharge the battery even more.
• reducing the value if the battery is discharged too much.
In order to set the meter for battery charge level, consideration must be given
to the following:
• Acid density when the battery is fully charged to check the quality of the
battery. This value should be between 1.27 and 1.29.
© TMHE 5 – 12 T Code(s): 887, 888

Please note that the acid density may vary between different types of
battery.
• When the lifting capacity is disabled (battery 80% discharged), the value
must be close to (but not below) 1.14.
Refer to the table below for recommended parameter settings.
• Lead/acid batteries
Parameter 107 Battery size

1
2
Slight
3
discharge
4
5
6
7
8
9
10
11 561-650 Ah
12 481-560 Ah
13 321-480 Ah
14 < 320 Ah
15
16
Deeper 17
discharge 18
19
20
© TMHE 5 – 13 T Code(s): 887, 888

Gel batteries
Parameter 107 Battery size
1
2
Slight
3 581-650 Ah
discharge
4 481-580 Ah
5 381-480 Ah
6 281-380 Ah
7 < 280 Ah
8
9
10
11
12
13
14
15
16
Deeper 17
discharge 18
19
20
DANGER!
Battery service life will be reduced if the value of parameter 107 is set too high.
The standard setting of parameter 107 is set for normal truck handling. Other
applications may require a different setting of parameter 107. Check that the
parameter setting is the correct one using the instructions below.
Verifying parameter settings for freely ventilated batteries (lead-acid

batteries)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator shows a
discharged battery (0% on the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
minutes.
Note:
Do not charge or discharge during this time.
4. Measure the specific gravity of the battery electrolyte at room
temperature.
If the specific gravity is below 1.15 g/cm3 , then the parameter value must
be reduced. If the value is considerably higher than 1.15 g/cm3 the risk of
© TMHE 5 – 14 T Code(s): 887, 888

damage to the battery is reduced. At the same time, the operating time of
the truck is reduced. If extended operating time is desired, then increase
the parameter value by no more than one unit.
Note:
Each change should be followed up by a new verification of the parameter
setting.
#111 - Reset procedure after collision
Specifies the condition for how the truck is to be taken into operation again
after the collision sensors have been triggered.
Truck speed is limited to creep speed and the truck horn sounds every five
seconds.
Value Function
0 Login with a special PIN code is required
The truck can be reset using all activated PIN
1
codes.
2 Deactivates the acoustic signal.
3 Options 1 and 2 combined.
The PIN code to be activated can be found in operator profile 1 and special
block 10. See section "6.6.1 Setting collision sensor parameters (option)".
#112 - Clear application data
Specifies whether information from the histogram/collision sensor is to be
deleted at login.
Value Function
0 Do not clear
1 Clear histogram at start-up
2 Clear collision log at start-up
© TMHE 5 – 15 T Code(s): 887, 888

#201 - Deceleration when reversing

Note:
This value must not be lower than the value of parameter 4. If it is lower, error
code 2.002 is shown at start-up and the value of #201 is not changed.
Parameter 201 may be used to produce a smoother retardation when the
application requires this for all operator profiles.
#207 - Operation, walk alongside truck
This parameter is used to activate/deactivate the possibility of the operator
operating the truck with the steering unit while walking alongside the truck.
Value 0 = Activated
Value 1 = Deactivated
# 220 - OTP, speed reduction.

This parameter is used to set when the speed reduction when cornering in
the drive wheel direction should begin. Set between 0-25º
• Unless the parameters are changed from their default values, the truck will
behave in the same way as previously
# 221 - OTP reduction of the acceleration

This parameter is used to set when the reduction of acceleration should
begin. Set between 0-35º
# 222 - OTP, speed at maximum steering angle.

This parameter is used to set the minimum speed at maximum steering angle
in the drive wheel direction. To be set between 4-6 km/h
#308 - Platform, lowering speed

This parameter is used to adjust the platform lowering movement that applies
for the truck in a specific application.
Parameter value 100% represents the maximum lowering speed.
© TMHE 5 – 16 T Code(s): 887, 888

5.2.5 Factory parameters

The truck's factory parameters are preset in the truck during production at the
factory. Factory parameters can only be changed using the TruckCom
software application with a PC or PDA.
Note:
Remember that a change of specific truck parameters changes the truck's
properties.
The user ID and time of changing parameters will be logged in the logic card
housed in the tiller arm handle.
DANGER!
All factory parameters affect the truck's configuration and performance.
Changes must only be carried out by persons who are trained in parameter
setting and can prove they have good knowledge of how truck parameter
changes affect the truck and how factory parameter changes are to be
carried out.
Min./ Incre
Max. ment
0 = Unknown truck type
1 = OSE250
2 = OSE250P
3 = OSE120
4 = OSE120P
5 = OSE200X
6 = OSE180XP
1001 Truck type 0:13 1 0
7 = OSE120CB
8 = OSE100
9 = OSE100W
10 = TSE300 (12 km/h)
11 = TSE300 (9 km/h)
12 = OME100N
13 = OME100NW
Non-configurable
1002 0:15 1 0 Not used
option
See section " # 1253 - Steering offset".
Note:
1003 Optional function 1 0:20 1 0
With the “Automatic height adjustment”
option, set parameter 1003 to 11.
See section " Factory parameters # 1003 to
1042 - configurable optional functions".
Optional function
1004 0:255 1 0 Note:
1Arg1
Optional function
1005 0:255 1 0 Note:
1Arg2
© TMHE 5 – 17 T Code(s): 887, 888

Min./ Incre
Max. ment
Optional function
1006 0:255 1 0 Note:
1Arg3
Optional function
1007 0:255 1 0 Note:
1Arg4
1008 Optional function 2 0:20 1 0 See section " # 1253 - Steering offset".
Optional function See section " Factory parameters # 1003 to
1009 0:255 1 0
2Arg1 1042 - configurable optional functions".
1010 0:255 1 0
1011 0:255 1 0
1012 0:255 1 0
1014 0:255 1 0
1015 0:255 1 0
1016 0:255 1 0
1017 0:255 1 0
1019 0:255 1 0
1020 0:255 1 0
1021 0:255 1 0
1022 0:255 1 0
1024 0:255 1 0
1025 0:255 1 0
1026 0:255 1 0
1027 0:255 1 0
© TMHE 5 – 18 T Code(s): 887, 888

Min./ Incre
Max. ment
1029 0:255 1 0
1030 0:255 1 0
1031 0:255 1 0
1032 0:255 1 0
1034 0:255 1 0
1035 0:255 1 0
1036 0:255 1 0
1037 0:255 1 0
1039 0:255 1 0
1040 0:255 1 0
1041 0:255 1 0
1042 0:255 1 0
0 = No walkie button selected
1 = Walkie buttons connected to ACT
Configuration of walkie
2 = Walkie buttons connected to
1043 buttons (operation 0:4 1 0
SEU 0
from the side)
3 = Buttons at backrest connected to ACT
4 = Buttons at backrest connected to SEU 0
Activates the option of setting a maximum
speed that overrides the maximum speed
Overall maximum set in the operator parameter. Please note
1044 5:120 1 120
speed that if the speed is set higher than the
maximum speed specified for the truck, the
maximum speed will be (km/h*10).
0: Lead-acid or Gel type battery.
1045 Choice of battery type 0:1 1 0
1: Li-Ion battery
© TMHE 5 – 19 T Code(s): 887, 888

Min./ Incre
Max. ment
Deactivates a hydraulic function when the
operator is absent.
0 = First hydraulic function, lifting
1 = Second hydraulic function, lifting
Deactivation of the 2 = Third hydraulic function, lifting
hydraulic function 3 = Fourth hydraulic function, lifting
1051 0:255 1 0
when the operator is 4 = First hydraulic function, lowering
absent. 5 = Second hydraulic function, lowering
6 = Third hydraulic function, lowering
7 = Fourth hydraulic function, lowering
Set the parameter to 255 if you want to
switch off all hydraulic functions.
0 = The hydraulic controls are deactivated.
1 = The front control is connected to the
hydraulic function for fork lifting/lowering.
Lift controls –
1102 0:4 1 1 2 = The rear control is connected to the
configuration
hydraulic function for fork lifting/lowering.
3 = Both controls for fork lifting/lowering.
4 = Analogue control
(OME100N)
0 = Gate limitation deactivated
1103 Gates – configuration 0:2 1 1
1 = Gate limitation at 0.5 metres
2 = Gate limitation at 1.2 metres
(OME100N, OME100NW)
Configuration – safety
1104 0:1 1 0 0 = Auxiliary safety handle deactivated
handle
1 = Auxiliary safety handle activated
(OME100N, OME100NW, OSE120CB)
Activates two-stage
1105 0:1 1 0 0 = Two-stage lowering deactivated
fork lowering
1 = Two-stage lowering activated
Value 1 must be set so that OSE200X
achieves the specified speed when it is
1109 Battery size OSE200X 0:1 1 0 equipped with a large battery
0 = Not large battery
1 = Large battery (applies to OSE200X)
Battery indicator reset/ Voltage required in order to restore battery
1110 248:270 1 252
dV measurement.
Power steering -
Offset adjustment of analogue setpoint for
1251 calibration 5000:50 1 0
steering. Value set during calibration.
Analogue offset/mV 00
Power steering Sum of the analogue steering
1252 calibration 0:6000 1 0 potentiometers' inputs. Value set during
Checksum/mV calibration.
Steering offset Fine adjustment of steering (zero)
-
1253 Calibration/(degrees/ 1 0 -300: 30 degrees to the left
300:300
10) 300: 30 degrees to the right
Max. current for proportional valve.
Fork lowering speed 500:160
1261 10 1200 Indicates the maximum lowering speed of
Calibration/mA 0
the forks. Value set during calibration.
© TMHE 5 – 20 T Code(s): 887, 888

Min./ Incre
Max. ment
Proportional valve - Indicates the starting point of the
1262 starting point 150:900 10 400 proportional valve. Value set during
Calibration/mA calibration.
© TMHE 5 – 21 T Code(s): 887, 888

#1001 – Type of truck

This parameter is used to set which truck type the program is to adapt
operational data for.
Value Configuration
0 Unknown truck type
1 OSE250
2 OSE250P
3 OSE120
4 OSE120P
5 OSE200X
6 OSE180XP
7 OSE120CB
8 OSE100
9 OSE100W
10 TSE300 (12 km/h)
11 TSE300 (9 km/h)
12 OME100N
13 OME100NW
#1043 – Configuration of walkie buttons (operation from the side)
This parameter is used to configure the controls for operating the truck while
the operator walks alongside.
Value Configuration
0 No walkie button selected
1 1 = Walkie buttons connected to ACT
2 Walkie buttons connected to SEU 0
3 Buttons at backrest connected to ACT
4 Buttons at backrest connected to SEU 0
Activation may require corresponding equipment on the truck.
a
#1102 – Lift control configuration
This parameter is used to configure the lift controls of the truck.
Value Configuration
The front control (a) handles fork lifting while the rear control handles
1
platform lifting.
The rear control (b) handles fork lifting while the front control handles
2
platform lifting.
3 Both controls handle fork lifting; no platform lifting.
In this case, rear refers to the control closest to the operator.
© TMHE 5 – 22 T Code(s): 887, 888

#1103 - Gate configuration (OME100N)

This parameter states the height where the cab lifting is to be discontinued if
one of the side gates is open.
Value Configuration
0 It is not necessary to close the gates during cab lifting
1 Maximum cab height 0.5 m with open gates
2 Maximum cab height 1.2 m with open gates
#1104 - Auxiliary safety handle (OME100N, OME100NW)

This parameter is used to activate/deactivate the auxiliary safety handle on
the cab. This function is only available if an auxiliary safety handle [S100,
S101] is fitted.
Value Configuration
0 Auxiliary safety handle deactivated
1 Auxiliary safety handle activated
#1105 - Two-stage lowering “Pallet to ground” (OSE100W, OSE120CB,
OME100N, OME100NW)
This parameter is used to activate/deactivate two-stage lowering. The pallet
stops 100 mm above the ground during lowering (“Pallet to ground” function)
Value Configuration
0 Two-stage lowering deactivated
1 Two-stage lowering activated
# 1110 - Battery indicator reset

The parameter is used to adjust the reset voltage for when a reset signal is
to be sent to the battery indicator. The parameter may be set between 24.8 V
and 27.0 V in increments of 0.1 V depending on battery type. Note that if the
value is set too high, the battery indicator will not be reset after charging.
# 1253 - Steering offset
This parameter can be used to “trim” the actual steering position of the drive
wheel in relation to the position of the steering unit. It should only be adjusted
after calibration has been carried out.
A situation which may require adjustment of parameter #1253 is if the truck
tends to drift away from a straight-ahead course when driving longer
distances. Since there are many factors that could contribute to this, it is
advisable to make adjustments to this parameter on a trial and error basis.
Whenever this parameter is adjusted, it is necessary to restart the truck
(disconnect and reconnect battery).
© TMHE 5 – 23 T Code(s): 887, 888

Factory parameters # 1003 to 1042 - configurable optional functions

Parameters #1003 to #1042 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parameters
configure and control the behaviour of the Spider expansion unit (SEU) which
must be fitted in the truck. This method of implementation enables use of the
standard program. This eliminates the need for any special program.
Normally, these parameters are configured by the manufacturer when the
truck is modified or customised. It is advisable to upload the parameter
settings from the truck when carrying out any modification. If the main control
unit [A2] has been replaced, the original parameter settings can be
transferred to the new unit, thus ensuring that special options function
correctly.
Factory parameter no. #1003, #1008, #1013, #1018, #1023, #1028, #1033
and #1038 can be adjusted to allow up to a maximum of 8 pre-programmed
"Basic options" to be activated and configured to suit a specific special option
or customisation.
Activation of optional functions
The system can use up to eight configurable optional functions
simultaneously. Each configurable function is controlled by five factory
parameters. During activation, an index parameter (#1003, #1008, #1013,
#1018, #1023, #1028, #1033, #1038) must first be set to a value equivalent
to an optional function. Four parameters that can be modified to configure the
optional function are linked to each index parameter.
• The index parameter is allocated one optional function (optional function is
determined).
• Each optional function can have up to 4 arguments associated with it.
Each argument holds a value which can be changed to configure the
function (optional function is configured).
• If the value of an argument is outside of the highest or lowest permitted
value, an error code is generated and the option cannot be used.
The error code cannot be eliminated until the argument is given a
permissible value.
© TMHE 5 – 24 T Code(s): 887, 888

Base option 1 - Option button controls SEU output

Argument #1 Selection of SEU unit 1 or 2
Values Meaning
0 option is handled by SEU unit 1 (A36)
1 option is handled by SEU unit 2 (the second SEU unit)
Argument #2 Selection of SEU digital output
Values Meaning Pin no.
0 activates digital output 1 (1.6 A) on SEU 16
Argument #3 Selection of option button
Values Meaning
0 activated by option button 2 or 5
1 activated by option button 1
Argument #4 Type of switching

Values Meaning
0 activated when the button is pressed
1 option is toggled when button is pressed
© TMHE 5 – 25 T Code(s): 887, 888

Basic option 2 - Reduced driving speed via SEU inputs

Values Meaning
Argument #2 Selection of SEU digital input
0 activates digital input 1 (1 mA) on SEU 5
Argument #3 Speed limitation as a percentage of max. speed
Values Meaning
Max. speed adjustable from 0-100%
0-100
(driving is not possible when value = 0)
Argument #4 Speed range
Values Meaning
0 Affects only high speed range
1 Affects only low speed range
2 Affects both speed ranges
© TMHE 5 – 26 T Code(s): 887, 888

Basic option 3 - Truck movement activates SEU output

Values Meaning
Argument #2 Selection of SEU digital output
Pin
Values Meaning
no.
© TMHE 5 – 27 T Code(s): 887, 888

Basic option 3 - Truck movement activates SEU output

Argument #3 Selection of activation movement
Driving
Driving Fork Fork
Values drive wheel
fork direction lifting lowering
direction
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16
17 X
18 X
19 X X
20 X
21 X X
22 X X
23 X X X
24 X
25 X X
26 X X
27 X X X
28 X X
29 X X X
30 X X X
31 X X X X
Argument #4 Output switching mode
Values Meaning
0 Output continuously on
1 Output switches at 1 Hz
© TMHE 5 – 28 T Code(s): 887, 888

Basic option 4 - Activate main contactor by SEU input

Values Meaning
0 activated by digital input 1 (1 mA) on SEU 5
2 activated by digital input 3 (1 mA) on SEU 3 33
Argument #3 Hold time in minutes
Values Meaning
Contactor is held from 0 to 30 minutes after the digital input is
0-30
activated
Argument #4 Not used
© TMHE 5 – 29 T Code(s): 887, 888

Basic option 5 - Activate lifting/lowering by SEU input

Values Meaning
Argument #2 Selection of SEU digital inputs
Lift - SEU digital input 1 on SEU 5
0 Lower - SEU digital input 2 on SEU 19
Lowering block - SEU digital input 3 on SEU 33
Argument #3 Enable/disable lowering block
Values Meaning
0 Lowering block disabled
1 Lowering block enabled
Argument #4 Selection of fork/support arm
Values Meaning
0 Selects fork lifting/lowering
1 Selects support arm lifting/lowering
© TMHE 5 – 30 T Code(s): 887, 888

Basic option 6 - Lift height limitation by SEU input and override

Values Meaning
Argument #2 Selection of SEU digital input for limitation switch
Argument #3 Selection of option button for override function
Values Meaning
8 no override possible
Argument #4 Selection of time interval for override function
Values Meaning
0 open button must be held depressed for override
1-15 value corresponds to time in seconds, e.g. value 1 = 1 second
© TMHE 5 – 31 T Code(s): 887, 888

Basic option 11 - Automatic height preselector

Values Meaning
Argument #2 Selection of option button for automatic lift and lowering movement
Values Meaning
0 option not activated by option button
6 activated by option button 1.6 or 2.5
7 activated by option button 2.5 or 3.4
Argument #3 Selection of SEU digital inputs/outputs
photocell - digital input 1 on SEU 5
lowest position - digital input 2 on SEU 19
highest position - digital input 3 on SEU 33
0
external lift button - digital input 4 on SEU 6
external lower button - digital input 5 on SEU 20
lamp - digital output 1 on SEU 16
1
2
3
© TMHE 5 – 32 T Code(s): 887, 888

Basic option 11 - Automatic height preselector

Argument #4 Engagement/disengagement of external lift/lower button

Values Meaning
0 external lift/lower button disengaged
1 external lift/lower button engaged
Basic option 13 – Activates SEU outputs at login

Values Meaning
Argument #2 Selection of SEU digital output Pin no.
Argument #4 SEU output's connection mode

Values Meaning
0 Output continuously on
© TMHE 5 – 33 T Code(s): 887, 888

Basic option 14 – Activate restrictions on hydraulics via operator profiles

Argument #1 Not used. SEU unit not required
Argument #2 Selection of operator profile

Values Meaning
1 Operator profile 1
2 Operator profile 1-2
Connecting restrictions. The values in argument #3 can be combined
Argument #3
through addition, e.g. value 1 + value 8 = value 9
Values Meaning
1 Block lift/pressurising of hydraulic function 1
2 Block lowering/pressure release of hydraulic function 1
© TMHE 5 – 34 T Code(s): 887, 888

Basic option 15 – Activate restrictions on hydraulics via SEU inputs

Values Meaning
Connecting restrictions. The values in argument #3 can be combined
Argument #3
through addition, e.g. value 1 + value 8 = value 9
Values Meaning
Argument #4 Override button
Values Meaning
0 Option button 2 or 5 has override function
1 Option button 1 has override function
7 Option button 3 or 4 has override function
8 No override possible
© TMHE 5 – 35 T Code(s): 887, 888

5.3 Calibration
5.3.1 Steering servo calibration

The calibration function is used for calibration of the steering servo (steering
angle potentiometer [R2]). Calibration sets the centre position of steering
(straight ahead). The CAN service key must be connected in order to perform
calibration.
The following situations may require this calibration to be done.
• When the steering angle potentiometer [R2] has been disconnected or
replaced.
• The truck does not steer straight ahead when the steering unit points
straight ahead. May also require adjustment of parameter 1253.
• Display of error code 5.586
Before carrying out this calibration, check that the reference sensor [S65]
works and is correctly set.
Method
1. Place the steering unit in the straight-ahead position and maintain this
position.
2. Ensure that the truck is switched off. Connect the CAN key.
4. Turn the speed control several times until “CAL” is shown on the display.
6. Turn the speed control to move between the calibration modes.
- Calibrate steering "1"
- Calibrate the proportional valve (fork lifting and lowering) "2"
7. Press the horn button to select steering servo calibration, "1".
8. In calibration mode, “push” will be shown on the display until you press one
of the two horn buttons.
9. Keep the steering unit in the straight-ahead position and press and release
the horn button.
10. “Done” is shown on the display. The setting has now been stored.
11. Switch off the truck by pressing the OFF button.
If the actual steering position must be “trimmed” (fine-tuned), see parameter
#1253.
The calibration process affects the following parameters:
• Analogue offset (parameter 1251)
• Checksum (parameter 1252)
These parameters must not be adjusted manually after calibration.
© TMHE 5 – 36 T Code(s): 887, 888

5.3.2 Hydraulic calibration

A calibration function can be used to handle the proportional valve's [Q4]
tolerance. When calibration is carried out, the CAN service key must be
connected, the max. nominal load must be loaded on the forks and the forks
must be raised.
Method
1. Ensure that the truck is switched off. Connect the CAN key.
3. Turn the speed control several times until “CAL” is shown on the display.
5. Turn the speed control to move between the calibration modes.
- Calibrate steering "1"
- Calibrate the proportional valve (fork lifting and lowering) "2"
6. Press the horn button to select proportional valve calibration, "2".
7. In calibration mode, “push” will be shown on the display until you press
one of the two horn buttons.
8. Press and hold the horn button. The valve now opens slowly. The
parameter symbol flashes while calibration is in progress.
9. As soon as the forks are felt to begin lowering, the horn button must be
released. The setting has now been stored.
• Maximum lowering speed of the fork (parameter 1261)
• Starting position of the proportional valve (parameter 1262)
© TMHE 5 – 37 T Code(s): 887, 888

© TMHE 5 – 38 T Code(s): 887, 888

6. Installation and commissioning

This chapter describes the work that is necessary before the truck can be put
into use.
6.1 Transporting the truck

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

When transporting the mast alone, you must properly anchor all loose parts.
The guides must be secured so that they cannot glide apart. Chains and any
hoses must be fastened so that they cannot come loose or be damaged. The
entire mast is then anchored on load pallets or another suitable support for
transport.
© TMHE 6– 1 T Code(s): 887, 888

6.3 Safe lifting
• Lift the truck at its centre of gravity using another fork lift truck.
• Secure the truck to the forks of the lifting truck.
• Lift it very carefully.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted incorrectly.
Always lift the truck when it has been fastened to the forks of the lifting truck
and its centre of gravity between the forks.
• Only lift the truck at the indicated lifting points using suitable lifting
equipment.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted in the wrong places.
Always lift the truck in the indicated lifting points.
© TMHE 6– 2 T Code(s): 887, 888

6.4 Battery installation
6.4.1 Safety for battery handling

Keep the following safety precautions in mind when working with the battery.
• Always use safety equipment to protect the eyes, face and skin while
checking or handling batteries.
Note:
Parameter 107 must always be checked and adapted to the battery installed
in the truck. The parameter setting depends on battery type, truck type,
battery size and the truck application.
Note:
Only change to a battery that complies with the data given on the truck
identification plate. The weight of the battery affects the stability and braking
capacity of the truck. Information on the minimum permitted battery weight is
on the truck identification plate.
DANGER!
Risk of moving the centre of gravity.
A battery weight that is too low gives impaired stability and braking capacity.
The battery weight must be in accordance with the information on the truck’s
identification plate.
DANGER!
Battery acid causes burns. If battery acid gets onto your skin or clothes,
immediately flush the area with cold water. If you get battery acid in the face
or the eyes, flush the area with cold water and immediately seek medical
assistance.
• Ensure there is a shower and an eye bath nearby in case an accident
happens.
• Batteries generate explosive gases. Never use an open flame or other
sources of ignition in close vicinity to a battery.
• Do not place tools or other metal objects on the battery. This can cause a
short-circuit and even an explosion.
• Gel batteries are only intended for use at room temperature within the
interval +15 to +30°C. Otherwise, there is a risk of the battery being
damaged or its service life being shortened.
6.4.2 Installing the battery

DANGER!
To prevent the battery from falling down when it is released from the lifting
device, prepare trestles or other suitable supports of the right height to
support it. Check the height of the supporting material before releasing the
lifting hook.
The battery to be installed in the truck must be the right size. If the battery is
too small in terms of size and weight, it can seriously affect the truck's braking
© TMHE 6– 3 T Code(s): 887, 888

ability and truck stability when lifting goods. See the truck's identification plate
for the correct battery data.
The truck is also supplied with shims. Use these to eliminate any play
between the battery and the battery compartment walls. Fit these if
necessary.
1. Park the truck on a level surface.
2. Apply the parking brake.
3. Lift the battery into place using an approved lifting device and a suitable
battery lifting yoke or lifting loops. Check that the cables are not pinched
when the battery is lifted into place.
4. Activate the battery lock.
5. Check the electrolyte level in the battery. Normally, the level should be
around 10-15 mm above the cell plates.
6. Connect the battery cables/battery connector.
DANGER!
Check that the polarity is correct when connecting the battery cables.
Compare the markings on the cables with those on the battery terminals. An
incorrectly connected battery may cause short-circuiting.
7. Close the battery compartment cover.
8. Check or set battery parameters. Refer to the section “Setting battery
parameters” in this chapter.
9. Perform a function check on the truck and check that the lift height
limitation sensor has the correct settings before using the truck. The lift
must stop 25 mm from the top of the mast.
Battery indicator
Each time you start the truck, the operation time is shown for a few seconds
in the numeric field. At the same time the hour meter indicator is lit. After it
goes out, the battery capacity is continuously shown in the numeric field at
the same time as the battery indicator is lit.
When the battery indicator symbol lights, the battery capacity can be read in
% in the numeric field of the display:
• 100% = Fully charged battery
• 0% = Discharged battery
When the field shows 10% capacity, the symbol starts to flash.
Charge the battery when the symbol flashes to save the battery.
If you continue to use the truck without charging the battery, the lift function
is shut down when the field shows 0% capacity. The truck can still be driven,
so that it can be taken to the charging station.
© TMHE 6– 4 T Code(s): 887, 888

6.5 Using PIN codes
6.5.1 General
PIN codes can be used e.g. to link different operator experience levels to
specific truck characteristics – Operator profiles.
Operator parameters can be adjusted individually for up to ten different
operator profiles.
The PIN codes are organised in blocks and profiles. Each block can hold ten
operator profiles, each with its own PIN code.
In order to use the PIN codes in a block, the block must first be activated.
By default, block 0 (zero) is always active, which means that the truck has 3
ready-to-use operator profiles from the beginning. See section " Factory
preset operator parameters".
PIN codes can be activated or changed according to the preferences of the
operator. An operator profile is activated upon normal log-in by all PIN codes
whose block number is activated.
If the truck is equipped with a collision sensor, it is possible to view
information on which PIN codes were used at login when forceful impacts
were detected.
6.5.2 Programming PIN codes

Note:
There are two possible methods for programming PIN codes.
The first and the simplest is to use TruckCom, which provides clear
instructions.
The other alternative is to use the truck keypad.
If the truck is configured to handle PIN codes, 100 different PIN codes can be
programmed. See section "5.2.4 Service parameters".
The first time a block is activated, all PIN codes in the block are set to “0000”.
If a block with PIN codes not set to “0000”, is deactivated and later
reactivated, the PIN codes with other values than “0000” will again be valid.
Use of PIN code “0000” is permitted, but it means that the position is
deactivated. It is never possible to log in with PIN code “0”.
The truck program stores a standard set of PIN codes as indicated in the
table in the section “PIN code defaults”.
Note:
The truck program will not accept attempts to program PIN codes that have
already been set. The previous code will be restored.
When a PIN code is programmed, there is a check to ensure that it is not used
elsewhere in the table, regardless of whether the block is active or inactive.
© TMHE 6– 5 T Code(s): 887, 888

The PIN code setting menu is used for managing PIN codes; the menu can
only be accessed when a service key is connected.
To start programming, proceed as follows:
1. Ensure that the truck is switched off. Connect the CAN service key to
connector [X41].
3. Turn the speed control several times until “Pin” is shown on the display.
4. Press and then release the horn button to select.
5. Select programming commands from the table below:
Function Programming Comments
Blocks 1-9 are
deactivated. The original
PIN codes are reset
Restore factory settings. Press 1 + ON button
according to the Default
assignment of PIN codes
table.
PIN codes in the block can be
Press 2 + b + ON button b = Block 0-9
used.
The PIN-codes in the block
Press 3 + b + ON button b = Block 0-9
cannot be used
Press 4 + b + P + NNNN + ON button
Note:
b = Block 0-9
The block that should apply must first be
P = Operator profile 1-10
activated (see function 2 in the table above).
NNNN = PIN code
Note:
If the PIN code is correct, the code is shown
It is only possible to
Programming a new PIN code for 3 seconds, followed by the text "donE" for
assign one digit to an
2 seconds. It is possible to enter a new PIN
operator profile. As a
code within these 5 seconds by pressing a
result, operator profile 10
key on the keyboard.
should be assigned as 0
If the PIN code is wrong, the display shows
(zero).
“Err”. If you press the red button, the new PIN
code is not saved.
PIN code programming for truck
Press 6 + NNNN + ON button NNNN = PIN code
reset after collision

PIN code programming is now complete. Verify that programming has
been done correctly by logging in using one of the new PIN codes.
For PIN code management via TruckCom, refer to the TruckCom manual.
Note:
It is important to ensure the correct operator profile is activated when a
specific PIN code is entered. This is especially important when an operator
profile has been set to apply for a specific truck application.
© TMHE 6– 6 T Code(s): 887, 888

6.5.3 PIN code defaults

The PIN codes are factory set so that only block 0/operator profiles 1 – 9 are
activated.
Note:
Service personnel are urged to keep notes on activated blocks, changed
PIN codes and special operator profile settings.
Default assignment of PIN codes
Operator 10
Note:
profile 1 2 3 4 5 6 7 8 9
Entered
no. as 0
Block 0 0001 0002 0003 0004 0005 0006 0007 0008 0009 0000
Block 1 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 7 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 8 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 9 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
The factory-set operator profiles are classified as follows:

Profile Characteristic Remarks
1 Standard profile –
2 Beginner profile –
Operator parameters set to
3 Advanced profile
max. values
© TMHE 6– 7 T Code(s): 887, 888

6.6 Setting parameters

This chapter covers only those parameters that need to be set upon
commissioning of the truck and which, as a result, require a more detailed
description. For information about other parameters, refer to the chapter See
section "5.2.3 Operator parameters".
Check to make sure all parameters are set to the desired values in terms of
• maximum speed - See section "5.2.3 Operator parameters".
• acceleration - See section "5.2.3 Operator parameters".
• neutral braking - See section "5.2.3 Operator parameters".
• collision sensor - See section "6.6.1 Setting collision sensor parameters
(option)".
• battery - See section "6.6.2 Setting battery parameters".
Note:
When checking or setting parameters, remember to note down the truck's
specific parameter values, for example in a truck report. This separate
information on truck-specific parameters can come in handy, e.g. in case of
downtime, since the information is not available elsewhere.
6.6.1 Setting collision sensor parameters (option)

Collision sensitivity parameters must be set during truck installation.
If there is a collision sensor installed on the CAN bus, it registers when the
truck bumps into something. If a collision exceeds a certain force, set by
parameters 105 and 106, it is interpreted as a collision, and the truck travel
speed is reduced to creep speed, a signal is heard and error code 8.001 is
displayed.
Information about the collision is stored in the truck's internal memory. The
last ten registered collisions can be read directly from the display together
with operator identity via the PIN code. Additional information is available via
TruckCom, where collision levels and time indications can also be read.
© TMHE 6– 8 T Code(s): 887, 888

Collision sensor parameters 105 and 106

See the table below for information about the possible values:
Min./ Increm
Max. ent
X-level collision what should be interpreted as a side impact.
105 0/100 1 0
sensor This parameter must be set during truck
installation.
Y-level collision what should be interpreted as a frontal/rear-end
106 0/100 1 0
sensor impact. This parameter must be set during truck
installation.
Note:
If the parameter value for the collision sensor is set to 0 (zero), this will
disable the collision sensor function as well a log keeping.
PIN code programming for truck reset

If the truck has stopped as a result of a collision, it needs to be reset by
entering a special PIN code. This PIN code must be programmed by a
service technician during installation.
The PIN code to be activated can be found in operator profile 1 and special
block 10. The default value of the PIN code is 0000. This must be changed to
the PIN code selected by the service technician.
Note:
The PIN code cannot contain the same combination of digits as any of the
other programmed PIN codes.
With parameter #111, it is possible to change how reset after collision is
carried out. See section "5.2.4 Service parameters".
© TMHE 6– 9 T Code(s): 887, 888

6.6.2 Setting battery parameters

The following parameters must be set or checked on battery installation.
Note:
Even if the battery comes with the truck from the factory, the parameters
must be set or checked.
Incre
Parameter Name/unit Min./Max. Std. Description
ment
OSE250/P:
8 = Large battery
10 = Medium battery
13 = Small battery
OSE120P:
Service Battery 15 = Large battery
1/20 1 8
parameter 107 adjustment, Ah 18 = Medium battery
20 = Small battery
Verify parameter setting.
For more information, See section
"5.2.4 Service parameters".
© TMHE 6 – 10 T Code(s): 887, 888

6.7 Function check

c b a a b c
n
d
r
j
m
h
f p
g m
Prior to putting the truck into use, check the following items:
Pos. Inspection point Measure
a Operating control Check the function
b Hydraulic functions Check the function
c Horn Check the function
d Steering Check the function
f Platform Brake switch Check the function
g Hydraulic system Check all components
h Drive unit Check for any noise or oil leakage
j Brakes Check the function
k Chassis Inspect for any damage, remove dirt etc.
m Wheels Inspect for any damage, remove dirt etc.
Inspect for damages, remove dirt, etc.
n Lifting device The lifting movement must stop 25mm from the
top of the mast
o Fork carriage Inspect for any damage, remove dirt etc.
p Battery Inspect the battery acid level and charge level
q Battery lock Check the function
r Emergency switch off Check the function
Carry out maintenance. See section "7.5 First
Running time
service".
© TMHE 6 – 11 T Code(s): 887, 888

© TMHE 6 – 12 T Code(s): 887, 888

7. Maintenance
7.1 Introduction
To maintain a high level of truck safety and to minimise downtime, all the
points specified in the service programme must be carried out.
The intervals specified are those that fulfil the truck manufacturer's
requirements for a truck used in standard applications. The local operating
environment may require service intervals that differ from those specified.
Once a truck's service intervals have been determined, the hour recorder is
primarily used for determining when servicing is to be carried out.
To maintain truck safety, only spare parts approved by the truck manufacturer
may be used for servicing and repairs.
During the truck's warranty period: If repairs/servicing have been carried

out by non-authorised personnel, or if non-approved spare parts are used,
the truck warranty ceases to be valid.
7.2 Maintenance instructions
7.2.1 Cleaning and washing

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

High-pressure washing may only be performed on metal surfaces.
Under no circumstances may high-pressure washing be performed in the
truck's motor compartment.
When using a high-pressure wash, the jet must be directed in such a way that
it does not damage electric cables, electric sensors, hydraulic hoses or
decals.
Lifting chains, piston rods and end pieces of hydraulic cylinders, ball and
roller bearings – including those that are fully enclosed – must not be
exposed to the jet, as there is a risk that water may penetrate and cause
corrosion.
After performing a high-pressure wash, all bearings and chains must be
lubricated/greased as specified in the maintenance instructions.
© TMHE 7– 1 T Code(s): 887, 888

7.2.3 Degreasing agents

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

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

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

• Cover electric motors, connectors and valves prior to washing.
Note:
Risk of damage to the electrical system.
Electrical components must never be cleaned using high-pressure washing
equipment.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water.
7.2.7 Electric components

• Clean electric motors using vacuum cleaner or a rag.
© TMHE 7– 2 T Code(s): 887, 888

• Clean electric panels, logic cards, contactors, connectors, magnetic

valves, etc. with a rag moistened with water and a suitable detergent.
Note:
Risk of damage to electrical components.
Do not break the warranty seals on the electronic circuit boards.
© TMHE 7– 3 T Code(s): 887, 888

7.3 Checking normal truck function

At each service, the truck must be checked to ensure normal function and
safety.
1: Battery capacity
Check that the battery indicator on the display shows enough capacity
2: Horn
Check the function by pressing the button.
3: Travel brake
Check the function by releasing the speed control to the centre position
while driving or moving the speed control to the opposite travel direction.
4: Travel direction selector
Check the function, forward/backward
5: Speed control
Check that the truck moves when you affect the speed control
6: Fork operation control
Try to lift and lower the forks
7: Platform operation control
Try to lift and lower the platform
8: Platform/brake switch
Check the function
9: Emergency switch off/parking brake
Check that the truck stops when the emergency switch off is pressed.
Note: Check at low speed
10: Steering
Check the function.
© TMHE 7– 4 T Code(s): 887, 888

7.4 Safety checks

Interval: 1000 h unless local regulations prescribe more regular checks.
Should also be carried out after large repairs.
Note:
safety. These checks are carried out following the instructions in the tables
under “Checking normal truck function”.
C code Component / Type of Work to be carried out Notes

Function work
1700 Motors Check Check that the drive motor is not
damaged.
Check electrical connections.
1700 Motors Check Check the drive motor fastening
screws/mountings.
3370 Mechanical Check Clean and check the mountings.
brake
3370 Mechanical Check Check the air gap. 0.2-0.45 mm
brake between the pressure disc and the
magnet housing
2550 Drive unit Check Check for proper attachment.
2550 Drive unit Check Check that there is no leakage
1730 Steering servo Check Check the steering servo pinion
1730 Steering servo Check Check the steering servo for correct
mounting.
6100 Hydraulic Check Check that there is no leakage from
system hoses and hose couplings
5110 Battery Check Check that the battery complies with the
truck specification
5110 Battery Check Check the battery locking device
9130 Operator cabin Check Screw joint/attachment at chassis
6600 Lift cylinders Check Check that there is no abnormal
leakage
6600 Lift cylinders Check Check the fastening of the cylinders
7100 Mast Check Check that there are no cracks or other
damage
7100 Mast Check for Check the mast fastening screws/
correct attachment
tightening
7100 Mast Check Check the play between the mast beam
and the inner runner rollers
© TMHE 7– 5 T Code(s): 887, 888


Function work
7100 Mast Check Check the lateral play of the inner
runner
7120 Lifting chain Check Check the wear on the lifting chains and
chain rollers
7120 Lifting chain Check Check the chain pin shafts and
associated split pins
7120 Lifting chain Check Check the chain bolts and the chain
mountings
Check the locking nuts
Check the chain safety pins
7410 Lift forks Check Perform a crack indication check on
cast forks
Perform a visual check on welded forks
7420 Fork carriage Check Check that there no cracks or other
damage that can affect the safety/
function
7420 Fork carriage Check Check guide pins for wear
0000 Chassis Check Inspect all links and spring pins
0000 Chassis Check Inspect the chassis for damage.
0000 Chassis Check Check that the load support finger
guard is not damaged.
3500 Drive wheel Check Check the wear and fastening of the
drive wheel.
3500 Castor wheels Check Check that the castor rotates and turns
freely
Check the castors' wear and fastening
3500 Support wheel Check Check the wear and fastening of the
support wheels.
4110 Steering unit Check Check the mechanical locking at the
sides and centre position
0000 Chassis Check Check signs and adhesive labels
3370 Mechanical Check Check function by pressing the
brake emergency switch off while driving at
low speed
5000 Emergency Check Check the emergency switch off
stop switch
5000 Horn Check Check the horn
5000 Operator Check Check for correct function of the
controls operator controls and walkie buttons
© TMHE 7– 6 T Code(s): 887, 888


Function work
5000 Inductive limit Check Check that the fork lift height limiter
switch functions
5000 Inductive limit Check Check that the platform lift height limiter
switch functions
9130 Operator cabin Check Presence check (Operator on platform)
4110 Steering arc Check Check that the truck cannot be
operated from the side when set to
walkie mode if the steering unit has a
rotation angle of 30° or more.
operated from the side with walkie
buttons if the steering unit has a rotation
angle of 5° or more.
© TMHE 7– 7 T Code(s): 887, 888

7.5 First service

The first service must be carried out after 500 operating hours or 6 months,
whichever occurs first. Check the following points.
Note:

Function work
1700 Drive/pump Check Check the drive/pump motors
motor for damage
1700 Drive/pump Check Check electrical connections
motor
1700 Drive motor Check Check drive motor attachment/
fastening screws
2550 Drive unit Check Check that there is no
abnormal leakage
2550 Drive unit Lubrication Change the drive gear oil*
6100 Hydraulic Lubrication Change the oil and clean the
system tank*
* See section "22.3 Oil and grease specification".
© TMHE 7– 8 T Code(s): 887, 888

7.6 Maintenance schedule

The first maintenance service is to be carried out after 500 operating hours/6
months according to the instructions above. Thereafter, maintenance service
is done at intervals of 500 operating hours or 6 months, whichever occurs
first.
Preparations:
Open the motor compartment, remove the chassis front plate, disconnect the
battery and support the truck on trestles
Required tools:
• Allen keys 5 mm, 6 mm, 8 mm
• Ladder
• Jack
• Feeler gauge
• Screwdriver
• Fixed spanner 13 mm
• Flex head spanner 8 mm
• Spirit level
• Torx 20
• Battery tester
• Wooden blocks
© TMHE 7– 9 T Code(s): 887, 888

7.6.1 Maintenance service every 500 operating hours/6 months

Oil and grease specification. See section "22. Service data and grease
specifications".
Note:
Preparations:
battery and support the truck on trestles

Function work
0000 Chassis Check Check all hood locks
1700 Drive motors Check Check that the drive motor is
not damaged.
1700 Drive motors Check Check the drive motor fastening
screws/attachment
1700 Drive motors Check Check that the sensors on the
drive motor are properly
mounted
3370 Mechanical Check Clean the mechanical brake
brake and check that it is properly
fastened
brake between the pressure disc and
the magnet housing
and its mounting
1730 Steering servo Check Check the steering servo for
correct mounting
5400 Transistor Clean / Clean (vacuum) and check that
regulator T1 Check the unit is properly fastened
5400 Transistor Check for Check that the cables are
regulator T1 correct properly fastened
tightening
5000 Wiring harness Check Check that the wiring
harnesses in the compartment
are not damaged
5110 Battery Check Check the electrolyte level: 10-
15 mm above the cell plates
© TMHE 7 – 10 T Code(s): 887, 888


Function work
5110 Battery Check Check all battery connections
5110 Battery Check Verify that the cell and pole
protectors are not damaged
5110 Battery Check Check the fluid density and
temperature
5110 Battery Check Suck up excess fluid from the
Clean battery pan
3500 Drive wheel Check Check the wear and fastening
of the drive wheel.
3500 Castor wheels Check Check that the castor rotates
and turns freely
Check the castors' wear and
fastening
Replace if necessary
3500 Support wheel Check Check the wear and fastening
of the support wheels.
Remove the trestles and connect the battery
7100 Mast Check Check that there are no cracks
or other damage
7100 Mast Check for Check the mast fastening
correct screws
tightening
7100 Mast Lubrication Lubricate the mast rails
7100 Mast Check Check the play between the
mast beam and the inner guide
rollers in the lower and upper
positions
7100 Mast Check Check the lateral play of the
inner runner
6100 Hydraulic Check Check that there is no leakage
system from hoses and hose couplings
7120 Lifting chain Check Check the wear on the lifting
chains and chain rollers
7120 Lifting chain Measure/Adjust Check-measure and adjust the
lifting chains
© TMHE 7 – 11 T Code(s): 887, 888


Function work
7120 Lifting chain Check Check the chain bolts and the
chain mountings
7120 Lifting chain Lubrication Lubricate the lifting chain
are not damaged
9130 Operator cabin Check Cable chain or cable roller
7420 Fork carriage Lubrication Press grease into the grease
nipples
7420 Fork carriage Check/ Check the guide pins wear and
Lubrication grease them
nipples
0350 Support arms Check Inspect the push rods for cracks
and other damage
0350 Bogie rocker Check Press grease into the grease
Lubrication nipples
Adjust or replace if necessary
9130 Operator cabin Check/ Lateral guide
Lubrication
9130 Operator cabin Check Screw joint/attachment of
operator lift at chassis
9130 Operator cabin Check Joint in steering pillar and
mechanical lock
4110 Steering unit Check Check the play and return travel
4110 Steering unit Check Check the mechanical locking
at the sides and centre position
4110 Steering unit Check Inspect correct mounting of the
steering linkage on both side
3500 Drive wheel Check Check that the truck is correctly
pressure measuring adjusted horizontally
Adjust if necessary to obtain the
correct drive wheel pressure
controls operator controls and walkie
buttons
© TMHE 7 – 12 T Code(s): 887, 888


Function work
stop switch
3370 Mechanical Clean / Check function by pressing the
brake Check emergency switch off while
driving at low speed
5000 Steering unit Check Check the function of the
steering unit brake switch
5000 Display Check Check that all segments and
indicators light
5000 Inductive limit Check Check that the fork lift height
switch limiter functions
5000 Inductive limit Check Check that the platform lift
switch height limiter functions
9130 Operator cabin Check Presence check (Operator on
platform)
operated from the side when
set to walkie mode if the
steering unit has a rotation
operated from the side with
walkie buttons if the steering
unit has a rotation angle of 5° or
more.
© TMHE 7 – 13 T Code(s): 887, 888


Oil and grease specification. See section "22. Service data and grease
specifications".
Note:
Preparations:
battery and support the truck on trestles. Make sure a ladder is available.

Function work
0000 Chassis Check Check that there are no cracks
or other damage
1700 Drive motor Clean Clean the drive motor (vacuum)
not damaged.
screws/attachment
mounted
fastened
the magnet housing
2550 Drive gear Check Check the oil level
2550 Drive gear Lubricate/clean Lubricate and clean the ring
gear if necessary
and its mounting
correct mounting
© TMHE 7 – 14 T Code(s): 887, 888


Function work
tightening
5400 Power system Check Check the contactor electrical
connections
are not damaged
6100 Hydraulic Check Check the fastening of the
system hydraulic unit
in the compartment
6100 Hydraulic Check Check that the hoses are
system undamaged and that there is no
mechanical damage
6100 Hydraulic Lubrication Replace the oil and clean the
system reservoir
6100 Hydraulic Check Check that the tank is not
system damaged
temperature
Clean battery pan
5110 Battery Check Check the battery locking
device
of the drive wheel.
and turns freely
fastening
© TMHE 7 – 15 T Code(s): 887, 888


Function work
or other damage
correct screws
tightening
positions
inner runner
leakage
6600 Lift cylinders Check Check the fastening of the
cylinders
lifting chains
chain mountings
are not damaged
7420 Fork carriage Check Check that there no cracks or
other damage that can affect
the safety/function
7420 Fork carriage Check Inspect the lift limiter switch
nipples
© TMHE 7 – 16 T Code(s): 887, 888


Function work
nipples
7410 Lift forks Check Perform a crack indication
check on cast forks
Perform a visual check on
welded forks
and other damage
0000 Chassis Check Check that the load support
finger guard is not damaged.
Lubrication nipples
0000 Chassis Check Check signs and adhesive
labels
Lubrication
mechanical lock
1700 Drive motor Check Check for abnormal noises in
the motor bearings
2550 Drive unit Check Check for abnormal noise
© TMHE 7 – 17 T Code(s): 887, 888


Function work
buttons
stop switch
indicators light
platform)
more.
© TMHE 7 – 18 T Code(s): 887, 888


Oil and grease specification.See section "22. Service data and grease
specifications".
Note:
Preparations:
battery and support the truck on trestles. Make sure a ladder is available.

Function work
0000 Chassis Check Check that there are no cracks
or other damage
1700 Drive motor Clean Clean the drive motor (vacuum)
not damaged.
screws/attachment
mounted
fastened
the magnet housing
2550 Drive unit Check Check that there is no leakage
2550 Drive gear Lubricate/clean Lubricate and clean the ring
gear if necessary
2550 Drive unit Lubrication Change the drive gear oil
and its mounting
correct mounting
© TMHE 7 – 19 T Code(s): 887, 888


Function work
tightening
5400 Power system Check Check the contactor electrical
connections
are not damaged
6100 Hydraulic Check Check the fastening of the
system hydraulic unit
in the compartment
6100 Hydraulic Check Check that the hoses are
system undamaged and that there is no
mechanical damage
6100 Hydraulic Lubrication Replace the oil and clean the
system reservoir
6100 Hydraulic Clean Clean the oil strainer.
system
6100 Hydraulic Check Check that the tank is not
system damaged
temperature
Clean battery pan
5110 Battery Check Check the battery locking
device
of the drive wheel.
© TMHE 7 – 20 T Code(s): 887, 888


Function work
and turns freely
fastening
or other damage
correct screws
tightening
positions
inner runner
leakage
6600 Lift cylinders Check Check the fastening of the
cylinders
lifting chains
chain mountings
are not damaged
© TMHE 7 – 21 T Code(s): 887, 888


Function work
7420 Fork carriage Check Check that there no cracks or
other damage that can affect
the safety/function
7420 Fork carriage Check Inspect the lift limiter switch
nipples
nipples
7420 Fork carriage Check/adjust Checking fork carriage lateral
play. Max. play 2 mm
7410 Lift forks Check Perform a crack indication
check on cast forks
Perform a visual check on
welded forks
and other damage
0000 Chassis Check Check that the load support
finger guard is not damaged.
Lubrication nipples
0000 Chassis Check Check signs and adhesive
labels
Lubrication
mechanical lock
© TMHE 7 – 22 T Code(s): 887, 888


Function work
1700 Drive motor Check Check for abnormal noises in
the motor bearings
2550 Drive unit Check Check for abnormal noise
buttons
stop switch
indicators light
platform)
more.
© TMHE 7 – 23 T Code(s): 887, 888

5000
5000
5700
5000
4110
0380
5400
3370 1700
3500
7120
6600
1700
0000
5100 0450
9130 2550
6100
3500 1730
© TMHE 7 – 24 T Code(s): 887, 888

8. Troubleshooting
If the error cannot be remedied through troubleshooting, contact the supplier
for more information.
8.1 Towing a defective truck

The towed truck shall always have an operator who can steer and apply the
brake when towing using a tow-truck and tow-rope.
Always remove the load before towing or transporting the truck to the
specified repair site.
Tow or transport a defective truck as follows:
• Start the truck, move the tiller arm to the drive position and push the truck
by hand.
DANGER!
The truck can start to roll when the parking brake function is disabled.
Never leave the truck with the parking brake disconnected, chock the
wheels in a satisfactory manner.
Tow using a tow truck and tow wagon:
1. Lift the truck onto the tow wagon. See the instructions under Lifting a
truck.
2. Connect the truck to the wagon.
3. Drive with care.
4. Lift off the truck according to the instructions under Lifting a truck.
© TMHE 8– 1 T Code(s): 887, 888

8.2 Auxiliary functions
8.2.1 Emergency driving mode

If the truck for some reason stops operating and remains immobile in an
unsuitable place, it is possible to active the emergency travel mode to move
the truck out of the way (max. 1.3 km/h).
1. Ensure that the truck is switched off. Enter your PIN code.
3. Turn the speed control several times until “Ed” is shown on the display.
5. All lamps flash and “SLO” is shown on the display.
It is now possible to drive the truck, but exercise extreme caution. It is not
possible to brake suddenly by raising the steering unit.
If the truck is on an incline, be even more careful when using the emergency
travel mode. If you apply too much throttle, there is a risk the truck will roll
away. To stop the truck, turn the sped control in the opposite drive direction.
Note:
Some errors block emergency travel mode. You then cannot obtain
information on the error.
© TMHE 8– 2 T Code(s): 887, 888

8.2.2 Error code history

Up to 50 of the most recent error code events can be stored in a log along
with the hour meter reading when the error occurred. The error code log
displays error codes in chronological order starting with the most recent error
code.
Do as follows to display the error code log:
3. Press and then release the horn button to select the "Info" menu.
4. Turn the speed control several times until “E” is shown on the display.
The error code symbol lights up.
6. The most recent error is then displayed. The display alternates between
the error code and the hour counter reading when the error occurred. If
the error code log contains more than one error code, the codes can be
displayed by repeatedly pressing the speed control.
The display of error code history is now complete.
© TMHE 8– 3 T Code(s): 887, 888

8.3 Error code system

See the tables below for an explanation of the error code system.
Structure Description
X.YZZ Example: 3.510
X (3) Group. Indicates which truck system is affected by the
error.
Y (5) Error category. Describes the type of error that occurred
and the severity of the error.
ZZ (10) Type of error.
Group. Description
1 Not used
2 Integrated Controller Handle (ICH)
3 Drive system
4 Hydraulic system
5 Steering system
6 Not used
7 Not used
8 Option/auxiliary system
9 Not used
Error Description
category.
0 Caution. This is primarily an information code that
indicates that some of the truck functions have been
reduced or do not operate.
1-2 Warning. Some functions may be deactivated or
reduced.
3-5 Critical error. The main contactor is open. The truck
stops.
Code Description
00-09 Miscellaneous error codes.
10-19 CAN related error codes.
20-39 Error codes for specific components.
40-59 Error code for short-circuited outputs.
60-79 Error codes for output data from open electrical circuit
80-99 Faulty signals from sensor.
© TMHE 8– 4 T Code(s): 887, 888

8.4 Error codes

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

Integrated Controller Handle (ICH) and non-classified error
S-0h Time for service. The hour recorder • Check the service meter (S hour
reading to the next service has reached 0. counter). Maybe it was not reset
after the latest service.
Truck can be operated as usual.
• Carry out servicing and reset the S
counter using TruckCom.
2.002 Default parameters values were loaded in • Check that the parameter settings
ICH [A2]. are suitable for the truck application
Indication only; not logged. in question.
2.004 Values stored in the secondary unit Use TruckCom to copy the truck's
backup copy (ACT/ACC) differ from the configuration.
values stored in the logic card in the
• If the primary unit ICH [A2] has been
handle in terms of parameters, hour meter
replaced, use TruckCom to load the
and/or serial number.
backup values. Select “Copy
configuration to primary unit: ICH”.
• If the secondary unit ACT/ACC [T1]
has been replaced, use TruckCom to
load the backup values. Open
TruckCom and select “Copy
configuration to secondary unit ACT/
ACC”.
• When you update to the latest
software check whether the
parameter settings are suitable for
the truck application in question or
use TruckCom to load the backup
values. Open TruckCom and select
“Copy configuration to secondary
unit ACT/ACC”.
2.005 Internal program error ICH [A2] • Report the fault to the manufacturer.
The truck cannot be driven and lifting/
• Restart the truck.
lowering is not possible.
• If the error recurs, update the truck
software to the latest version.
© TMHE 8– 5 T Code(s): 887, 888


2.006 Saving to NVM failed. Voltage is too low to • Battery parameter incorrectly
store data in the memory. adjusted.
• Check the battery.
• Charge the battery.
2.007 Internal program error ICH [A2] • Creating truck reports
No indication, logged only. Truck can be
• Report the fault to the manufacturer.
operated as usual.
• Rectify the error code that occurred
in direct conjunction with this error
code.
operated as usual.
code.
operated as usual.
code.
2.010 CAN communication warning. The ICH 1: Check that CAN is intact in terms of
CAN module received too may erroneous wiring harness, final resistance and
messages. connectors. Disconnect the battery.
Check that the resistance between
[T1:99] and [T1:100] is 54 - 66
ohm.
2: Check that the CAN wiring harness
is not pinched. Measure resistance
between the chassis and CAN
connector.
3: Update the truck software to the
latest version.
4: Deactivate and disconnect units
connected to the CAN wiring
harness (e.g. DHU and collision
sensor). Activate and then connect
them one by one to identify which
unit gives rise to the
communication error.
2.011 New software installed
Logged in the error log to see when
the software was updated
operated as usual.
© TMHE 8– 6 T Code(s): 887, 888


• Update the truck software to the
latest version.
• If the error persists, replace ICH [A2]
2.102 Configuration error If parameter 1102 is set to 4, verify that
Indication only; not logged. an analogue rocker for fork lifting/
Creep speed. Blocked lifting/lowering lowering is installed.
movement.
Indication only; not logged.
Creep speed. Blocked lifting/lowering
movement. • If the error recurs, update the truck
software to the latest version.
2.280 Incorrect signal combination from fork 1: Verify that all fork heigh position
position sensor. sensors ([S31], [S32] and [S12])
function normally.
• Check that the distance between the
movement.
sensors and the mast beam is
correct.
• Verify that each sensor has feed
voltage
• Inspect cabling.
• Replace any sensor that does not
change status.
2: Download new software
3: Replace the transistor regulator.
2.281 Incorrect signal combination from Verify correct functionality of the
platform position sensor. platform height sensor, [S103] and
[S107]
movement.
sensors and the platform is correct.
• Verify that each sensor has feed
voltage
• Replace any sensor that does not
change status.
• Download new software
• Replace the transistor regulator.
© TMHE 8– 7 T Code(s): 887, 888


2.282 Platform sensor locked. The platform 1: If the operator has been on the
sensor has been activated for more than 5 platform for more than 5 minutes
minutes without any truck activity. without lifting/lowering or driving,
Indication only; not logged. switch the platform sensor by
Creep speed. exiting the platform
2: Check the platform's "presence"
sensor
sensor and the platform is correct.
• Verify that the sensor has feed
voltage
2.283 Safety handle - error. Safety handle Safety handle on OME100N/
activated for more than 3 minutes with the OME100NW activated or defective.
truck inactive.
• If the safety handle has been
unintentionally activated, release it
Creep speed
and activate it again.
• Check the safety handles.
• Check all safety handle sensors
using the built-in test function for
digital inputs or using TruckCom.
• Replace sensor or entire unit after
locating the fault.
2.501 Low battery voltage • Charge the battery.
• Inspect all cables and connectors.
The main contactor is open.
• Battery parameter incorrectly
adjusted.
2.502 Unknown truck type. The truck type has 1: Restore data from backup.
not been set.
2: Specify truck type by setting factory
parameter 1001. Check that the
parameter settings are suitable for
the truck application in question.
2.504 Main contactor does not close. The voltage across the capacitors in
Voltage is too low to enable the main ACT is below 16 V. The main contactor
contactor to close. requires 16 V to draw.
• Charge the battery
© TMHE 8– 8 T Code(s): 887, 888


2.511 CAN communication error. The ICH has Check:
trouble sending messages via CAN.
• connections and wiring harness
• logic card in the handle (ICH).
2.515 Login error – DHU. Check that parameter 102 corresponds
No response is received from DHU/TWIS to the truck's equipment:
during login
1: Check that it is possible to connect
The main contactor is open
TruckCom to the DHU.
If it is possible to connect them,
check the DHU's configuration.
2: Check that the DHU's green LED is
lit.
If the LED is not lit: Check the
DHU's feed voltage = battery
voltage
If there is a battery voltage:
Replace the DHU.
3: Check that the CAN is intact in
terms of wiring harness, final
resistance and connectors.
4: Check fuses
5: Replace the DHU.
2.516 Box address error. ICH has an incorrect 1: Check the wiring harness in ICH.
box address.
2: Replace the ICH
2.520 Checksum error, parameters. 1: Restart ICH.
The parameter checksum does not match
2: Set new checksum
the parameter values.
The main contactor is open. • Change the value of one parameter
in each category - operator
parameters, service parameters,
factory parameters and calibration
parameters.
• Save the changes and restart the
truck
• Reset the values you changed in the
previous set to their original values.
• Restart the truck
• The program will have made a new
checksum
3: Download new software.
4: Replace the ICH
© TMHE 8– 9 T Code(s): 887, 888


2.522 Incorrect power supply to the Hall 1: Use TruckCom to check whether
sensors. the Hall sensors are defective.
2: Replace the ICH
The truck cannot be driven
2.523 Error in ICH RAM. Hardware error in ICH; replace the
The main contactor is open. ICH.
2.525 ICH has no application. 1: Software error in ICH; download
Software download interrupted new application.
2: Transfer cable disconnected.
Restart the download in
"Emergency download" mode.
2.526 CPU - error Replace the ICH

2.540 Main contactor [Q10] – connectors welded 1: Check the function of the main
The main contactor connectors are welded. contactor and that there is no
connection between Q10:3 and
Q10:4.
2: Check that there is no short-circuit
that can cause improper power
supply.
3: Replace main contactor [Q10]
2.541 Main contactor [Q10] – connectors welded 1: Check the function of the main
The main contactor connectors are welded. contactor and that there is no
connection between Q10:1 and
Q10:2.
that can cause improper power
supply.
3: Replace main contactor [Q10]
© TMHE 8 – 10 T Code(s): 887, 888


2.560 Main contactor [Q10] – Activated but the 1: Check fuses
ACT does not detect this.
2: Check the main contactor's
function and that there is a
relationship between [Q10:3] and
[Q10:4].
3: Check that there are no breaks in
the conductor between the main
contactor and the fuse panel, as
well as the conductor between the
fuse panel and ACT.
4: Log in to emergency travel mode to
reset the status of the main
contactor.
2.561 Main contactor [Q10] – Activated but the 1: Check fuses
EPS does not detect this.
2: Check the main contactor's
function and that there is a
relationship between [Q10:1] and
[Q10:2].
3: Check that there are no breaks in
the conductor between the main
contactor and the fuse panel, as
well as the conductor between the
fuse panel and ACT.
4: Log in to emergency travel mode to
reset the status of the main
contactor.
2.580 Run controller off. One or more of the Hall 1: Use TruckCom to check the Hall
sensors is defective. sensors.
2: Replace the ICH
The truck cannot be driven
Drive system
3.001 Speed control active. The speed control Check:
was not in the neutral position during
1: that the speed control is in the
start-up.
neutral position.
Travel is disabled until the speed control is 2: via TruckCom that the Hall-sensors
reset to the neutral position. work.
© TMHE 8 – 11 T Code(s): 887, 888


3.002 Temperature sensor in the transistor • Intensive use of the truck. Let the
regulator power stage shows a high level. truck cool down.
The transistor regulator temperature
• Inspect for dirt around the transistor
exceeds +85°C.
regulator. Too much dirt can cause
insufficient cooling of the transistor
The transistor regulator reduces maximum
regulator.
current to 50%.
3.003 The motor temperature sensor shows a • Intensive use of the truck. Let the
high level. The motor temperature truck cool down.
exceeds +150°C.
• Inspect for dirt around the motor. Too
much dirt can cause insufficient
cooling of the motor.
current to 50%.
3.004 Temperature sensor in the transistor • The truck is stored at too cold a
regulator power stage shows a low level. temperature.
The transistor regulator temperature is
• More the truck to a location with
below -20°C.
suitable environmental conditions.
The transistor regulator reduces the current
linearly from 100% at -20°C to 0% at -70°C.
3.005 The motor temperature sensor shows a • The truck is stored at too cold a
low level. The motor temperature is below temperature.
-20°C.
• More the truck to a location with
The transistor regulator reduces the current
suitable environmental conditions.
linearly from 100% at -20°C to 0% at -50°C.
3.080 The temperature sensor in the transistor Internal transistor regulator error.
regulator power stage is outside of the
• Restart the truck. If the error
limit values. The sensor shows abnormal
remains, then replace the transistor
values.
regulator.
current to 50%.
3.081 The motor temperature sensor is outside 1: Check wiring.
of limit values. The sensor shows
2: Check the cables of the
abnormal values.
temperature sensor in the motor.
Creep speed
The transistor regulator reduces maximum 3: Sensor [B1] may be defective.
current to 50%.
© TMHE 8 – 12 T Code(s): 887, 888


3.100 Transistor regulator warning. Unknown 1: Incongruence may have occurred
error. during software update or unit
Creep speed. Blocked lifting/lowering replacement (ACT/ICH). Check
movement. that ACT and ICH have software
from the same program package.
2: Update to the latest software.
3: Software error, inform the
manufacturer.
3.120 Transistor regulator - checksum error. 1: Internal transistor regulator error.
Incorrect checksum for the transistor Restart the truck.
regulator parameters.
2: If the error remains, then replace
the transistor regulator (ACT).
movement.
3.127 ACT reports that excessively high current Check:
is measured in the horn when it should be
in the OFF position.
Truck can be operated as usual. • the cabling between the horn and the
transistor regulator
• the horn.
3.128 ACT reports that excessively high current Check:
is measured in the fan when it should be
in the OFF position.
Truck can be operated as usual. • the cabling between the fan and the
• the fan
3.140 Horn – short-circuit. The horn output is Check:
short-circuited.
• the cabling between the horn and the
• the horn.
3.141 Fan – short-circuit. The fan output is Check:
short-circuited.
• the cabling between the fan and the
• the fan
3.225 Motor speed - high ACT reports high 1: Check:
motor speed
• motor
Creep speed
2: Replace the rotational speed
sensor
© TMHE 8 – 13 T Code(s): 887, 888


3.303 Transistor regulator - start-up. Transistor 1: Check the transistor regulator's
regulator start-up failed. cables and wiring harness.
2: Verify that the correct transistor
regulator (ACC/ACT) is used for
The truck cannot be driven nor lift/lower the
the truck in question.
forks.
3.500 Internal transistor regulator error. • Restart the truck.
Defective transistor regulator.
• Create a truck report. Send a report
to the manufacturer
latest version.
• If the error remains, then replace the
transistor regulator.
Faulty transistor regulator.
3.505 Unknown error in transistor regulator; can 1: Update the truck software to the
be incongruence between software latest version.
versions.
2: Software error, inform the
manufacturer.
3.506 Battery charge error. Transistor regulator 1: Check the battery voltage. Charge
detects excessively low battery voltage at the battery.
start-up.
2: Check that the battery cables are
free of damage and oxidation.

3.511 CAN communication problem ACT-ICH Check the CAN bus signal cables and
The main contactor is open. connections [T1, A2]. Restart the truck!
© TMHE 8 – 14 T Code(s): 887, 888


3.520 ACT - external ground triggered. Restart the truck so that ACT is reset
3.523 ACT reports that excessively high current 1: Check the resistance in the parking
is measured in the brake when it should brake coil. If the resistance
be in the OFF position. measurement indicates a short-
The main contactor is open. circuit, replace the brake.
2: Check that the parking brake does
not receive the wrong voltage feed.
3: Replace the transistor regulator
(ACT).
3.524 ACT reports that excessively high current 1: Check that the main contactor coil
is measured in the main contactor when it is not short circuited.
should be in the OFF position.
in connection [T1:118], cable 32.
3: Check connectors and wiring.
3.525 Motor speed - extremely high ACT reports 1: Check:
high motor speed
• motor
The drive is stopped immediately with the
parking brake • connections and wiring harness
2: Replace the rotational speed
sensor
3.540 Power stage – short-circuit. The transistor Check:
regulator has detected a short-circuit in
• motor cables
the output stage.
• motor
The main contactor is open. • transistor regulator
3.542 Sensor – short-circuit. A short-circuit has Detach the sensor and measure
been detected in the rotational speed resistance:
sensor.
• if the resistance measurement
indicates a short-circuit, replace the
rotational speed sensor
parking brake
• if the resistance measurement rules
out short-circuit, check the
connections and wiring harness
• if the conductors are undamaged,
then replace the transistor regulator
© TMHE 8 – 15 T Code(s): 887, 888


3.545 Brake – short-circuit. The transistor 1: Check the resistance in the parking
regulator output to the parking brake has brake coil. If the resistance
short-circuited. measurement indicates a short-
The main contactor is open. circuit, replace the brake.
2: Check that the parking brake does
not receive the wrong voltage feed.
3: Replace the transistor regulator
(ACT).
3.546 Main contactor - short-circuit. The 1: Check that the main contactor coil
transistor regulator output to the main is not short circuited.
contactor has short-circuited.
3: Check connectors and wiring.
3.547 A short-circuit has been detected - "high Check connectors and wiring.
side out".

3.560 Motor rotational speed sensor [B12] not Check:
connected
The drive is stopped immediately with the • sensor
parking brake
3.563 The circuit between the transistor Check:
regulator coil to the parking brake is open.
The main contactor is open. • parking brake
© TMHE 8 – 16 T Code(s): 887, 888


3.564 Break in output for main contactor [Q10]. 1: Verify that there are no breaks in
the contactor coil.
2: Verify that there are no breaks
between terminal [Q10:2] and
[T1:118].
3: Verify that there is battery voltage
between [Q10:1] and B-.
If there is no battery voltage:

• Check that the emergency stop
switch is not pressed.
• Verify that the fuses are not
defective.
4: Check whether the main contactor
works properly.
5: Replace the contactor.
3.584 The sensor feed voltage is outside of Check:
variation range.
1: connections and wiring harness
The transistor regulator output has
incorrect voltage level.
parking brake
3.586 Overcurrent. Drive motor phase current is Check:
too high.
1: That the motor cables are
undamaged and there is no
parking brake
relationship between them or with
B-.
2: The motor windings' resistance to
the motor yoke - there should be no
relationship.
3: Test using a new transistor
regulator. If the error persists, the
fault is probably an internal motor
problem. Replace the motor and
refit the old transistor regulator.
© TMHE 8 – 17 T Code(s): 887, 888


3.587 Battery overvoltage. Fully charged battery in combination
The main contactor is open. with hard regenerative reverse braking
or possible battery charger defect.
• Check the battery charger.
• Check the battery.
• Wiring harness between the battery
and the transistor regulator.
3.589 Low battery voltage. The transistor Check:
regulator software detects that battery
• battery parameter not correctly
voltage is too low.
adjusted.
• the cabling between the battery and
the transistor regulator.
• the battery.
3.590 Rotational speed sensor- acceleration too Check:
high. Too large a change in motor rotation
• rotational speed sensor for damage
is detected
or foreign objects
parking brake • replace the sensor.
3.591 Rotational speed sensor - feasibility error. Check:
Too high (impossible) a motor speed is
• rotational speed sensor for damage
detected
or foreign objects
parking brake • replace the sensor.
3.592 Current sensor - offset. Error is indicated Replace the transistor regulator.
if sensor offset is too high
parking brake
3.593 ACT reported a loss of channel A in the Detach the sensor and measure
rotational speed sensor resistance across the + and -
The drive is stopped immediately with the connections:
parking brake
• Replace the sensor if the resistance
measurement indicates break/short-
circuit.
• Check the connections and wiring
harness if the resistance
measurement rules out short-circuit/
break.
• If the cables and connections are
undamaged, replace the ACT.
© TMHE 8 – 18 T Code(s): 887, 888


3.594 ACT reported a loss of channel B in the Detach the sensor and measure
rotational speed sensor resistance across the + and -
The drive is stopped immediately with the connections:
parking brake
• Replace the sensor if the resistance
measurement indicates break/short-
circuit.
• Check the connections and wiring
harness if the resistance
measurement rules out short-circuit/
break.
• If the cables and connections are
undamaged, replace the ACT.
3.596 Transistor regulator power stage • Intensive use of the truck. Let the
Temperature sensor high. The transistor truck cool down.
regulator temperature exceeds +110°C.
The transistor regulator reduces
maximum current to 50%.
regulator.
parking brake
3.597 The motor temperature sensor shows a • Intensive use of the truck. Let the
high level. The motor temperature truck cool down.
exceeds +180°C.
• Inspect for dirt around the motor. Too
The transistor regulator reduces
much dirt can cause insufficient
maximum current to 50%.
cooling of the motor.
parking brake
3.598 Transistor regulator's internal 5 V supply Check:
is outside of variation range.
• Fuse
• Battery voltage at transistor
regulator connection
• If the voltage deviates from battery
voltage, check that the wiring
harness between the fuse panel and
transistor regulator is free from
damage and that the connections
are not oxidised.
• If the voltage is the same as the
battery voltage, replace the ACT.
© TMHE 8 – 19 T Code(s): 887, 888


3.599 Analogue power supply outside of Check:
variation range.
The transistor regulator's output for
power supply has the wrong voltage level. • Internal transistor regulator error.
Creep speed, blocked lifting/lowering Change transistor regulator.
movement
Hydraulic system
4.001 Lifting/lowering control is not in neutral Check:
position at start-up.
• Lifting control in neutral position
when truck is started.
Lifting/lowering is prevented until the lifting/
lowering controller is back in the neutral • wiring in the handle
position. • replace the potentiometer.
4.002 Sensors faulty at login Check:
Indication only; no logging.
• whether the platform was up at start.
Creep speed.
• If the platform is in the lifted position
at shut-off/logout, the forks must be
lowered so that the sensors can
receive the correct signal before the
error code disappears. In order to
lower the forks, the operator must be
standing on the platform.
• break in any cable to the sensors
4.101 The control signals for lifting and lowering Check:
show abnormal values.
• Lifting control in neutral position
Blocked lifting/lowering movement.
when truck is started.
• wiring in the handle
• the potentiometer.
4.102 Maladjusted controls for hydraulic Check the setting of factory parameter
functions. 1102 and compare with the handle type
Indication only; not logged. used on the truck.
Blocked lifting/lowering movement.
© TMHE 8 – 20 T Code(s): 887, 888


4.103 Measurement/Calibration error in the 1: Log off and cut off voltage to the
ACT's current measurement. truck for at least one minute.
Blocked lifting movement.
2: Restart the truck and log in again.
If the fault persists:
Check
undamaged and there is no short
circuit between them or with B-.
the motor yoke, there should be no
relationship.
3: Replace ACT.
4.120 Proportional valve for lowering not Calibrate the proportional valve for
calibrated. lowering.
4.121 DC voltage too high 1: Log off and cut off voltage to the
Blocked lifting movement. truck for at least one minute.
2: Restart the truck and log in again.
If the fault persists:
Check
undamaged and there is no short
circuit between them or with B-.
the motor yoke, there should be no
relationship.
3: Replace ACT.
4.122 Chain guard Check the chains.
movement.
© TMHE 8 – 21 T Code(s): 887, 888


4.180 Problem with the pressure sensor [B10] or 1: Check that the voltage is
the cabling. Voltage outside of variation approximately 5 V between the
range. cables 26 and 40 connected to the
Creep speed. Blocked lifting movement. pressure sensor.
2: Check the voltage between wires
40 and 66. The output voltage
should be 0.5 V (no load) to 4.5 V
(max. load)
3: Verify that the cabling is intact.
latest version.
5: Replace the pressure sensor [B10].
4.181 Problem with the pressure sensor [B11] or 1: Check that the voltage is
the cabling. Voltage outside of variation approximately 5 V between the
range. cables 26 and 40 connected to the
Creep speed. Blocked lifting movement. pressure sensor.
2: Check the voltage between wires
40 and 65. The output voltage
should be 0.5 V (no load) to 4.5 V
(max. load)
3: Verify that the cabling is intact.
latest version.
5: Replace the pressure sensor [B11]
4.231 Lift valve - OFF current. ACT measures 1: Inspect:
current in the lift valve when it should be
in the OFF position
Main contactor open • the cabling between the valve and
the transistor regulator
4.232 Pump contactor - OFF current. ACT 1: Check that the pump contactor's
measures current in the pump contactor coil has not short-circuited.
when it should be in the OFF position
Main contactor open
© TMHE 8 – 22 T Code(s): 887, 888


4.233 Platform valve - OFF current. ACT 1: Inspect:
measures current in the platform valve
when it should be in the OFF position
Main contactor open • the cabling between the valve and
the transistor regulator
4.234 Proportional valve - OFF current. ACT 1: Inspect:
measures current in the proportional
valve when it should be in the OFF
position • the cabling between the valve and
Main contactor open the transistor regulator
4.242 Pump motor – short-circuit. A short- 1: Check that the motor cables are
circuit has been detected in the pump undamaged and there is no short-
motor circuit circuit between them or with B-.
in the pump motor coil.
3: Internal transistor regulator error.
Replace the transistor regulator.
4.243 Proportional valve – short-circuit. A short- 1: Inspect cabling.
circuit has been detected in the
2: With the truck disconnected, check
proportional valve circuit
whether resistance in the
Blocked lifting/lowering movement
proportional valve coil is
abnormally low.
4.245 Lift valve – short-circuit. 1: Inspect cabling.
A short-circuit has been detected in the
lift valve circuit
whether resistance in the lift valve
coil is abnormally low.
4.246 Pump contactor – short-circuit. 1: Check that the pump contactor's
A short-circuit has been detected in the coil has not short-circuited.
pump contactor circuit
4.247 Platform valve – short-circuit. 1: Inspect cabling.
A short-circuit has been detected in the
platform valve circuit
whether resistance in the platform
valve coil is abnormally low.
© TMHE 8 – 23 T Code(s): 887, 888


4.280 Temperature sensor in power stage - short 1: Restart the truck
circuit.
2: If the fault persists, replace the
An error has been detected in the
temperature sensor of the power stage's
DC component.
4.281 Temperature sensor in power stage - high • Intensive use of the truck. Let the
temperature. truck cool down.
High temperature detected in DC part of
power stage.
regulator.
4.561 Lift valve break. A break has been 1: Inspect cabling.
detected in the lift valve circuit
whether resistance in the lift valve
coil is abnormally low.
4.562 Pump contactor break. A break has been 1: Verify that there are no breaks in
detected in the pump contactor circuit the pump contactor coil.
2: Verify that there are no breaks
between terminal [Q30:2] and
[T1:116], cable 45.
3: Verify that there is battery voltage
between [Q30:1] and B-.
If there is no battery voltage:

• Check that the emergency stop
switch is not pressed.
• Verify that the fuses are not
defective.
4: Check whether the pump contactor
works properly.
5: Replace the pump contactor
4.563 Platform valve break. A break has been 1: Inspect cabling.
detected in the platform valve circuit
whether resistance in the platform
valve coil is abnormally low.
© TMHE 8 – 24 T Code(s): 887, 888


4.564 Proportional valve break. A break has 1: Inspect cabling.
been detected in the proportional valve
circuit
whether resistance in the
Main contactor open.
proportional valve coil is
abnormally low.
Steering system
5.035 The steering servo temperature exceeds • Clean the steering servo cooling
68°C. element.
• If the error recurs, the fault is
probably an internal steering servo
problem. Replace the servo.
5.080 Reference sensor error. Reference sensor • Check the sensor cabling.
not connected to EPS
• Defective home reference sensor
[S65] /
5.081 Steering servo - 12V supply voltage. Low supply voltage to reference
Voltage to sensor outside of variation sensor. Should be approx. 9.8-13.5 V
range. between cables 95-97.
• Check cabling to reference sensor
[S65].
• Check fuse [F50].
• Defective home reference sensor
[S65] /
5.135 Risk of thermal overcurrent in the steering 1: Check that there are no objects
servo. blocking the steering movement.
The error code is shown from 80% up to
2: Check that the steering gear is not
100%. At 100%, the indication switches over
jammed or blocked by dust, thread
to error code 5:325.
or contaminants.
Creep speed. 3: Replace the steering servo
© TMHE 8 – 25 T Code(s): 887, 888


1: Check the reference sensor
• Steer slightly to the right so that the
crown wheel is correctly positioned
in relation to the reference sensor.
• Cut the power to the truck.
• Check the space between the sensor
and the ridge on the crown wheel
using a feeler gauge. Nominal
measurement:
1.5 mm
Note: There is a risk of personal injury
if power is restored to the truck while
work is performed on the gear ring.
• Restore power to the truck.
• Check if there is any power supply to
S65, 9.8 - 13.5V between wires 95
and 97.
When S65 indicates 0 degrees, R2 must
• If there is a power supply, replace
be
S65.
in the interval of +/- 7 degrees
• Check if there is any short-circuit
between wires 95 and 97, and
Creep speed.
5.182 also between 95 and the rest of the
electrical system.
1: The clearance between reference sensor
• If there is no power supply or short
and the crown wheel is
circuit
wrong
- replace M6
2: Defective component
3: Erroneous steering angle signal 2: See above
3: Check the steering angle sensor
• Troubleshoot the wiring harness
between M6 and R2
for short circuits and breakages -
repair
or replace the wiring harness.
• Digital PWM signal from R2 cannot
be measured, use a working R2
for comparison.
• Compare the steering angle to the
angle
indicated by the system via Service
Information Mode 13 or TruckCom
If it does not seem to be correct, check
the mechanical fitting of the
steering arm, and perform a new
steering angle calibration.
© TMHE 8 – 26 T Code(s): 887, 888


5.301 Steering servo power stage defective. 1: Check fuse [F53].
2: Check that there is battery voltage
between conductors 23/[A5:8] +
[A5:16] and 40/[A5:7] + [A5:15].
3: Replace the steering servo
5.303 The steering servo does not respond on 1: Check fuse [F53].
start-up. No response from the EPS
during initialisation
[A5:16] and 40/[A5:7] + [A5:15].
3: Disconnect the battery. Check that
there is about 60 ohm in the wiring
harness between [T1:99] and
[T1:100].
5.320 Erroneous DC voltage. The steering servo 1: Check the battery voltage.
power supply is less than 24 VDC.
2: Check fuse [F53].
[A5:16] and 40/[A5:7] + [A5:15].
4: Battery parameter may not be
correctly adjusted.
5.325 Thermal overcurrent in the steering servo, This error can occur if the operator
100 % of permitted value. The EPS is continues to steer when the truck has
limiting the current to the nominal value stopped or is stationary.
(10 A).
1: Check that there are no objects
blocking the steering movement.
2: Check that the steering gear is not
jammed or blocked by dust, thread
or contaminants.
5.326 Temperature error. The temperature in the Park the truck where the ambient
steering servo power stage is outside of temperature is within the temperature
the permitted variation range. limits.
© TMHE 8 – 27 T Code(s): 887, 888


5.335- EPS internal error. 1: Download software to ICH, even if
5.336 The main contactor is open. the truck already has the latest
version.
2: Restart the truck. (the first startup
after software installation takes
more time than a regular startup).
Do not cut the power.
3: Replace the steering servo if the
error code remains when the truck
is started.
5.337 and Reference run. EPS reports an error Check the reference sensor
5.580 during reference run or reference run not
completed after 15 seconds
5.380 Supply error - Steering potentiometer. Check that there is 5 V between [R2 +]
and [R2 -].
• Check the cabling.
• Replace the steering servo
5.414- CAN communication error. The ICH or 1: Check fuses [F50] and [52].
5.416 steering servo has not responded via CAN
2: Check that CAN is intact in terms of
within 70 ms.
wiring harness, final resistance and
connectors. Disconnect the battery.
Check that the resistance between
[T1:99] and [T1:100] is 54 - 66
ohm.
[A5:16] and 40/[A5:7] + [A5:15].
5.417 CAN communication error. Check the wiring
5.421 Power steering DC voltage is over 24 V. 1: Check whether there are other,
The main contactor is open. simultaneous error codes being
stored. Resolve simultaneous
errors before continuing with
troubleshooting.
2: Check cabling and fuses.
© TMHE 8 – 28 T Code(s): 887, 888


5.422 Short-circuit in the steering servo 1: Disconnect the battery connector
The main contactor is open. and wait 30 seconds.
2: Re-connect the battery connector
and switch on the truck.
3: If the fault persists, replace
steering servo.
5.435- Internal error in the steering servo. Replace the steering servo
5.438 The main contactor is open.
5.500 Unknown steering servo error. 1: Update the truck software package
The main contactor is open. to the latest version.
2: Inform the manufacturer.
5.520 Error in EPS 5 V output. • Check cabling to potentiometer [R2].
Move the steering unit in all
The main contactor is open. directions to ensure no cabling
problems exist.
• Check that cables and connectors
are undamaged.
• Replace the steering servo.
5.540 Short-circuit in analogue input. • Check cabling to steering signal
potentiometer [R2] for short-circuit/
The main contactor is open. break.
• Move the steering handle in all
directions to ensure no cabling
problems exist.
• Replace the steering servo.
5.580 See 5.337
5.582 Input error - analogue steering signal. • Move the steering unit in all
Both analogue inputs outside of variation directions to ensure no cabling
range. problems exist.
• Defective potentiometer
5.583 Error in analogue steering signal input 0. Move the steering unit in all directions
Voltage in analogue input 0 is outside of to ensure no cabling problems exist.
variation range
5.584 Error in analogue steering signal input 1. • Move the steering unit in all
Voltage in analogue input 1 is outside of directions to ensure no cabling
variation range problems exist.
© TMHE 8 – 29 T Code(s): 887, 888


5.585 Defective parallel potentiometer. Minimum • Move the steering unit in all
voltage difference between analogue directions to ensure no cabling
inputs 1 and 2 if it is outside of variation problems exist.
range
5.586 The total of analogue inputs is outside of • Calibrate the steering potentiometer.
variation range.
• Move the steering handle in all
directions to ensure no cabling
problems exist.
Option
8.001 The collision sensor has detected Check the limits for registering
collision levels exceeding the specified collisions.
value limit values.
Reset the collision sensor with the PIN
code
Creep speed.
8.002 The truck was intentionally taken out of Reset the truck to normal operation.
use.
Creep speed.
8.003 Argument error in option. Invalid Check option parameters 1003-1042.
configuration in one or more options. One or more arguments are outside of
Indication only; not logged. the limit for the selected option.
8.004 One or more option buttons on ICH is Restart the truck and make sure no
activated at start-up. option buttons are activated.
8.110 CAN communication problem with Spider Check connectors and wiring.
expansion unit at start-up.
movement. Option via Spider expansion unit
deactivated.
8.111 CAN communication problem with Spider Check connectors and wiring.
expansion unit.
movement. Option via Spider expansion unit
deactivated.
© TMHE 8 – 30 T Code(s): 887, 888


8.112 Collision sensor communication error. If no collision sensor is connected,
Error during communication with collision parameters 105 and 106 must be set to
sensor via CAN. 0
8.123 Program warning - Spider expansion unit. • An option attempted to register a
Creep speed. Blocked lifting/lowering digital output that is already
movement. requested by another option or an
option is trying to register a digital
input that is already requested by the
application.
• Check option parameters 1003-
1042.
8.130 CAN-communication to battery Check the voltage to other CAN buses
Creep speed, lifting blocked. If possible, lift check that the CAN wiring harness is
with the service key connected. OK.
8.131 Temperature in the li-ion battery is too high Let the battery cool off
Creep speed. Blocked lifting movement.
8.132 Current in the li-ion battery is too high Regenerative braking with fully-
Creep speed. Blocked lifting movement. charged battery.
Check the connections.
8.133 Low Li-ion battery temperature Move the truck to a warmer area
8.134 Defective hardware in the li-ion battery Sensor in a module is defective.
Creep speed. Blocked lifting movement. Contact the battery manufacturer.
8.135 Internal CAN problem in the li-ion battery Communication problem between
Creep speed. Blocked lifting movement. modules in the battery. Contact the
battery manufacturer.
8.136 Overvoltage in the li-ion battery A module in the battery has been
Creep speed. Blocked lifting movement. switched off because the voltage is too
high. Restart the battery.
8.137 Battery cells deactivated by internal Overvoltage, undervoltage, to high
monitoring. temperature, too low temperature. Let
Creep speed. Blocked lifting movement. the battery rest, and then restart the
battery.
8.138 Low battery voltage in the li-ion battery Charge the battery
Creep speed. Blocked lifting movement. Check connectors, joints and splices
for damage or corrosion
8.139 Wrong battery type selected via parameter • Check that factory parameters are
1045 set according to the truck
Creep speed. Blocked lifting movement. configuration.
• Check that other parameters are set
correctly.
© TMHE 8 – 31 T Code(s): 887, 888


8.140 1: Update the truck software
Start-up problem between truck and li-ion • Create a truck report. Send a report
battery during start. to the manufacturer.
latest version.
8.150 Walkie button activated during start-up. • Make sure the buttons are not
It is not possible to drive the truck. Blocked activated.
lifting/lowering movement. • Check if the wiring is short-circuited.
© TMHE 8 – 32 T Code(s): 887, 888

8.5 Built-in test function for the tiller arm

1: Make sure the battery is connected.
2: Check that the truck is switched off. Press the OFF switch.
3: Connect the CAN key or enter the PIN code. Note: Do not press the ON
switch.
4: Press and then release the horn button. “Info“ is shown on the display.
5: Press and release the horn button to select the "Info" menu.
6: Turn the speed control several times until “tESt” is shown on the display.
7: Press the horn button and release it to enter the test mode.
8: The first one you arrive at is the display test. Press on the button/function
you want to test to proceed. In this mode, the 2 LEDs on the keypad
flash.
8.5.1 Display test

The digital display [A6] can be tested to verify all the segments of the display
function correctly. A moving 8 tests all the segments of the display.
8.5.2 Speed control

The Hall elements are tested by moving the speed control all the way back
and forward. Follow these steps to test the Hall elements:
Move the rocker from the neutral position to begin the test. This is visualised
as number X Y when the rocker is moved in the fork direction and X-Y when
the rocker is moved in the drive wheel direction. X is the total number of Hall
elements that are affected by the magnet and Y is the number of existing Hall
elements. At full movement in both directions 9-9 or 9 9 is shown when all Hall
elements are OK.
8.5.3 Controls for lifting/lowering

Press a button for lifting / lowering in order to start the test. “L1”, “L2”, “L3” or
“L4” is shown in the display depending on which button has been pressed.
© TMHE 8 – 33 T Code(s): 887, 888

8.5.4 Sensilift
Move the sensilift rocker switch from the neutral position to begin the test.
The analogue value from the sensilift potentiometer is shown in mV.
8.5.5 Keypad
Press any number to start testing the keypad. “b1” up to “b11” is shown in the
display depending on which button is pressed. The numbers 0-9 are shown
as “b0” to “b9”. The red button “b10” and the green button “b11”
9: Switch off the truck by pressing the OFF button or return to the previous
menu by pressing the horn button.
© TMHE 8 – 34 T Code(s): 887, 888

8.6 Built-in test function

The truck’s control system has a number of built-in test functions that can be
used to aid the troubleshooting process. To active the test functions, proceed
as follows:
1. Connect the CAN service key to [X41] and log in.
2. The battery status symbol lights up.
3. Press the horn button [S18] repeatedly to select the desired mode in the
built-in test function.
Note
All truck functions work as normal when the built-in test function is active.
Care should be taken when operating the truck and reading the display at
the same time.
Mode Flashing symbol Data that is shown on the Comments

display
1 The speed setting sent to the transistor Norm. value:
regulator (rpm/10). -361 - +361
2 Status of digital inputs/outputs, transistor See section . “Test

regulator [T1] and ICH [A2] mode “2” –”
3 Battery voltage (V) Norm. value:

Compare to battery
voltage (nominally 24
V)
4 Pot1 voltage (V) If equipped with
sensilift,
norm. value:
0.5 - 4.5
No sensilift, norm.
value: 0
5 Pot2 voltage (V) Not used
6 Current, drive (A) Norm. value:

0 - 350
7 Current, pump (A) If equipped with ACC,

norm. value: 0 - 300
No ACC
norm. value: 0
8 Input/output status, expansion unit See section . “Test
(option) mode “8” – Expansion
unit SEU (option).”
© TMHE 8 – 35 T Code(s): 887, 888

Mode Flashing symbol Data that is shown on the Comments

display
9 Analogue 1 (pressure sensor [B10]) (V) If equipped with [B10],
norm. value: 0.5 - 4.5
No [B10],
norm. value: 0
10 Analogue 2 (pressure sensor [B11]) (V) If equipped with [B11],
norm. value: 0.5 - 4.5
No [B11],
norm. value: 0
11 Analogue 3 (V) Not used
12 Voltage feed “High side” (V) Same range as for

mode 3: "Battery
voltage"
© TMHE 8 – 36 T Code(s): 887, 888

8.7 Digital input/output status
8.7.1 Test mode “2” –
In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
A
F G B
E C
1 2 3 4 D H
Position:
1. Digital input of ICH [A2]
2. Digital input/output of ICH [A2]
3. Transistor regulator inputs
4. Transistor regulator inputs
A – H: Reference to segment
Function Pos 1 Pos 2 Pos 3 Pos 4

Opt 6 A * * * On: Button pressed
Opt 5 B * * * On: Button pressed
Opt 4 C * * * On: Button pressed
Opt 1 D * * * On: Button pressed
Opt 2 E * * * On: Button pressed
Opt 3 F * * * On: Button pressed
Rear fork lift button * A * * On: Button pressed
Rear fork lowering button * B * * On: Button pressed
Front fork lift button * C * * On: Button pressed
Front fork lowering button * D * * On: Button pressed
Main contactor [Q10] * E * * On: Contactor closed
Off: Contactor open
Sound signal control [S18] * F * * On: Button pressed
Parking brake [Q1] * G * * On: Brake released
Off: Brake applied
Pump activated * H * * On: Contactor closed
Off: Contactor open
© TMHE 8 – 37 T Code(s): 887, 888


Input 1 * * A * On: Button pressed
Input 2 * * B * On: Button pressed
Input 3 * * C * On: Button pressed
Input 4 * * D * On: Button pressed
Input 5 * * E * On: Button pressed
Input 6 * * F * On: Button pressed
Input 7 * * G * On: Button pressed
Input 8 * * H * On: Button pressed
Input 9 * * * A On: Button pressed
Input 10 * * * B On: Button pressed
Input 11 * * * C On: Button pressed
Input 12 * * * D On: Button pressed
Input 13 * * * E On: Button pressed
A
F G B
E C
D H
© TMHE 8 – 38 T Code(s): 887, 888

8.7.2 Test mode “8” – Expansion unit SEU (option).
In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
A
F G B
E C
1 2 3 4 D H
Position:
1. SEU 0 inputs
2. SEU 0 outputs
3. SEU 1 inputs
4. SEU 1 outputs
A – H: Reference to segment

Digital input 1, SEU0 A * * * -
Digital input 2, SEU0 B * * * -
Digital input 3, SEU0 C * * * -
Digital input 4, SEU0 D * * * -
Digital input 5, SEU0 E * * * -
Digital input 6, SEU0 F * * * -
Digital input 7, SEU0 G * * * -
Digital input 8, SEU0 H * * * -
Digital output 1, SEU0 * A * * -
Digital output 2, SEU0 * B * * -
Digital output 3, SEU0 * C * * -
Digital output 4, SEU0 * D * * -
Digital input 1, SEU1 * * A * -
Digital input 2, SEU1 * * B * -
Digital input 3, SEU1 * * C * -
Digital input 4, SEU1 * * D * -
Digital input 5, SEU1 * * E * -
Digital input 6, SEU1 * * F * -
Digital input 7, SEU1 * * G * -
© TMHE 8 – 39 T Code(s): 887, 888


Digital input 8, SEU1 * * H * -
Digital output 1, SEU1 * * * A -
Digital output 2, SEU1 * * * B -
Digital output 3, SEU1 * * * C -
Digital output 4, SEU1 * * * D -
A
F G B
E C
D H
© TMHE 8 – 40 T Code(s): 887, 888

9. Chassis – C0000
9.1 Details dampened floor
12
11
13
14
15
16
17
18
19
20
21
33
34
23 22
25
24 35
26
27
28 36
29
30
31 32
5830
© TMHE 9– 1 T Code(s): 887, 888

Quantit
Pos. Description
y
11 Screw 6
12 Bracket 2
13 Carpet 1
14 Nut 7
15 Plate 1
16 Screw 4
17 Sleeve 4
18 Screw 8
19 Bracket 4
20 Screw 8
21 Spring 4
22 Washer 8
23 Nut 8
24 Spring 4
25 Screw 2
26 Nut 2
27 Bracket 1
28 Adjustment screw 1
29 Spring 1
30 Plate 1
31 Split pin 1
32 Bolt 1
33 Screw 4
34 Washer 4
35 Damper 4
36 Screw 4
© TMHE 9– 2 T Code(s): 887, 888

9.2 Adjust dampened floor

1: Unscrew the metal rails securing the rubber mat and remove the rubber
mat (see below).
2. Adjust the sensor plate (see below).
Important: Adjust the adjusting screw so that the sensor is activated (lamp
lights up) when 30 kg of weight is placed on the vibration-damping floor. Note
that the sensor must only be activated if the vibration-damping floor is
loaded with 30 kg or more.
3: Reinstall the rubber mat and metal rails.

Make sure to tighten the screws to the correct torque (9.5 Nm) to avoid
that the nuts shake loose.
© TMHE 9– 3 T Code(s): 887, 888

9.3 Platform with operator lift – C9130
The operator lift uses 8 adjustable side guides (A and B). Besides this, there
are two outer side guides (D) which are also adjustable.
9.3.1 Adjusting the side guides

When lifted to the highest position, it is possible to adjust the side guides (a)
with the screws (b) through the holes in the side member (section C). The
side member must be lubricated according to the lubrication chart every 500
hours. The backrest must be removed for access for all adjustments.
NOTE:
It is important that the operator's cabin is raised to the topmost position
before adjustment is made.
C
A
e
d
c
b
a C
Pos. Description Remarks

a Steering
b Screw
Applies from machine no.
c Threaded insert
XXXXXXX
d Circlip
e Ball bearing
© TMHE 9– 4 T Code(s): 887, 888

9.3.2 Adjusting the outer side guides

The outer side guides (section D) are accessible from the outside once the
operator lift has been raised to the topmost position. Adjust the side guards (j)
using the adjuster screws (e and f) until any play has been eliminated.
NOTE:
The operator's cabin must be lifted to its topmost position prior to performing
this adjustment.
D
i j
h
g
f

e Screw
f Screw
g Nut
h Bracket
i Plate
j Outer side guide
© TMHE 9– 5 T Code(s): 887, 888

9.3.3 Removing the platform with operator lift
Step 2 Step 3
Step 4 Step 6
Step 7
Step 8 Step 9
© TMHE 9– 6 T Code(s): 887, 888

Step 10 Step 11
Step 12
Steps 13 and 14 Step 15 Step 16
© TMHE 9– 7 T Code(s): 887, 888

Step 17 Step 18
Step 19
Step 20 Step 21
© TMHE 9– 8 T Code(s): 887, 888

Method
NOTE:
Clean the surfaces around the cylinder connections before removing the
cylinder from the truck. When the hydraulic hose has been removed, the
cylinder connections must be plugged to protect the cylinder from dirt.
1: Disconnect the battery
2: Remove the backrest
3: Remove the bracket of the main lift position sensor and put it aside. The
fastening screws of the operator lift wiring harness cover plate are now
accessible
4: Undo the screws and remove the cover plate.
5: Note the position of the cable ties on the operator lift wiring harness and
cut them away.
6: Unplug the contact of the operator lift wiring harness and move it aside
so it is not damaged during continued work.
7: Disconnect the platform height sensor wiring harness from the chassis
wiring harness and put the two contacts aside so they are not damaged
during continued work.
NOTE:
Note the dimensions of the chain bolt before removing it. This facilitates
refitting.
8: Slacken the platform lifting chain by loosening, but not removing, the
chain bolt from the lift cylinder.
9: Detach the lifting chain from the chain bolt and lift the chain from the
chain yoke.
10: Detach the chain yoke from the lift cylinder of the operator lift.
11: Install a lifting device, e.g. flat iron, with two M8 screws in the backrest
mounting.
NOTE:
The lifting strap around the steering unit bracket must not bear any weight. It
is only intended to prevent the operator lift from tipping forward.
12: Prepare lift of the operator lift by fastening lifting straps in the flat iron and
around the steering unit bracket.
DANGER!
Make sure that the lifting straps are well secured.
13: Tension the lifting straps by using a lifting device (overhead crane, crane
or truck).
14: Carefully raise the platform at the top using the lifting device to gain
access to the fastening screws of the operator lift.
DANGER!
Risk of crushing
The platform must be reliably secured.
© TMHE 9– 9 T Code(s): 887, 888

15: Secure the platform with a block.

NOTE:
Oil leaking.
Risk of valve or cylinder failure if dirt enters the hydraulic connections.
Therefore, plug all hydraulic connections.
16: Lower the lift cylinder to the bottom.
17: Detach the hydraulic hose and hose coupling from the cylinder and plug
the connections.
18: Lift out the lift cylinder of the operator lift
19: Undo the upper and lower fastening screws of the operator lift. Leave the
lower fastening screws and washers in place.
20: Remove the trestle support.
21: Carefully lift out the operator lift and place it horizontally on some pallets
or suchlike.
The platform and operator lift are now accessible for service and repairs
© TMHE 9 – 10 T Code(s): 887, 888

9.3.4 Reinstalling the platform with operator lift
Step 1
Steps 2, 3 and 4 Steps 5, 6 and 7
Step 10 Step 11
Steps 8 and 9
© TMHE 9 – 11 T Code(s): 887, 888

Step 12 Step 13
Step 15 Steps 16 and
Step 18 Step 20
© TMHE 9 – 12 T Code(s): 887, 888

Method
1: Install the lifting device, e.g. flat iron, with two M8 screws in the backrest
mounting.
NOTE:
The lifting strap around the steering unit bracket must not bear any weight. It
is only intended to prevent the operator lift from tipping forward.
2: Prepare lift of the operator lift by fastening lifting straps in the flat iron and
around the steering unit bracket.
DANGER!
Make sure that the lifting straps are well secured.
3: Tension the lifting straps by using a lifting device (overhead crane, crane
or truck).
4: Carefully raise the platform at the top using the lifting device.
5: Carefully lift the operator lift into place in the truck. Ensure that the
operator lift catches latch in the chassis back plate and that the lower
attachment points are correctly positioned compared to the lower
fastening screws.
6: The operator lift must be centred in the chassis. Check that the distance
from the operator lift to the chassis frame sides is the same on both sides
of the truck
DANGER!
Risk of crushing
The platform must be reliably secured.
7: Secure the platform with a block.
8: Tighten the upper fastening screws of the operator lift.
9: Tighten the lower fastening screws.
10: Fit the operator lift's lift cylinder. Turn the cylinder so that there is no risk
of the lifting chain lug coming into contact.
11: Install the cylinder hose coupling and connect the hydraulic hose. See
section "15.13 Hydraulic couplings C6230".
12: Connect the platform height sensor wiring harness with the chassis
wiring harness and fit the contacts in the intended brackets with cable
ties.
13: Connect the contact of the operator lift wiring harness with the chassis
wiring harness and fit new cable ties where the old ones sat.
NOTE:
If the operator lift seizes during lowering, the outer side adjustments can be
loosened slightly.
14: Carefully lower the platform and ensure that the cylinder rod steering
toward the chain yoke. Stop just before the platform reaches its bottom
position.
© TMHE 9 – 13 T Code(s): 887, 888

15: Apply Loctite 243 to the locking screw that locks the chain yoke at the
cylinder rod and tighten. Ensure that locking is correct.
16: Route the lifting chain over the chain yoke and secure it at the chain bolt
with locking pin and split pin.
NOTE:
The operator lift must always hang in the lifting chain when the operator lift is
in its lower position. It must not therefore rest against the chassis.
17: Tighten the chain bolt as per notations and lock with locking nuts and split
pin.
18: Check that the operator lift platform is level with the chassis frame. Re-
adjust the lifting chain if necessary.
19: Remove the lifting straps and lifting device.
20: Reinstall the backrest with 4 screws and 2 screws and washers.
21: Connect the battery.
22: Test operator lift functionality. Adjust the operator lift side adjustments if
necessary. See sections “Adjusting the side guides” and “Adjusting the
outer side guides”
© TMHE 9 – 14 T Code(s): 887, 888

9.4 Automatic height adjustment – C9390

OSE120/120P trucks can be fitted with a photocell, which in the automatic
mode controls lifting and lowering of the forks to maintain a preset height
when the sensor detects the load.
NOTE: This function is configured by setting factory parameters.
The table below shows factory parameter defaults when the truck is equipped
with the automatic height preselector option.
Parameter Parameter Parameter Parameter Parameter

1003 1004 1005 1006 1007
Value 11 0 4 0 0
© TMHE 9 – 15 T Code(s): 887, 888

9.5 Signs, warnings, adhesive labels – C0850

The figure shows the position and significance of the signs on the truck.
NOTE:
Illegible warning plates must be replaced.
c b
a
a
b c M-PLATE
d
e A
B
f
f C D
g
a: Modification plate
b: Identification plate
c: No passengers allowed
d: Warning plate (only on trucks for Japan)
e: Radio transmitter
f: Lifting points
g: Hydraulic oil filler neck
h: Serial number
© TMHE 9 – 16 T Code(s): 887, 888

Identification plate
a: Truck model
a b: Truck serial number
b c c: Manufacturing year
d d: Rated capacity - Highest permitted load on the forks
e e: Weight excluding battery

f: Battery weight - Lowest and highest permitted battery weight. Braking
f
capacity may be affected and the truck may become instable and
f therefore dangerous in traffic if the battery weight is not within the
g specified interval.
g: Battery voltage
h h: Battery type (only ANSI)
© TMHE 9 – 17 T Code(s): 887, 888

© TMHE 9 – 18 T Code(s): 887, 888

10. Motors - C1700

10.1 Pump motor - C1710
10.1.1 General
The pump motor is a compound motor, a stator winding in series with the rotor
winding and an additional stator winding in parallel with these.
Tightening torque
a
Pos. Spanner width Tightening torque

a 13 mm 8.5 (max 9) Nm
b 10 mm 10 (max 12) Nm
© TMHE 10 – 1 T Code(s): 887, 888

10.1.2 Replacing the pump motor
Step 6 Step 7
Step 9 Step 10
© TMHE 10 – 2 T Code(s): 887, 888

Method
1: Disconnect the battery
2: Open the motor compartment.
3: Remove the hydraulic unit. See section "15.9 Removing/installing the
hydraulic unit".
4: Remove the reservoir from the motor. See section "15.8.3 Emptying the
hydraulic tank".
5: Remove the oil pump from the main valve. See section
"15.9.1 Replacing valves".
6: Remove the main valve block from the pump motor by removing its two
fastening screws.
7: Carefully knock out the pump motor. Hold the motor and main valve
block upside down so that the motor’s rotor does not fall out.
8: The motor is now accessible for service and repairs.
9: Align the pump motor and main valve block to each other. Make sure the
pump motor electrical connectors assume the same position in relation
to the valve block as they had before removal.
10: Assemble the main valve block together with the motor with the two
fastening screws. See section "15.8.2 Tightening torque for hydraulic
unit".
11: Reassemble the oil pump. See section "15.9.1 Replacing valves".
12: Fit the reservoir to the motor. See section "15.8.3 Emptying the hydraulic
tank".
13: Fit the hydraulic unit.See section "15.9 Removing/installing the hydraulic
unit".
14: Close the motor compartment.
© TMHE 10 – 3 T Code(s): 887, 888

10.2 Steering motor - C1730 (steering servo assembly)
10.2.1 General
Steering servo repairs are limited to replacing the gears.
The steering servo is made up of three main components mounted as a unit
on the bottom plate of the motor compartment:
a: the steering servo electronics,
b: the motor, which is a brushless synchronous motor with permanently
magnetised rotor,
c: a two-stage planetary gear, which has a gear wheel on its output shaft in
direct contact with the gear ring on the drive gear
a
Note:
Apart from gear replacement, repair of mechanical parts is not permitted for
reasons of safety.
© TMHE 10 – 4 T Code(s): 887, 888

Tightening torque
c
Pos. Tightening torque
a 9 Nm
b 33 Nm (+ centre punch mark)
c 23 Nm
© TMHE 10 – 5 T Code(s): 887, 888

10.2.2 Replacing the steering servo assembly
Step 2. Step 3.
Step 4.
Step 5.
Step 6. Step 7.
© TMHE 10 – 6 T Code(s): 887, 888

Method
1: Disconnect the truck battery.
2: Disconnect the cable from the steering servo's electronic card [A5]
3: Unscrew the steering servo.
4: Remove the steering servo.
Lift the motor straight up to prevent damage to the gear drive and cover
the hole with a sheet of cardboard or similar
5: Position the new motor by inserting it straight down without damaging the
gear ring.
6: Fasten the four screws of the steering servo alternately, applying a
×n 7:
torque of 23 Nm.
Connect the steering servo electronics cable
s mm
Start the truck and check that the steering functions without problem. The
Step 6, s: 6 mm, steering servo may require calibration. See section "5.3.1 Steering servo
n: 4, T: 23 Nm. calibration".
10.2.3 Gear replacement

Steering servo repairs are limited to replacing the gears.
1: Remove the steering servo. See section "10.2.2 Replacing the steering
servo assembly".
2: Secure the steering servo gears.
3: Remove the nut that holds the gear on the rotor shaft. Discard the nut.
4: Remove the gear, using a puller if necessary. Make sure the key remains
in its groove.
×n 5:
6:
Adjust and press the new gear onto the shaft
Fit the washer in place and use a new locking nut to screw on the gear.
Torque tighten the nut to 33 Nm and punch mark the nut.
s mm
7: Reinstall the steering servo. See section "10.2.2 Replacing the steering
Step 6, s:19 mm, servo assembly".
n: 1, T: 33 Nm.
© TMHE 10 – 7 T Code(s): 887, 888

10.3 Drive motor - C1760
10.3.1 General
The drive motor is a brushless, short-circuited, three-phase asynchronous
motor.
The motor has the following for monitoring:
• a thermoelement that measures motor temperature
• a sensor that measures direction of rotation and speed
10.3.2 Tightening torque - Drive motor

The drive motor tightening torques are depicted in the figure below:
11Nm 11Nm
5 mm 5 mm
13 mm
23 Nm
T45
© TMHE 10 – 8 T Code(s): 887, 888

10.3.3 Component overview – Drive motor
e
a
d
b
Pos. Description
a N-shield
b Stator
c D-shield (drive side)
d Rotor
e Speed sensor
f Toothed wheel for speed sensor
g Cable connection for temperature sensor
© TMHE 10 – 9 T Code(s): 887, 888

10.3.4 Removing the drive motor
Step 5 Step 6
Step 7 Steps 8, 9 and 10
© TMHE 10 – 10 T Code(s): 887, 888

Method
1. Switch off the truck and pull out the battery connector
2. Remove the hood over the motor compartment
3. Thoroughly clean the area round the drive motor.
4. Mark or note the position of the drive motor to ensure the motor wiring
harness is correctly positioned during reinstallation.
5. Disconnect the drive motor power cables (make a note of the
connections) and place them so that they are not in the way when the
motor is later lifted.
6. Disconnect the connectors for the motor temperature and rotational
speed sensors
7. Remove the brake. See section "12.2.2 Removing/fitting the parking
brake".
8. Unscrew the four screws holding the motor shield against the motor plate
9. Carefully lift the motor out of the truck and place it on a clean surface.
Note:
Be careful of the gear on the motor output shaft.
10. Clean the contacting surfaces at the motor plate and cover the opening in
the transmission with appropriate material, such as plastic or a piece of
carton, to prevent loose objects from falling into the transmission.
The necessary service and repairs can now be carried out on the motor.
© TMHE 10 – 11 T Code(s): 887, 888

10.3.5 Fitting the drive motor
Step 2 Step 3
Step 1
Step 4 Step 7
Step 8
© TMHE 10 – 12 T Code(s): 887, 888

Method
1. Fit a new, lubricated, O-ring on the sealing flange of the drive shaft before
reinstalling the drive motor
2. Taking care not to damage sealings and gears, lift the motor into place in
the truck and make sure it is correctly positioned so that motor cables can
be connected.
×n 3. Turn the motor shaft if its output shaft does not fit into the drive gear input
shaft.
s
4. Tighten the four screws holding the motor shield in place against the
Step 4, s: Torx no. T45, motor plate to a torque of 23 Nm
n: 4, T: 23 Nm.
5. Refit the brake and connect the brake electronically. See section
"12.2.2 Removing/fitting the parking brake".
×n 6. Connect the motor cables, 15 Nm. Verify that the polarity is correct
7. Refit and connect the connectors/cable fasteners for the motor
s mm temperature and rotational speed sensors.
8. Fit the motor hood and connect the battery
Step 6, s: 13 mm,
n: 1, T: 15 Nm. 9. Test drive the truck and check that the brake works correctly
© TMHE 10 – 13 T Code(s): 887, 888

10.3.6 Replacing the temperature sensor

It is not possible to replace the motor's internal temperature sensor. If a fault
occurs with the temperature sensor the internal sensor is replaced by an
external sensor.
1: Clean the surface where the new temperature sensor will be mounted.
2: Position the temperature sensor as shown in the illustration:
3: Apply plastic steel over the sensor. The entire sensor must be covered.
4: Affix the steel plastic and the sensor with masking tape and allow to set.
5: Remove the masking tape.
The temperature sensor should now be firmly positioned and entirely covered
by the plastic steel.
© TMHE 10 – 14 T Code(s): 887, 888

10.3.7 Replacing the RPM sensor
Step 2 Step 3. Step 4.
Step 5 Step 6.
Method
2: Remove the screw and pull out the sensor.
3: Disconnect the sensor's cable connection.
4: Detach the sensor's cable connection from the motor.
×n 5: Check the new sensor's O-ring sealing, mount the sensor and torque
tighten to 11 Nm.
s mm 6: Refit and reconnect the sensor's cable connection.
Step 5, s: 5 mm, 7: Connect the truck battery, start the truck and check for proper function.
n: 1, T: 11 Nm.
© TMHE 10 – 15 T Code(s): 887, 888

10.3.8 Replacing the speed sensor toothed wheel
Step 4. Step 5.
Step 3.
Method
1: Remove the drive motor. See section "10.3.4 Removing the drive motor".
2: Remove the rotational speed sensor. See section "10.3.7 Replacing the
RPM sensor".
3: Remove the circlip at the gear.
4: Remove the gear. If needed, use a puller and save the key.
5: Use a puller to remove the speed sensor toothed wheel from the rotor
shaft.
6: Replace the toothed wheel
7: Install in reverse order.
© TMHE 10 – 16 T Code(s): 887, 888

10.3.9 Disassembly
Step 2 Step 3
Step 4 Step 5.
Step 6. Step 6. Useful Hints
© TMHE 10 – 17 T Code(s): 887, 888

Step 7. Step 8.
Step 9 Step 10
Step 11.
© TMHE 10 – 18 T Code(s): 887, 888

Method
1: Remove the drive motor. See section "10.3.4 Removing the drive motor".
2: Mark, using a centre punch or similar, how the N-shield, stator and D-
shield are located in relation to each other.
3: Disconnect the cable connection of the temperature sensor and speed
sensor and remove the speed sensor.
4: Unscrew the terminal block for the power cables from the flat iron.
5: Remove the screws that hold the N-shield, stator and D-shield together.
6: Lift away the N-shield and the armature out of the stator.
Hint: If the shield does not release from the stator, you can carefully tap it
with a plastic mallet so that a gap is opened between the shield and
stator. In the gap you can insert a screwdriver and then carefully tap with
a rubber mallet on the opposite side of the shield until the units part.
7: Remove the circlips at the gear.
8: Extract the gear (c), using a puller if necessary – save the key
9: Use a puller to remove the speed sensor toothed wheel from the rotor
shaft
10: Remove the circlip that locks the rotor and N-shield together.
11: Pull the N-shield from the rotor with an extractor.
10.3.10 Cleaning
To assure proper truck operation, it is important to keep the motor clean.
Make sure the motor and motor compartment are free from dust and other
contaminants.
If the motor windings and internal compartments are dry, use a vacuum
cleaner with a suitable nozzle to clean the motor.
The use of water or other liquids is not recommended as these may damage
the insulation and cause stray currents.
Use of compressed air to clean motors is not recommended as the
compressed air presses dirt into the bearings and thereby shortens the
service life of the motors.
© TMHE 10 – 19 T Code(s): 887, 888

10.3.11 Replacing the upper bearing
Step 1. Step 2.
Step 3. Step 4.
Method
1: Remove the circlip that locks the bearing in the N-shield.
2: Press out the bearing from the shield, it may be necessary to use a brass
mandrel.
3: Fit the new bearing and press it down past the circlip groove; it may be
necessary to use a brass mandrel.
4: Fit the circlip and check that it locks properly in the groove.
© TMHE 10 – 20 T Code(s): 887, 888

10.3.12 Replacing the lower bearing
a
b
Removal method
1. Remove the drive motor from the truck. See section "10.3.4 Removing
the drive motor".
2. Open the lock washer (a).
3. Unscrew the hook nut (b) and remove the lock washer (a). The lock
washer must be discarded
4. Extract the motor gear (c), using a puller if necessary – save the key (d)
5. Use a puller to detach the hub (e) from the rotor shaft
6. Remove the circlip (f)
7. Tap the bearing (g) loose
8. Remove the sealing (h) and O-ring (j)
Installation method
1. Fit a new, lubricated sealing (h) in the hub (e)
2. Press in the bearing (g) and lock it in the hub with the circlip (f)
3. Press the now complete hub (k) onto the rotor shaft
4. Fit the key (d) in its groove and fit in the motor gear (c)
5. Position a new lock washer (a) and tighten the hook nut (b)
6. Lock the nut using a lock washer
7. Fit a new, lubricated O-ring (j) into the hub groove
© TMHE 10 – 21 T Code(s): 887, 888

10.3.13 Assembly
Step 1 Step 2. Step 3. Step 4.
Step 5. Step 6. Step 7.
Step 11.
Steps 8, 9 and 10
© TMHE 10 – 22 T Code(s): 887, 888

Method
1: Press the N-shield onto the rotor shaft so far that the groove for the circlip
is free.
2: Position the circlip and check that it locks properly.
3: Lift down the N-shield/rotor into the stator and be careful so that the N-
shield locates in towards the centre punch.
4: Fit the power cable attachment plate between the N-shield and D-shield
×n 5: Screw together the N-shield, stator and D-shield, align the parts with the
centre punch; tightening torque 11 Nm.
s mm
Step 5, s: 5 mm,
n: 4, T: 11 Nm.
6: Fit the power cable terminal to the

×n bracket, torque to 3.5 Nm.
7: Press the speed sensor toothed wheel onto the clamping sleeve.
s mm
8: Secure the gear by fitting the lower circlip in its groove on the rotor shaft.
Step 6, s: 4 mm,
n: 2, T: 3.5 Nm. 9: Fit the key and press on the gear
10: Fit the circlip that locks the gear in place
×n 11: Check the new sensor's O-ring sealing, mount the sensor and torque
tighten to 11 Nm.
s mm 12: Reinstall the drive motor. See section "10.3.5 Fitting the drive motor".
Step 11, s: 5 mm,
n: 1, T: 11 Nm.
© TMHE 10 – 23 T Code(s): 887, 888

© TMHE 10 – 24 T Code(s): 887, 888

11. Drive gear - C2000

11.1 General
The drive gear is interconnected with the motor and brake assembly in a
complete drive unit. The drive gear is fitted to the chassis using 6 bolts. The
steering bearings and a gear ring for the steering motor are fitted in the top
edge of the gear.
These service instructions cover descriptions of service performed on site at
the customer. A complete reconditioning of the drive gear must be performed
in the workshop by trained technicians.
© TMHE 11 – 1 T Code(s): 887, 888

11.2 Component overview – drive gear

b
a c
t
d
e
f
k
r g
s
q h j
m
n
o
Pos. Description Note
a Motor gear wheel Belongs to drive motor – 1760
Tightening torque 130 Nm
b Locking nut
Lock with centre punch
c Primary gear wheel
Tapered roller
d
bearing
e Shim
f Shim
Tapered roller
g
bearing
Tapered roller
h
bearing
j Locking nut
Lock with centre punch
k Cover
m Screw
Secure with Loctite 243
n Shim
o Pinion/crown wheel
p Drive shaft
q Wheel bolt
Secure with Loctite 270
© TMHE 11 – 2 T Code(s): 887, 888


Fill the sealing ring with grease
r Jointing ring
Seal using Loctite 574
Tapered roller
s
bearing
t Locking nut Belongs to drive motor – 1760
11.3 Service and repairs with the drive gear in the truck
Normal service activities include changing the oil and checking for leakage.
Activities that can be carried out with the drive gear in position:
• Oil change
• Replacing the lower cover seal, O-ring
• Replacing stud bolts.
For other activities, the transmission must be removed from the truck.
© TMHE 11 – 3 T Code(s): 887, 888

11.3.1 Checking and changing the oil
Method
To access the drive gear, remove the chassis front plate at the motor
compartment.
Checking/refilling oil
1. Remove the oil filler plug (a) on the upper part of the gear housing.
Discard the gasket (b).
2. Top up with oil up to the lower edge of the opening to reach the correct
level, approx. 1.8 litres. See section "22.3 Oil and grease specification".
3. Fit a new gasket and screw in the plug.
Oil change
1. Drain the old oil by removing the lower cover (c). Discard the gasket (d).
2. Fit a new O-ring in the groove of the cover.
3. Spread a thin layer of oil on the O-ring and fasten the cover
×n 4. Apply Loctite 243® to the screw threads and torque tighten to 25 Nm
5. Fill the drive gear with oil through the oil filler plug. See instructions
s mm above.
Step 4, s: 6 mm, Leakage from the lower cover
n: 6, T: 25 Nm.
If there is any leakage from the lower cover, change the oil and replace the O-
ring as described above.
© TMHE 11 – 4 T Code(s): 887, 888

11.3.2 Replacing studs
Method
The drive wheel is fixed to the hub with 5 M14 studs, conical washers and
nuts.
1. Remove the chassis front plate at the motor compartment.
2. Hoist the truck using a pneumatic jack and put it on blocks.
3. Unscrew the nuts and remove the drive wheel.
4. Remove the damaged studs.
Use a stud tool to remove any studs with damaged threads.
For broken studs, there are two methods:

Method 1: Drill a hole in the centre of the stud and remove it using a bolt
extractor for M14 bolts
Method 2: If the stud will not come loose with a bolt extractor, it will have
to be drilled out
– Mark the centre of the stud with a punch as close to the centre of the
bolt as possible
– Drill a pilot hole through the stud using a 5 mm bit
– Drill out the stud using an 11.5 mm bit
– Try to remove the stud remains using pliers, etc. If that does not work,
remove the remains by clearing the threads with an M14x1.5 tap.
5. Apply Loctite® 270 to the stud thread.

6. Use the stud tool to fit the new stud and tighten to 90 Nm.
7. Fit the drive wheel and torque tighten the nuts crosswise
8. Remove the blocks and lower the truck
9. Refit the chassis front plate
© TMHE 11 – 5 T Code(s): 887, 888

11.4 Repairs with transmission removed

The following procedures can be done out in the field but require the drive
gear to be removed from the truck:
• Replacing the steering bearing See section "13.5.1 Replacing the steering
bearing".
• Replacing the drive shaft seal
• Sealing the upper cover
• Replacing the primary gear
11.4.1 Removing/fitting the drive gear

To work on the transmission, it must be lifted out of the truck. Before doing
this, the drive unit, motor and drive gear must be separated while they are still
in the truck. Next, disconnect the drive gear
a
b
c
Removal method
1. Disconnect the battery. Remove the motor cover.
2. Remove the chassis front plate at the motor compartment
3. Use a jack to raise the truck until the wheel lifts from the floor
4. Secure the truck on blocks
5. Unscrew the drive wheel
6. Drain the oil from the transmission
© TMHE 11 – 6 T Code(s): 887, 888

7. Remove the drive motor. See section "10.3.4 Removing the drive motor".
8. Support the transmission so it cannot fall
9. Loosen and remove the screws (a) holding the drive gear in the chassis.
10. Lower the transmission and lift it out of the truck
You can now carry out the intended work on the transmission.
Installation method
×n 11. Lift the drive gear into position in the chassis and secure it with six
screws, 23 Nm. If the steering bearing has been replaced, it must be
adjusted so that the screw holes in the steering bearing align directly
s mm under the screw holes in the motor bracket.
Step 11, s: 6 mm, 12. Fit a new O-ring on the drive motor bearing holder.
n: 6, T: 23 Nm. 13. Install the drive motor. See section "10.3.4 Removing the drive motor".
14. Fill the drive gear with oil if this has not already been done, approx. 1.8
litres. See section "22.3 Oil and grease specification".
15. Lower the truck and refit the chassis front plate.
16. Check brake function.
17. Test Drive the Truck
.
© TMHE 11 – 7 T Code(s): 887, 888

11.4.2 Replacing the drive shaft seal

Removing the drive shaft
d
h f
j c b
i a
g
Method
1. Remove the drive gear from the truck. See section "11.4.1 Removing/
fitting the drive gear".
2. Remove the lower cover (a).
3. Loosen the drive gear nut (b).
4. Remove the nut (b) and washer (c). Discard the nut.
5. Press out the drive shaft (e).
6. Pull off the bearing (f) from the drive shaft using a bearing puller.
7. Check that the shims (g) are not damaged.
If they have been damaged by the puller, measure the combined
thickness of the spacer washers and use new washers with the same
combined thickness when assembling
8. Remove the sealing ring (h) from the drive shaft.
Installing the drive shaft

Method
1: Position the outer bearing (f) in the drive gear housing (i).
2: Fit shims, with the same thickness as the original shims, on the bearing.
3: Apply a thin coat of oil on the outer side of the new sealing. Press it into
its seat in the drive gear housing (i).
When pressing the sealing into place, use care to make sure it is correctly
positioned.
4: Align the drive shaft splines (j) with the crown wheel splines
© TMHE 11 – 8 T Code(s): 887, 888

5: Press the drive shaft (e) into the gear.

6: Oil and screw on a new shaft nut and washer (b, c). Torque tighten to 400
Nm and lock using a centre punch.
×n 7: Fit a new O-ring (d) in the groove of the cover and apply a thin layer of oil
on it
s mm
8: Apply Loctite® 243 to the cover screws, screw on the cover (a) and
torque tighten the screws to 25 Nm.
Step 6, s: 46 mm,
n: 1, T: 400 Nm. 9: Apply a thin layer of grease to the drive wheel screws.
×n 10: Fit the drive wheel and torque tighten crosswise.
11: Fill the drive gear with oil up to the lower edge of the oil plug, approx. 1.8
s mm litres. See section "22.3 Oil and grease specification".
Step 8, s: 6 mm, 12: Reinstall the drive gear and motor in the truck. See section
n: 6, T: 25 Nm. "11.4.1 Removing/fitting the drive gear".
11.4.3 Sealing the upper cover

Method
2. Loosen all 10 screws holding the upper cover to the drive gear housing
and remove the cover.
3. Carefully clean the sealing surfaces of the cover and gear housing.
4. Apply Loctite® 574 to the surfaces.

5. Apply Loctite® 243 to the cover screws, screw on the cover and torque
tighten to 25 Nm.
6. Apply a thin layer of grease to the drive wheel screws.
×n 7. Screw the drive wheel into place and torque tighten the nuts crosswise
8. Fill with oil up to the lower edge of the oil plug, approx. 1.8 litres. See
s mm section "22.3 Oil and grease specification".
Step 5, s: 6 mm, 9. Reinstall the drive gear and motor in the truck.See section
n: 10, T: 25 Nm. "11.4.1 Removing/fitting the drive gear".
© TMHE 11 – 9 T Code(s): 887, 888

11.4.4 Replacing the primary gear
b
a c
d

Described together with drive motor
a Pinion gear
(1760)
b Gear wheel
c Collar nut 130 Nm + centre punch
d Washer
Method
2. Remove the steering bearing. See section "13.5.1 Replacing the steering
bearing".
3. Remove the upper cover (gear ring) from the drive gear housing. The
screws are accessible from the underside of the housing.
4. Unscrew nut (c) and discard it.
5. Remove washer (d) and pull off the gear wheel (b) using a puller.
6. Press a new gear wheel onto the shaft.
© TMHE 11 – 10 T Code(s): 887, 888

7. Fit the washer (d).

8. Fasten a new nut (c), applying a torque of 130 Nm.
×n 9. Lock the nut using a centre punch.

10. Replace the gear (a) according to the instructions for work on the drive
s mm motor (1760). See section "10.3.4 Removing the drive motor".
11. Carefully clean the sealing surfaces of the cover and gear housing.
Step 8, s: 30 mm,
n: 1, T: 130 Nm. 12. Apply Loctite® 574 to the surfaces.
13. Apply Loctite® 243 to the cover screws, screw on the cover and torque
tighten to 25 Nm.
14. Fill with oil up to the lower edge of the oil plug, approx. 1.8 litres. See
×n section "22.3 Oil and grease specification".
15. Reinstall the drive gear and motor in the truck.See section
"11.4.1 Removing/fitting the drive gear".
s mm
16.
Step 13, s: 6 mm,
n: 10, T: 25 Nm.
© TMHE 11 – 11 T Code(s): 887, 888

© TMHE 11 – 12 T Code(s): 887, 888

12. Brake system/Wheels C3000

12.1 General
The brake [Q1] is a single stage electromechanical spring-loaded brake that
is released when the magnetic coil is energised. This brake serves as a
parking brake and emergency brake.
12.2 Parking brake - C3370

DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function being
partly or completely lost.
Only the actions described in this section may be carried out on the parking
brake.
12.2.1 Checking the parking brake air gap

If the brake has an air gap that cannot be adjusted, the rotating friction disc
must be replaced with a new one before the maximum air gap is exceeded.
Method
1: Check that the parking brake is applied.
2: Use a feeler gauge to check that the spacing between the brake unit
magnet housing and the movable pressure disc does not exceed 0.45
mm or fall below 0.2 mm at any place.
3: If the air gap is not within the permitted values, the brake must be
cleaned or the friction disc replaced. See section "12.2.3 Cleaning the
parking brake".
© TMHE 12 – 1 T Code(s): 887, 888

12.2.2 Removing/fitting the parking brake
Step 3 Steps 4 and 5 Step 6 Step 7
Steps 10 and
Steps 8 and 9 Step 12
© TMHE 12 – 2 T Code(s): 887, 888

Method
DANGER!
When the load is relieved from the parking brake friction disc or if the brake is
released mechanically and removed from the truck, the truck may move
unintentionally.
1. Disconnect the battery and open the motor compartment
2. Ensure that the truck cannot begin moving
3. Relieve the load on the parking brake movable pressure disc with two
screws M5×40
4. Disconnect the brake unit electrically.
5. Undo the brake's 3 retaining screws.
Note:
As the brake is now separated, take care to ensure that spacers between the
pressure discs do not fall away.
6. Remove the brake unit from the truck by taking hold of both the magnet
housing and the lower pressure disc. Note the position of the brake so
that refitting is done correctly.
7: If the brake unit is to be replaced together with the gear:
Remove the circlip in the end of the motor shaft and remove the gear.
The brake is now accessible for repair or cleaning
8. If the gear has been removed, fit it with a grooved key on the motor shaft
during reinstallation and fit the circlip in the end of the motor shaft.
×n 9. Reinstall the brake as noted so that the electrical connection of the brake
is correctly positioned.
10. Plug in the connector unit.
s mm 11. Torque tighten the brake retaining screws to 10.1 ±1.0 Nm.
Step 11, s: 4 mm, 12: Remove the transport screws from the new brake or the reinstalled
n: 3, T: 12 Nm. brake.
DANGER!
The sleeved screws must be removed in order to engage the parking brake.
Note:
Check that the dust guard is in place over the brake hub and that it is
correctly installed.
DANGER!
Be careful when test driving after performing operations on the truck parking
brake.
14: Start the truck and check that the brake works correctly.
© TMHE 12 – 3 T Code(s): 887, 888

12.2.3 Cleaning the parking brake

1: Disconnect the battery and open the motor compartment
2: Remove the parking brake. See section "12.2.2 Removing/fitting the
parking brake".
3. Place the parking brake on a workbench with the magnet housing facing
downwards.
4. Lift away the pressure disc and the three spacers.
5. Remove the friction disc and replace it if necessary.
6. Clean the brake using compressed air. Clean from the inside outwards.
7. If there are particles that cannot be cleared away with compressed air,
these may be carefully scraped away.
8. Place the friction disc on the revolving pressure disk.
9. Position the three spacers and position the fixed pressure disc about the
friction disc with the mounting screw holes positioned correctly.
10. Check that the friction disc is centred in relation to the magnet housing.
11. Reinstall the parking brake. See section "12.2.2 Removing/fitting the
parking brake".
Note:
It is extremely important that an air gap of min. 0.2 mm is maintained all
around the brake. If the prescribed measurement cannot be maintained, the
brake must be replaced
12: Repeat the cleaning as necessary until a 0.2 mm feeler gauge can be
inserted. Measure the air gap between the magnet housing of the brake
unit and the movable pressure disc. Measuring must be done around the
entire pressure disc, both on the inside and the outside.
12.2.4 Releasing the parking brake

Note:
The brakes should only be released when the truck needs to be moved in
connection with service and repair work.
If it is necessary to release the truck brake manually:
1: Disconnect the battery and open the motor compartment
2: To release the brake, gradually screw in the two transport screws
(M5×40) evenly.
4: Move the truck with great caution.
5: Disconnect the battery.
DANGER!
6: Unscrew the two sleeved screws gradually.
7: Connect the battery and check that the parking brake engages.
© TMHE 12 – 4 T Code(s): 887, 888

12.3 Drive wheel - C3530
12.3.1 Component overview
b c

a Drive wheel/Vulkollan
b Washer 5 pcs
c Nut 5 pcs
12.3.2 Replacing the drive wheel

Method
DANGER!
Risk of crushing since a poorly supported truck could fall down.
1. Disconnect the battery connector.
2. Lift up the truck and support it with trestles.
3. Remove the chassis front plate by the drive wheel
4. Turn the drive wheel so that the nuts are facing you.
5. Undo the 5 nuts, and remove them along with the washers.
6. Pull out the wheel. If the drive wheel is stuck, use a hammer or similar to
tap it free.
Installing the drive wheel on the truck
1. Fit the drive wheel.
2. Fasten the nuts and washers.
3. Tighten the nuts diagonally.
4. Remove the trestles and lower the truck to the ground.
5. Install the front plate
© TMHE 12 – 5 T Code(s): 887, 888

12.4 Castor wheel – C3540

The truck has an adjustable castor wheel assembly. It is easily accessible
once the front cover of the chassis has been removed.
12.4.1 Component overview - Castor wheel
j i
k
l
m
n
a b
c
f
p
d
q g e
r
h
Pos. Description Pos. Description

a Top plate j Spring washer
Locking screw for height
b k Guard
adjustment
c Screw for height adjustment l Spacer
d Link arm m Wheel bearing
e Spacing sleeve n Castor wheels
f Wheel fork o Wheel bolt
g Wheel bolt p Linkage bearing
h Spacing bolt q Serrated washer
i Nut r Nut
© TMHE 12 – 6 T Code(s): 887, 888

12.4.2 Castor wheel maintenance and inspection

Castor wheel height adjustment is of the utmost importance for the drive
wheel pressure and the truck's braking ability. Because of drive wheel wear,
the castor wheel height must therefore be adjusted regularly at intervals of
500 operating hours. See section "12.4.3 Adjusting castor wheel height".
The bearings in the castor wheel assembly are sealed and lubricated from
the factory.
Check
1. Park on the truck on a level surface.
2. Remove the motor cover and its two brackets.
3. Place a spirit level on the motor plate in the motor compartment and
check that it is level.
12.4.3 Adjusting castor wheel height

To obtain the correct pressure on the drive wheel, the castor wheel must be
adjusted so that the truck’s motor plate is level.
Adjustment of the castor wheel must be done:
• Every time the castor wheel/drive wheel is replaced
• When a maintenance inspection shows that the truck is not level.
Step 5
Steps 3 and 4
Adjustment
1. Carry out a check. See section "12.4.2 Castor wheel maintenance and
inspection".
2. Remove the front cover of the chassis to gain access to the castor wheel
assembly.
3. Turn the castor wheel to gain access to the locking screw.
4. Remove the locking screw to release the adjuster screw.
5. Turn the adjuster screw until the truck is level.
6. Lock the adjuster screw with the locking screw.
© TMHE 12 – 7 T Code(s): 887, 888

12.4.4 Replacing the castor wheel

In order to replace castor wheel assembly components, the chassis front
plate must be removed and the truck lifted and securely supported on
trestles.
Work with the castor wheel is most easily done with the complete castor
wheel assembly removed from the chassis. This is done by removing the four
retaining screws from the castor wheel assembly.
Step 1 Step 3 Steps 5 and

6
Method for replacing the complete wheel
1. Remove the nut from the wheel axle and remove the spring washer.
Scrap the spring washer. Tap out the shaft.
2. Remove the wheel together with the guards, spacers and bearings.
3. Replace the guard if necessary. Fit the new wheel with bearings, spacers
and guard in the wheel fork.
4. Press the wheel axle through the fork and wheel.
5. Fit a new spring washer to the wheel axle.
6. Screw on and tighten the wheel axle locking nut. 30–45 Nm.
Note:
Always check that the wheel can spin by hand.
© TMHE 12 – 8 T Code(s): 887, 888

Method for replacing the wheel bearing

1. Remove the wheel as described above.
2. Press out the wheel bearing’s spacer sleeve and tap out the bearing race
on the one side.
3. Turn the wheel over and tap out the second bearing race.
4. Press new bearings into place.
5. Place the spacer sleeves in the bearings.
6. Grease the bearings.
7. Fit the wheel with bearings, spacers and guard in the wheel fork.
8. Press the wheel axle through the fork and wheel.
9. Fit a new spring washer to the wheel axle.
10. Screw on and tighten the wheel axle locking nut. 30–45 Nm.
Note:
Always check that the wheel can spin by hand.
© TMHE 12 – 9 T Code(s): 887, 888

12.5 Fork wheels – C3550
Max. 0,5mm
12.5.1 Removing/fitting for wheel OSE250, OSE250P (bogie)

1. Lift and support the side of the truck where the work is to be done.
2. Rotate the bogie so that the screw heads are easily accessible and
unscrew the two screws (b)
3. The links can be removed after the wheels have been removed
4. Bushes can be tapped out using a suitable drift.
The required work can now be carried out. Replace the wheels or clean them.
Before assembly, clean all reused parts from dirt and old grease.
5. Press the bushes into the wheel fork
6. Press in the links
Note:
The wheels must be centred with max. play 0.5 mm
×n 7. Position the wheels and washers (a) and fasten the wheels with the
screws (b). Tightening torque 60 Nm. Grease the screws according to the
instructions for normal maintenance of the truck
s mm
Step 8, s: 8 mm, n: 2,
T: 60 + 30 Nm.
© TMHE 12 – 10 T Code(s): 887, 888

12.6 Wheel wear
Normal Minimum
Type mm
dimensions, mm (H) dimensions, mm
Drive wheel D = 250 30 15
Castor wheel D = 152 10 5
Support arm wheel D =
10 5
85
© TMHE 12 – 11 T Code(s): 887, 888

© TMHE 12 – 12 T Code(s): 887, 888

13. Steering system - C4000

13.1 General
The electric steering system consists of the steering unit and steering servo.
A potentiometer in the steering unit sends information to the electronic
module in the steering servo system. When the truck is started, a reference
run is conducted to check the steering and update the actual steering angle.
© TMHE 13 – 1 T Code(s): 887, 888

13.2 Component overview

c b
a
a Screw
Electronic
b
module
a
c Gasket
d Motor
e Pinion gear
d
f Washer
g Nut
e
Secures the drive gear in the motor
h Screw
f plate
g i Screw Secures the steering to the gear ring
h
j Steering
k Nilos ring
Steering
l
bearings
m Gear ring
i
j
k
m
l
© TMHE 13 – 2 T Code(s): 887, 888

13.3 Steering unit - C4110
13.3.1 Calibration
The calibration function is used for calibration of the steering servo (steering
angle potentiometer [R2]). Calibration sets the centre position of steering
(straight ahead). The CAN service key must be connected in order to perform
calibration.
The following situations may require this calibration to be done.
• When the steering angle potentiometer [R2] has been disconnected or
replaced.
• The truck does not steer straight ahead when the steering unit points
straight ahead. May also require adjustment of parameter 1253.
• Display of error code 5.581 or 5.586.
Additional instructions are found in chapter See section "5.3.1 Steering servo
calibration"..
© TMHE 13 – 3 T Code(s): 887, 888

13.3.2 Disassembling/assembling the steering unit handle
Step 2
Step 3
Step 4 Step 5
Step 6
© TMHE 13 – 4 T Code(s): 887, 888

Warning!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure you take the necessary steps to prevent static electricity, ESD
protection, before starting work on the steering module.
Disassembly
2: Detach the keypad and disconnect it from the logic card
3: Remove the screws holding the upper cover and keep hold of the upper
cover to prevent damage to the logic card cable
4: Disconnect the CAN connection to the logic card
5: Remove the screws holding the cover over the logic card and carefully lift
away the cover.
Hint: Hold a finger between the cover and the shaft for the speed control
buttons to prevent the speed control assembly from falling down.
6: Lift off the speed control assembly
7: If the logic card is to be replaced, disconnect its connectors and lift out
the logic card.
© TMHE 13 – 5 T Code(s): 887, 888

Assembly
1: Fit the new logic card in place and connect it.
2: Check the cable connection on the logic card and that the connectors are
correctly connected.
3: Fit the speed control assembly in position. Hook the ends of the spring
around two the lugs in the cover
4: Fit the cover in place and screw it down. Make sure the conduit entry is
intact and correctly positioned.
5: Check that the conduit entry is also correctly positioned in the cover.
6: Connect the CAN bus connection to the logic card
© TMHE 13 – 6 T Code(s): 887, 888

7: Press together the upper and the lower parts, and turn the screws five
complete turns. Start with the left side, and then proceed with the right
side.
x5
8. Turn the screws crosswise as depicted below a further four complete

turns (a total of nine turns, which corresponds to 1 Nm).
2 3
x4
4 1
© TMHE 13 – 7 T Code(s): 887, 888

9. Check that there is no space between the tiller arm and the steering
head.
10: Make sure that the control can be moved back and forth without difficulty,
and that the control returns to the neutral position.
If the control shows signs of being difficult to move: Re-adjust the screws
according to step 8.
11: Connect the keypad and screw it in position
12: Connect the truck battery

13: Test drive the truck and check the handle functions. If a new logic card
without software has been installed, use TruckCom to download
software and reset the parameters.
See the TruckCom manual.
© TMHE 13 – 8 T Code(s): 887, 888

13.3.3 Disassembly/Assembly Replacing the potentiometer [R2]

1. Remove the rear cover (A) where the emergency switch off is located.
2. Unseat the connector device (B) from the emergency switch off by
depressing the locking device on the connector device.
3. Unplug the connector (C) and pull the entire cable assembly bracket
straight up.
© TMHE 13 – 9 T Code(s): 887, 888

4. Remove the articulated arm covers (D, E) and the keypad.
D E
5. Remove the upper part of the tiller arm handle. See section
"13.3.7 Replacing buttons in the tiller arm handle".
6. Cut away the two cable ties holding the cable.
Note:
Make a note of how the old cable ties are attached as it is important to fit the
new cable ties in exactly the same position.
© TMHE 13 – 10 T Code(s): 887, 888

7. Undo the cable clamp and lift the potentiometer and its wiring harness
straight up.
8. Align the shaft of the new potentiometer so that the recess engages in the
driver down in the hub (X).
9. Screw in the cable clamp.
10. Fasten the cable with two cable ties in exactly the same places as the old
ones.
11. Connect the cable in the tiller arm handle’s electronic card “A2”.
12. Screw in the upper part of the tiller arm handle.
13. Screw in the keypad and articulated arm covers.
14. Reinstall the cable assembly bracket and plug in the connector.
15. Fit the emergency stop switch connector device.
16. Fit the rear cover.
17. Calibrate steering. Additional instructions are found in chapter See
section "5.3.1 Steering servo calibration"..
18. Check the operation of the emergency stop function.
19. Test drive the truck.
© TMHE 13 – 11 T Code(s): 887, 888

13.3.4 Replacing the inductive brake sensor [S10]

1. Remove the articulated arm covers (D, E) and the keypad.
D E
2. Remove the upper part. See section "13.3.7 Replacing buttons in the
tiller arm handle".
3. Cut away the cable ties.
Note:
Make a note of how the old cable ties are attached as it is important to fit the
new cable ties in exactly the same position.
© TMHE 13 – 12 T Code(s): 887, 888

4. Unplug the connector (a)
5. Loosen the screw holding the sensor in position.
6. Lift the sensor straight up to free the guide

pin at the rear of the sensor (B).
7. Fit the new sensor in position taking care to
align the guide pin before fastening the
sensor.
© TMHE 13 – 13 T Code(s): 887, 888

8. Secure the sensor unit, torque 1.5 Nm. The distance between the sensor
and the sensor plate must be 25 - 30 mm.
Note:
Be sure to apply Loctite 243 on the threads before fitting.
9. Secure the cables with cable ties in exactly the same places as the old
ones.
10. Connect the electronic card's [A2] cable in the upper part of the tiller arm.
11. Screw in the upper part.
12. Connect the keypad and screw it in position
13. Secure the articulated arm covers.
14. Start the truck and use the built-in test function, “Electrical system 5000”,
to check that the sensor is working correctly – segment 1:G.
15. Test drive the truck and check that the brake works correctly.
© TMHE 13 – 14 T Code(s): 887, 888

13.3.5 Replacing the damper

1. Remove the articulated arm covers.
2. Remove the cable clamp (a) and the four screws (b) that hold the steering
head.
© TMHE 13 – 15 T Code(s): 887, 888

3. Carefully lower the steering head, loosen the screws (a) that hold the ring
and lift away the ring without damaging the cables.
a=T 2.8 Nm
apply Loctite 2400
4. Remove the screws (b) for the gas strut and the spacer.
5. Lift away the old gas strut and align the new one to the shaft’s gears.
6. Screw the gas strut in place.
7. Screw on the ring (a) T=2.8 Nm. The cables must not be damaged.
Note:
Be sure to apply Loctite 2400 on the threads (a) before fitting.
8. Screw in the four screws that hold the steering head and fasten the cable
clamp.
9. Reassemble the articulated arm covers.
© TMHE 13 – 16 T Code(s): 887, 888

13.3.6 Checking and replacing the lateral movement line (Ergo

version)
1. Loosen the front and rear covers.

The steel line is attached with a screw at each end.
2. Make sure the line is not damaged.
3. If the line is to be replaced, it must be slackened by releasing the line

tensioner (A). The screws must not be loosened more than that the line
tensioner can be moved sideways.
© TMHE 13 – 17 T Code(s): 887, 888

D B
C
4. Remove the screw at the emergency stop switch (C), where the line splits
into two.
5. Remove the front screw (B) and pull out the line.
D
Note:
During later assembly, it is important to use the same type of screw and
washer.
If the steering unit is exposed to exceptional lateral forces, the weakest link
in the design is the screw (D), which will break.
The truck can still be steered, however, the steering unit cannot be locked in
its fixed positions.
6. Thread in the new line and screw it in place with screw (B).
7. Turn the tiller arm so that screw (C) is aligned and screw it in.
8. Press, using a suitable tool against one of the line tensioner screws (A),
the line tensioner so that the line is tensioned.
Lock, at the same time, the line tensioner in position with the other screw
(A).
9. Finally, tighten the two screws (A).
10. Refit the two covers.
11. Test drive the truck and check that the tiller arm functions normally.
© TMHE 13 – 18 T Code(s): 887, 888

13.3.7 Replacing buttons in the tiller arm handle

The tiller arm handle must be disassembled when replacing buttons. See
section "13.3.3 Disassembly/Assembly Replacing the potentiometer [R2]".
Signal button/switch
1. Remove the button using a screwdriver as illustrated.
2. Remove the connection for the switch on the electronic card.

3. Press out the switch from its bracket.
4. Insert the new switch and connect the cable to the electronic card.
5. Align the button with the catch and secure it by hand.
Lift/lower button
1. Remove the button by placing a screwdriver in the holes (A).
A A
2. Unscrew the plate securing the arm and remove the arm.
3. Press the springs together and fit the button in place. Snap the button in
place by hand.
© TMHE 13 – 19 T Code(s): 887, 888

Push button
1. Position a screwdriver as illustrated and carefully pry out the button.
2. Compress the springs and pull out the button and arm.
3. Align the pivot pins of the new button with the corresponding holes in the
upper part of the tiller arm handle.
4. Snap in the other pivot pin and check that the button can be moved.
© TMHE 13 – 20 T Code(s): 887, 888

13.4 Reference sensor - C4350

General
These instructions apply to the replacement of the steering reference sensor
[S65] located on the drive gear housing, up against the drive motor.
13.4.1 Replacing steering reference sensor [S65]

The sensor does not need adjusting on replacement.
1: Remove the screw securing the old sensor.
2: Undo the connector unit for the sensor.
3: Fit the new sensor and screw it in tight.
1: Switch off the truck and disconnect the battery connector.
2: Unplug the steering angle reference sensor connector.
3: Remove the steering angle reference sensor screw.
4: Pull the sensor straight up.
×n 5: Position the new sensor, apply Loctite 243 to the screw thread and screw
it into place. Tightening torque 6 Nm.
s
6: Connect the connector.
Step 5: s = torx 45, n = 1
7: Connect the truck battery.
T = 6 Nm
8: Log in and check that the steering functions without problem.
© TMHE 13 – 21 T Code(s): 887, 888

13.5 Steering bearing - C4380

If the steering bearing must be replaced, the drive gear must be removed
following the instructions,See section "11.4.1 Removing/fitting the drive
gear".
13.5.1 Replacing the steering bearing

a
Method
2. Secure the drive gear assembly in a vice or similar.
3. Undo screws (a) and remove steering bearing guide (b).
4. Lift away the Nilos ring (c) and the steering bearing (d).
5. Wipe away grease and other dirt from the top of the gear ring and position
×n the new steering bearing (d) on the gear ring neck.
6. Fit the Nilos ring (c) and fasten the steering bearing with the guide (b) and
the screws (a). Torque tighten to 25 Nm
s mm
7. Check that the steering bearing’s outer ring can move freely.
Step 6: s = 6 mm, n = 6
8. Fit the drive gear back in the truck See section "11.4.1 Removing/fitting
T = 25 Nm the drive gear".
© TMHE 13 – 22 T Code(s): 887, 888

9. Test drive and check that the truck follows the movements of the steering
unit.
Recalibrate the steering servo if necessary. See section See section
"5.3.1 Steering servo calibration".
© TMHE 13 – 23 T Code(s): 887, 888

© TMHE 13 – 24 T Code(s): 887, 888

14. Electrical system - C5000

14.1 Battery - C5110
14.1.1 Replacing the battery

DANGER!
Risk of short-circuiting.
An incorrectly connected battery may cause short-circuiting.
The polarity must be correct. Compare the markings on the cables with those
on the battery terminals.
NOTE:
Make sure the battery’s minimum and maximum weights comply with those
on the truck type plate.
Check the electrolyte level in the battery. Normally, the level should be
around 10-15 mm above the cell plates.
Battery installation/replacement using a battery changing table.

1: Open the cover of the battery compartment.
2: Move the truck close to the battery changing table.
If the battery is not installed, do as follows:
–Connect a temporary cable between the truck and battery.
–Move the truck to the battery changing table.
–Disconnect the temporary cable.
3: Release the catch and roll the battery over to the battery changing table.
4: Move the truck close to the new battery.
5: Push the battery in place and lock the battery.
6: Connect the battery connector.
7: Reposition the cover over the battery compartment.
8: If the truck is not to be used straight away, you must check to ensure that
logout has taken place.
© TMHE 14 – 1 T Code(s): 887, 888

Battery installation/replacement using a lifting device

DANGER!
To prevent the battery from falling down when it is released from the lifting
device, prepare trestles or other suitable supports of the right height to
support it. Check the height of the supporting material before releasing the
lifting hook.
1. Open the cover of the battery compartment.
2. When removing, pull out the battery connector and release the catch
3. Lift the battery in/out using an approved lifting device and a suitable
battery lifting yoke or lifting straps.
4. Lift the battery so that it just goes free.
5. Move the battery sideways and place it down.
6. When installing, connect the battery cables/battery connector and lock
the battery.
DANGER!
Check that the polarity is correct when connecting the battery cables.
Compare the markings on the cables with those on the battery terminals. An
incorrectly connected battery may cause short-circuiting.
7. Close the battery compartment cover.
8. If the truck is not to be used straight away, you must check to ensure that
logout has taken place.
© TMHE 14 – 2 T Code(s): 887, 888

14.1.2 Charging the battery
DANGER!
Always wear safety goggles and protective gloves when checking the
battery!
DANGER!
When charging the battery it is absolutely forbidden to smoke or use a naked
flame.
DANGER!
The battery case contains corrosive acid. Spilled fluid on the skin must
immediately be removed. Wash with soap and plenty of water.
If the fluid was in contact with your eyes, they should immediately be washed
with eye wash and a doctor should be contacted.
DANGER!
Risk of explosion.
During the charging process oxygen and hydrogen gases are always formed
in the battery. A short-circuit, an open flame or a spark near the battery may
cause an explosion.
Always switch off the charging current BEFORE removing the battery
connector. Provide good ventilation, especially if the battery is charged in a
confined area.
Use an automatic battery charger intended for charging traction truck
batteries.
The charger shall have an automatic maintenance charging feature for a
certain period after the main charging period has been completed. This
eliminates the risk of overcharging the battery and the need to monitor the
charging procedure is reduced to a minimum.
The charger shall have a minimum charging current as indicated in the
following table:
Battery (Ah) Charger (A)
300 – 480 50 – 70
480 – 730 80 – 110
730 – 900 130 – 150
© TMHE 14 – 3 T Code(s): 887, 888

Before charging
1: Park the truck in the assigned charging area.

2: Switch off the truck.
3: Open the battery door and let it remain open during the whole charging
time. Ensure nothing hinders ventilation above the battery.
4: Separate the battery connectors.
5: Rinse off and dry the battery.

6: Make sure the battery charger is switched off.
7: Connect the battery charger to the battery charging socket.
8: Start the charger.
During charging
9: After a couple of minutes, check that the charger indicates the correct
charge; see the charger's manual.
After charging
10: Make sure that the ammeter indicates an insignificant or no reading and
that the maintenance charging lamp is on, if fitted.
11: Switch off the battery charger.
12: Disconnect the battery charger connector from the charging connector of
the battery.
DANGER!
Risk of short-circuiting.
The terminals can otherwise be damaged inside and result in a subsequent
short-circuit.
Do not pull the cables to disconnect from the charger.
13: Check the fluid level and top up with distilled water if necessary. The fluid
level should be around 10 - 15 mm above the cell plates.
For detailed instructions, please see the instructions provided by the battery
manufacturer.
14.1.3 Performance limitations due to battery status

When the truck battery is 80% discharged, truck capacity is limited and the
lifting capacity is disengaged
© TMHE 14 – 4 T Code(s): 887, 888

14.2 Li-ion battery (Hoppecke)
14.2.1 Resetting/restarting the battery

If error codes are generated or the battery lamp does not light with a steady
green glow, the battery can be restarted.
1: Disconnect the battery yoke

Note: the yoke must be removed from the battery.
2: Disconnect the CAN connector X111.

3: Wait until the light goes out.
4: Reconnect the CAN connector.
5: Wait until the light on the battery is shining with a steady green light
6: Connect the battery yoke.
14.3 Inspecting the battery

1: Check that a green lamp is lit on the battery. This indicates that
everything is OK.
2: Check the attachment of the brackets.
3: Check electrical connections on the CAN wiring harness.
4: Check the attachment of the battery lock.
5: Check that the covers have been refitted properly.
© TMHE 14 – 5 T Code(s): 887, 888

14.4 Contactor - C5190
14.4.1 Replacing the contactor [Q10]
Step 4
Steps 2 and 3
Step 5
Method
1: Disconnect the truck battery and open the motor compartment.
2: Disconnect the cables for contactor control. Note the connection so that
refitting is done correctly
3: Disconnect the power cables and copper bar. Note the connection so
that refitting is done correctly
4: Undo the insulating terminal screws and remove the insulating terminal.
The screws securing the contactor are now accessible.
5: Undo the screws and remove the contactor from the electric panel.
6: Screw the new contactor into the electric panel.
×n 7:
8:
Reinstall the insulating terminal.
Screw the fuse, copper bar and power cables into place and torque
tighten to 9 +2/-1 Nm.
s mm
9: Connect the cables of the contactor guide as noted.
Step 8: s = 13, n = 6 10: Connect the truck battery and close the motor compartment.
T = 9 +2/-1 Nm 11: Start the truck and check functionality.
© TMHE 14 – 6 T Code(s): 887, 888

14.5 ACT/ACC regulators - C5460
14.5.1 General
Drive/pump motor output control is done via transistor regulators, ACT or
ACC.
The regulators contain software for drive motor and pump motor output
control. They are configured for their function during programming with
TruckCom via the truck's CAN service socket.
The transistor regulators have dedicated internal monitoring of CAN
communication, DC voltage levels, their own temperature and motor
temperature.
Any errors are recorded via internal monitoring and are sent via the CAN to
ICH, where the error code is registered and subsequently displayed on the
display [A6].
The regulators have a green LED to indicate status:
• Start-up – LED flashes twice
• Normal operation – LED remains lit
• Error – LED flashes or is unlit.
Power is fed via two copper bars B+ and B-. B+ is secured with a fuse.
© TMHE 14 – 7 T Code(s): 887, 888

14.5.2 Replacing the transistor regulator

NOTE:
This action requires access to TruckCom!
Step 3
Step 2
Step 5
Step 4
Step 6
© TMHE 14 – 8 T Code(s): 887, 888

Method
1. Disconnect the battery.
2. Open the motor compartment.
3. Remove the contact from the contact holder.
• First press in the clamp catch.
• Then lift up the contact clamp.
4. Disconnect all cables and copper bars from the transistor regulator. Note
the marking/connector to ensure the new transistor regulator is installed/
connected correctly.
5. Unscrew the retaining screws of the transistor regulator.
6. Remove the transistor regulator by pulling it straight up.
DANGER!
Risk of material damage.
When installing cables and copper bars, use a tightening torque of 8±1 Nm
7. Assembly is done in reverse. Lift the transistor regulator into place and
fasten it.
8. Connect copper bars and cables as noted.
9. Plug in the contact.
×n After installation of the new transistor regulator, the truck will display error
s
code 2.004.
1. Connect TruckCom.
Step 8: s = torx 30, n = 6
T = 8±1 Nm 2. Select “Copy truck configuration”.
3. Select “Copy configuration to secondary unit: ACT”
© TMHE 14 – 9 T Code(s): 887, 888

14.5.3 Replacing the transistor regulator cooling fan
Step 4 Step 5 Step 6
Method
2: Open the motor compartment.
3: Remove the transistor regulator contact from the contact holder.
• First press in the clamp catch.
• Then lift up the contact clamp.
4: Remove the 3 nuts securing the electric panel
5: Carefully fold out the electric panel from the motor compartment wall to
gain access to the cooling fans
6: Disconnect the cooling fan harness. Undo the screws securing the
cooling fan and remove the cooling fan.
7: Reassemble in reverse order. Fit the new fan (4 slotted screws) and
connect the wiring harness.
8: Reinstall the electric panel on the motor compartment wall.
9: Close the motor compartment.
© TMHE 14 – 10 T Code(s): 887, 888

15. Hydraulic system – C6000

15.1 General
Always take the following safety precautions prior to commencing work on
the truck's hydraulic systems:
• Slowly depressurise system pressure.
• Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hand.
• Be careful since the oil in the transmission and hydraulic systems can be
scalding hot.
DANGER!
Risk of burns if hot transmission oil or hydraulic oil gets onto the skin. Allow
the truck to cool down before changing the oil.
15.2 Hydraulic cleanliness

NOTE:
Risk of malfunction.
If impurities get into the hydraulic system, there is a risk of malfunctions in
part or all of the hydraulic system. There is also a risk of severe damage to
components.
For all work on the hydraulic system, the following instructions must be
followed.
15.2.1 Cleaning
Hydraulic components, including hydraulic hoses and pipes, must be cleaned
with a filtered washing fluid using a method suitable for the components
concerned.
The washing fluid must have purity code 19/16/13 in accordance with
ISO4406:1999 or 16/13 in accordance with ISO4406:1987.
Blowing clean with dry filtered air may be done when this is the only practical
method to carry out cleaning.
15.2.2 Packaging
After cleaning, all openings must be sealed with protective plugs. Connecting
surfaces must be protected against handling damage and dirt penetration.
Completely dry components can be packed in plastic bags or boxes with lids.
The packaging (protective plugs, masking, plastic bag, etc) must not be
removed until immediately before the component is to be fitted in a workplace
suitable for handling hydraulic components.
Tape must never be used without cleaning afterwards.
Protective plugs must be stored in plastic bags or boxes with lids until they are
used.
After use, discard the plugs and plastic bags.
© TMHE 15 – 1 T Code(s): 887, 888

15.2.3 Handling
Hydraulic components must be handled and transported with the greatest
care.
Transportation packaging must be used throughout the entire handling chain.
This packaging must be clean and free from dust, etc.
15.2.4 Storage
Hydraulic components must be handled and stored so that:
• no rusting can occur
• dust and dirt particles are shielded out
• no mechanical deformation can occur
15.2.5 Work procedures

When working on the hydraulic system, great cleanliness must be observed
so that no impurities can enter the system.
No work that generates particles may be carried out in the same workplace
or close to where work is being carried out on the hydraulic system.
The service technician must ensure that the components to be used are
carefully deburred and cleaned.
Couplings for pipe ends or other openings must never be removed until the
part is to be fitted to the receiving component.
Note:
All hydraulic components that have not been cleaned, e.g. pipe couplings
and nipples, must be blown clean before fitting.
© TMHE 15 – 2 T Code(s): 887, 888

15.3 Component overview - Hydraulic system
15.3.1 Overview OSE250
Pos. Type of component Remarks

a Hydraulic unit
b Pressure sensor
c Lift cylinder
© TMHE 15 – 3 T Code(s): 887, 888

15.3.2 Overview OSE120, OSE120P, OSE250P
© TMHE 15 – 4 T Code(s): 887, 888

Pos. Type of component Remarks

a Hydraulic unit
b Pressure sensor
c Fork lifting cylinder 2 pcs
d Platform lifting cylinder
15.4 Operating pressure

The operating pressure at rated load is:
- 185 bar – OSE120, OSE120P
- 155 bar - OSE250, OSE250P
15.5 Pressure limiting valve

Valve opening pressure:
- 190 bar (OSE120, OSE120P)
- 185 bar (OSE250)
- 190 bar (OSE250P)
15.6 Hose rupture valve

In case of a ruptured hose, the hose rupture valve ensures that the lowering
speed does not exceed 0.6 m/sec. The valve is mounted in the hose
coupling.
When the hydraulic hose is refitted on the cylinder after removal, check that
the valve is in place in the coupling.
15.7 Pressure sensor

The pressure sensor [B10] sends pulses to the truck's steering electronics,
which converts these to load weight. When load reaches a certain weight, the
truck's steering electronics reduce the speed.
© TMHE 15 – 5 T Code(s): 887, 888

15.8 Hydraulic unit - C6100
15.8.1 Overview
Overview OSE250
h b
c
d
e
g
f

a Pump motor [M3] e Solenoid valve, fork lowering [Q4]
b Pump motor cable connection f Max. oil level
c Filling cap g Tank
d Hydraulic connection, forks h Pressure limiting valve
© TMHE 15 – 6 T Code(s): 887, 888

Description OSE250P, OSE120, OSE120P
a
o
n
b
c
m
i
d h
g
f
e
03290.wmf

a Pump motor [M3] h Hydraulic fork connection
b Magnetic valve, platform [Q23] i Pressure limiting valve
c Magnetic valve, forks [Q22] k Max. oil level
d Proportional valve, lowering [Q4] m Filling cap
e Tank n Pump motor cable connection
f Screw o Pump motor cable connection
g Hydraulic connection, platform
© TMHE 15 – 7 T Code(s): 887, 888

15.8.2 Tightening torque for hydraulic unit

The hydraulic unit tightening torques are as follows:
Tightening torques OSE250
5 +2 Nm
8 mm
4 + 1 Nm
10 mm
29 + 2 Nm
22 mm
29 + 2 Nm
6 mm
6 Nm
© TMHE 15 – 8 T Code(s): 887, 888

Tightening torques OSE250P, OSE120, OSE120P
10 + 2 Nm
10 mm
8,5 +- 0,5
0,5
Nm
13 mm
45 + 5 Nm
24 mm
45 + 5 Nm
24 mm
5 +- 0,8
0,8
Nm
4 +- 0,5
0,5 Nm
7 mm
© TMHE 15 – 9 T Code(s): 887, 888

15.8.3 Emptying the hydraulic tank

Method
1: Remove the hydraulic unit. See section "15.9 Removing/installing the
hydraulic unit".
NOTE:
Oil leaking.
2: Undo the clamp to be able to detach the tank from the motor and lift the
valve unit away from the tank.
3: Drain the oil and clean the tank.
The oil must not be reused and must be disposed of according to current
regulations.
NOTE:
Be careful with hydraulic unit sealings during reinstallation
4: Fit the tank to the motor. Make sure the tank is correctly positioned in
relation to the motor and valve unit. See section "15.8.2 Tightening
torque for hydraulic unit".
15.8.4 Filling the tank

Method
1: Slacken and then unscrew the lid by hand.
2: Fill new, clean hydraulic oil according to specification.
Type: See section "22.3 Oil and grease specification".
Quantity: See section "22.3 Oil and grease specification".
3: Screw on the tank lid by hand.
© TMHE 15 – 10 T Code(s): 887, 888

15.9 Removing/installing the hydraulic unit
Step 2. Step 3.
Step 4.
Step 5.
© TMHE 15 – 11 T Code(s): 887, 888

Method
1. Before commencing any work on the hydraulic unit, make sure the forks
have been fully lowered. Disconnect the battery
2. Disconnect the pressure sensor electrical connector and detach
hydraulic hoses and the pressure sensor measuring adapter from the
unit. See section "15.13.2 Quick change connector".
NOTE:
Oil leaking.
3. Loosen the motor cables. Note how they are connected so they can be
reinstalled correctly.
4. Disconnect the electrical connections of the valves.
5. Loosen the hydraulic unit from the truck by releasing the clamps that
surround the pump motor.
The unit is now accessible for service.
6. Reassemble everything in reverse order. See section "15.8.2 Tightening
torque for hydraulic unit".
7. Remove the plugs and connect the hydraulic hoses. See section
"15.13 Hydraulic couplings C6230".
8. Connect the battery
9. Check whether the oil needs to be topped up before starting the truck.
10. Bleed the hydraulic system.
11. Check the operation of the truck's hydraulic functions.
© TMHE 15 – 12 T Code(s): 887, 888

15.9.1 Replacing valves

The same procedure is used for all valves.
Method
2: Disconnect the valve coil’s electrical connector.
3: Unscrew the nut by hand and pull the coil straight out. Be careful with the
sealings located between the nut and coil and between the coil and valve
body.
4: Use a socket spanner to loosen the valve and then pull it straight out.
NOTE:
There is a sealing inside the valve which must not be lost.
5: If the flow control valve located inside the proportional valve must be
replaced, it can now be removed with a needle nose pliers.
6: Install the new flow control valve in the valve unit. Be careful not to
damage the sealing mounted on the flow control valve.
7: Check that the seal is correctly positioned, insert the new valve and
tighten it. See section "15.8.2 Tightening torque for hydraulic unit".
8: Fit the sealing on the valve. It must be positioned between the valve and
the coil. Thread the coil onto the valve body and fit the electrical
connector.
9: Install a sealing under the nut and tighten the nut by hand. See section
"15.8.2 Tightening torque for hydraulic unit".
10: Connect the coil’s electrical connection.
11: Connect the truck battery.
12: Test run the function.
© TMHE 15 – 13 T Code(s): 887, 888

15.10 Adjusting the pressure limiting valve

The truck should be able to lift the rated load to the top of the mast at normal
lift speed. 1200 kg for OSE120/P and 2500 kg for OSE250/P.
The pressure limiting valve may need adjusting if:
• The valve is replaced
• The complete hydraulic unit is replaced
In either of the above cases, proceed as follows:
• Verify that the truck is able to lift the rated load.
• If the truck is able to lift the rated load, add another 100 kg to the forks and
check that the truck is not able to lift the load.
The pressure limiting valve may also need adjustment if the truck lifting
capacity is abnormally low and no other fault can be found in the hydraulic
system.
15.10.1 Adjustment OSE250
Location of pressure limiting valve

Method
1. Protective sleeve.
2. Adjusting screw, pressure limitation.
When turned clockwise, the pressure increases.
When turned anti-clockwise, the pressure decreases.
• Remove the protective sleeve. Place a load of 1200/2500 kg on the forks
and verify that the truck is able to lift this load.
• If the truck can lift 1200/2500 kg, place an additional 100 kg on the forks.
Verify that the truck cannot lift the load.
• If the truck can manage to lift 1300/2600 kg, adjust the pressure limiting
valve using the adjusting screw by turning it clockwise until it cannot lift the
load.
• Refit the protective sleeve
© TMHE 15 – 14 T Code(s): 887, 888

15.10.2 Adjustment OSE250P, OSE120, OSE120P
Valve location
c
b
Method
1: Pry off the sealing cap (a) attached to the pressure limiting valve using a
screwdriver.
2: Remove the protective cover (b) by turning it anti-clockwise. Remove the
protective cover and the washer housed inside it.
3: Loosen the locking nut (c) by screwing it anti-clockwise.
4: Place a rated load on the forks and check that the truck can lift this weight
to the top position.
© TMHE 15 – 15 T Code(s): 887, 888

5: If the truck cannot lift the rated load or can lift the rated load + 100 kg,
adjust the pressure limiting valve using the adjuster screw.
To reduce the lifting capacity – turn the adjuster anti-clockwise
To increase the lift capacity – turn the adjuster clockwise
6: Place the rated load + 100 kg on the forks and check that the truck is not
able to lift it.
7: Tighten the locking nut (c) clockwise.
8: Refit the washer and protective cover (b)
9: Push a new sealing cap (a) onto the pressure limiting valve
© TMHE 15 – 16 T Code(s): 887, 888

15.11 Hydraulic calibration

A calibration function can be used to handle the proportional valve's [Q4]
tolerance. When calibration is carried out, the CAN service key must be
connected, the max. nominal load must be loaded on the forks and the forks
must be raised. See section "5.3.2 Hydraulic calibration".

• Maximum lowering speed of the fork (parameter 1261)
• Starting position of the proportional valve (parameter 1262)
NOTE:
© TMHE 15 – 17 T Code(s): 887, 888

15.12 Hydraulic system, bleeding

Method
1. Lift slowly at a constant rate until the forks begin to rise.
2. Lower the forks and continue to press the lowering button for 10-15 s.
3. Repeat a couple of times.
4. Fill with oil.
5. Lift the forks to max.
6. Lower to min.
7. Let stand about 30 min.
© TMHE 15 – 18 T Code(s): 887, 888

15.13 Hydraulic couplings C6230
15.13.1 Tightening torques for hydraulic connections
Tapered coupling with O-ring

Tighten the nut by hand against the stop and then tighten to the torques or
the degrees presented in the table below. Common connection type on most
hydraulic hoses on the trucks.
Dimension ø Tightening torque
Tightening angle [°]
[mm] [Nm]
6 23 30-45
10 30 30-45
12 50 30-45
15 60 30-45
18 70 30-45
20 80 30-45
Tredo seal
The nut/connection should be tightened by hand against the stop and then
tightened to the torque indicated in the table below.
Dimension Tightening torque [Nm]
R 1/8 12-18
R 1/4 25-45
R 3/8 50-70
R 1/2 70-100
R 5/8 100-140
R 3/4 150-200
R1 195-250
R 1 1/4 250-310
R 1 1/2 310-400
M 18 50-70
M 22 100-140
M 26 150-200
© TMHE 15 – 19 T Code(s): 887, 888

Pipe coupling
Tighten the coupling by hand and then turn it another half turn to obtain the
correct tightening torque.
Coupling set in aluminium

Designation with cutting
Dimension Torque [Nm]
edge
G 1/8 R 1/8 ~7
G 1/4 R 1/4 ~12
G 3/8 R 3/8 ~20
G 1/2 R 1/2 ~30
G 3/4 R 3/4 ~80
G1 R1 ~100
© TMHE 15 – 20 T Code(s): 887, 888

Coupling set in steel

Pressure class L
Designation with
Designation with Dimensio Torque Torque
ELASTIC Dimension
cutting edge n [Nm] [Nm]
sealing ring
GE 6-LM M 10x1 ~20 GE 6-LM-ed M 10x1 ~10
GE 6-LR R 1/8 ~20 GE 6-LR-ed R 1/8 ~10
GE 8-LM M 12x1.5 ~29 GE 8-LM-ed M 12x1.5 ~20
GE 8-LR R 1/4 ~39 GE 8-LR-ed R 1/4 ~20
GE 10-LM M 14x1.5 ~39 GE 10-LM-ed M 14x1.5 ~29
GE 10-LR R 1/4 ~39 GE 10-LR-ed R 1/4 ~20
GE 12-LM M 16x1.5 ~59 GE 12-LM-ed M 16x1.5 ~29
GE 12-LR R 3/8 ~59 GE 12-LR-ed R 3/8 ~39
GE 15-LM M 18x1.5 ~69 GE 15-LM-ed M 18x1.5 ~39
GE 15-LR R 1/2 ~108 GE 15-LR-ed R 1/2 ~59
GE 18-LM M 22x1.5 ~108 GE 18-LM-ed M 18x1.5 ~59
GE 18-LR R 1/2 ~108 GE 18-LR-ed R 1/2 ~59
GE 22-LM M 26x1.5 ~128 GE 22-LM-ed M 22x1.5 ~69
GE 22-LR R 3/4 ~157 GE 22-LR-ed R 3/4 ~88
GE 28-LM M 33x2 ~216 GE 28-LM-ed M 33x2 ~118
GE 28-LR R1 ~265 GE 28-LR-ed M 33x2 ~137
GE 35-LM M 42x2 ~353 GE 35-LM-ed M 42x2 ~196
GE 35-LR R 1 1/4 ~392 GE 35-LR-ed R 1 1/4 ~235
GE 42-LM M 48x2 ~491 GE 42-LM-ed M 48x2 ~294
GE 42-LR R 1 1/2 ~491 GE 42-LR-ed R 1 1/2 ~294
© TMHE 15 – 21 T Code(s): 887, 888

15.13.2 Quick change connector
Overview
NOTE:
It is important that the instructions for connecting and disconnecting the
quick change connectors are followed. Otherwise, both the hose and insert in
the main valve unit must be replaced.
b
a
Pos. Description
a Disassembly ring
b Assembly stop
Assembling the quick change connector
Step 1. Step 2.
Step 3.
1: Fit the assembly stop to the hose coupling’s male fitting.

Check that the disassembly ring runs freely in the groove.
2: Push the male fitting into the female fitting until the assembly stop makes
contact with the female fitting.
3: The coupling is now made and locked.
© TMHE 15 – 22 T Code(s): 887, 888

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

2: Push the male fitting all the way into the female fitting.
3: Pull the male fitting out of the female fitting.
4: Refit the assembly stop to the male fitting.
5: Fit the protective plugs on the connection and hose to prevent oil
spillage.
© TMHE 15 – 23 T Code(s): 887, 888

15.14 Main lift - C6610
15.14.1 Component overview
a b
c
h
d
f
j
g

a Lift cylinder 2 pcs
b O-ring Stabilising guard
c Valve
d Chain guard
e Nut
f Chain yoke
g Stop screw
h Lifting chain 2 pcs, complete
j Nut 4 pcs
k Nut 4 pcs
m Split pin 4 pcs
© TMHE 15 – 24 T Code(s): 887, 888

15.14.2 Removing the lift cylinder OSE120, OSE120P

I
© TMHE 15 – 25 T Code(s): 887, 888

Method
NOTE:
Clean the surfaces around the cylinder connections before removing the
cylinder from the truck. Use a clean rag and make sure that no dust from the
rag or other particles that could damage the cylinder remain on the surface.
DANGER!
Risk of crushing. Do not work under a truck that is not securely supported
on trestles.
1. Run the lift to the top and support with blocks or secure the fork carriage
with lifting straps and a lifting device
NOTE:
Note the dimensions of the chain bolt before removing it. This facilitates
refitting.
2. Remove the split pin and locking nut from the chain and remove the lifting
chain.
3. Lower the cylinder to be replaced to drain the oil.
4. Lift away the chain.
5. Remove the hydraulic hose from the hose couplings and unscrew the
coupling from the cylinder.
NOTE:
Oil leaking.
6. Lift the cylinder out of its bracket.
7. Unscrew the stop screw from the chain yoke and remove the yoke from
the cylinder piston.
© TMHE 15 – 26 T Code(s): 887, 888

15.14.3 Installing the lift cylinder OSE120, OSE120P
Step 1 Step 2 Step 3 Step 4
Step 5
© TMHE 15 – 27 T Code(s): 887, 888

Method
1. Fit an O-ring around the cylinder.
NOTE:
Be careful so that no oil from the cylinder gets onto the O-ring as it may
corrode.
2. Fit the the chain yoke on the cylinder. Tighten the yoke's stop screw.
Ensure that the stop screw ends up in the correct position so that the
yoke is securely locked.
3. Rehang the chain on the chain yoke and set the cylinder in the cylinder
bracket.
4. Screw hose couplings into place and connect the hydraulic hose.
5. Refit the chain with its locking nuts. Fit a split pin to secure the chain in
place.
6. Remove the blocks and lower the lift.
7. Bleed the hydraulic system. See section "15.12 Hydraulic system,
bleeding".
8. Verify correct operation and adjust the chains if necessary. See section
"16.3.1 General - Fork carriage".
15.14.4 Removing lift cylinder OSE250

<TBD>
15.14.5 Installing the lifting cylinder OSE250

<TBD>
© TMHE 15 – 28 T Code(s): 887, 888

16. Mast/Lift system - C7000

16.1 Main lifting chain system C7120
16.1.1 Adjustment
The lifting chains must be adjusted at regular periods due to stretching. This
is to be done when other service work with chains is performed.
The lock nuts on the lift chains are to be tightened with 50 Nm (+12.5 Nm / -
5 Nm). .
a b
1. Make sure that the thinner nut (b) is placed closest to the chain fitting.
2. Use a fixed spanner and a torque wrench set to 50 Nm to ensure the
correct torque.
Using the main lifting chains, the mast guides must be adjusted so that the
bottom part of the mast is level.
.
16.1.2 Checking the chain

The chains are subjected to two types of wear – outline wear and stretching.
Wear to the bolts and plate holes causes the chain to stretch. The chains are
also affected by the environment in which they are used.
Noise
If there has been insufficient lubrication, there will be metallic friction on the
chain and this will result in noise.
Replace the chain.
Surface rust
Surface rust is easy to recognise as the chain will be reddish brown. Deep-
seated rust has generally started and the strength of the chain is impaired.
Replace the chain.
Rusty links
Fretting corrosion results in a reddish-brown powder being visible on the
outer plates. It can also appear as if the chain is bleeding if lubricated.
Replace the chain.
© TMHE 16 – 1 T Code(s): 887, 888

Stiff links
If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.
Replace the chain.
Bolt rotation
Bolt rotation can be a phenomenon of stiff links. The fault is easy to see when
comparing with a new chain.
Replace the chain.
.
Loose bolts
If a bolt is loose it will protrude from the side of the chain, and this is due to a
stiff link or bolt rotation.
Replace the chain.
© TMHE 16 – 2 T Code(s): 887, 888

Outline wear
H2 H3
P = Pitch, H2 = Nominal plate thickness H3 = Minimum plate thickness.

A new lifting chain has a specific nominal plate thickness (H2 in the figure).
As the truck is used, the lifting chain wears radially on the side that rolls over
the chain wheel. The minimum plate height (defined as H3 in the figure)
denotes the minimum permitted value of the plate height.
Maximal permitted outline wear is 5% of the thickness H2. If a lifting chain
reaches the maximum level of wear, it must be replaced.
The nominal and minimum Plate heights for respective lift chains are stated
in the table in the section “Stretching”.
© TMHE 16 – 3 T Code(s): 887, 888

Stretching
The amount of stretch on a lifting chain is measured on the part of the chain
that runs over the chain roller. The amount of stretch may, at the most, be 2%
on the most worn section of the chain.
The measurement is best made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are stated
in the table below.
Nominal Minimum Nominal chain Maximum permitted
Type of Pitch P
disc height plate height length for 20/30/ chain length for 20/
chain (mm)
H2 (mm) H3 (mm) 50 plates (mm) 30/50 plates (mm)
3/4", 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4", 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4", 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1", 4x4 23.6 22.4 25.4 508/762/1270 518/777/1295
1", 6x6 23.6 22.4 25.4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs is one reason why the
chain stretches. The chain must be replaced if stretching is more than 2%.
© TMHE 16 – 4 T Code(s): 887, 888

Damage
The chain must be replaced if damaged in any way.
Damaged plates
If a plate has broken on the chain, this may be due to overloading or
corrosion.
Replace the chain.
Damaged bolts
It can be difficult to determine whether a bolt has broken. It can appear as bolt
rotation and/or that the outer plate is loose.
Replace the chain.
Dirty chain
If a chain is very dirty replacement is recommended first and foremost. It can
also be removed and cleaned as set out in the chapter “Cleaning”.
16.1.3 Cleaning
We recommend you to replace a chain that is very dirty.
Dirty chains should be cleaned before they are lubricated, e.g. by washing
with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated directly
after cleaning.
Note:
Exercise care with degreasing agents as these can contain abrasives.
© TMHE 16 – 5 T Code(s): 887, 888

16.1.4 Lubrication
Both mineral and synthetic oils can be used to lubricate Rexnord chains.
Note:
Lubricants must not contain substances such as molybdenum disulphide,
PTFE or such.
A lift chain should be offloaded from the weight of the fork carriage (hanging
free) when lubricated.
Lubrication intervals:
500 hours with normal operations
100 hours when operating in rugged environments such as cold stores
and corrosive environments.
The chains are sprayed with lubricant. Please note that the entire chain must
be lubricated, even the fastening bolts. It is particularly important that the part
of the chain that runs over the chain wheel is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient Viscosity
Recommended products*
temperature class
> - 40°C Klüberoil 4UH 1-15, Klüber
VG 15
< - 30°C Lubrication
Klüberoil 4UH 1-68N, Klüber
> - 30°C
VG 68 Lubrication
< + 5°C Anticorit LBO 160 TT, Fuchs DEA
Klüberoil 4UH 1-150N, Klüber
> + 5°C Lubrication
VG 150
< +45°C Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C Klüberoil 4UH 1-220N, Klüber
VG 220
<+ 80°C Lubrication
* Similar products from other manufacturers may be used.

Note:
Do not use a special rust protective agent to prevent
rust on the lifting chains.
These agents impair lubrication of the chains. Regular lubrication is the best
method to prevent rusting.
© TMHE 16 – 6 T Code(s): 887, 888

16.2 Fork carriage – C0380
16.2.1 General - Fork carriage
Inspections and inspection intervals comply with ISO standard 5057.

Forks in operation must be inspected at intervals of no more than twelve
months and whenever a defect or permanent deformation is discovered. In
the case of demanding applications, more regular inspections may be
necessary.
Checking
The forks must be carefully checked by trained personnel. The aim of an
inspection is to discover any damage, malfunctions, deformation or similar
that may impair safety. A fork with such defects must be taken out of service
and must not be used until it has been repaired in a satisfactory manner and,
where necessary, tested.
Fork height OSE250/250P

Measure fork height over the floor at the fork back and tip.
Lowered forks: min 80 mm and max 93 mm The fork must be clear of the
floor.
Lifted forks: min 220 mm and max 235 mm
Lowered forks: 85mm minimum and 93mm maximum. The fork must be clear
of the floor.
Lifted forks: 795mm minimum. The lift must stop 25 mm from the top of the
mast.
© TMHE 16 – 7 T Code(s): 887, 888

16.2.2 Component parts OSE250, OSE250P

Applicable to trucks before serial number 6183177
15
16 35
17
23
22
21
20 19 18
34
33 24
25
26
32
31 27
29
30 28
14
13
12
11
© TMHE 16 – 8 T Code(s): 887, 888


11 Roller Initially lubricated
12 Circlip
13 Cup spring Minimum play with 2-4 spring washer
14 Steering
15 Wheel fork
16 Bushing
17 Shaft
18 Grease nipple
19 Spring pin
20 Shaft
21 Grease nipple
22 Bushing
23 Sleeve
24 Bushing
25 Shaft
26 Washer
27 Screw
28 Shaft
29 Bushing
30 Shaft
31 Grease nipple
32 Bushing
33 Grease nipple
34 Torsion tube
35 Spring pin
© TMHE 16 – 9 T Code(s): 887, 888

16.2.3 Component parts OSE250, OSE250P

Applicable for trucks starting with serial number 6183177
© TMHE 16 – 10 T Code(s): 887, 888


11 Roller Initially lubricated
12 Circlip
13 Cup spring Minimum play with 2-4 spring washer
14 Steering
15 Wheel fork including
bushing
16 Single wheel shaft
17 Bogie link
18 Bushing
19 Bushing
20 Shaft
21 Shaft
22 Spring pin
23 Bushing
24 Roller (complete)
25 Screw
26 Push rod
27 Bushing
28 Shaft
29 Bushing
30 Shaft
31 Shaft
32 Screw and washer
33 Torsion tube
© TMHE 16 – 11 T Code(s): 887, 888

16.2.4 Front linkage on older machines

Applicable for OSE250/250P with machine numbers: 917994-6183176
For older machines (see above), there is now a new wheel fork (A) in which the front
bronze bushings have been replaced with new, self-lubricating composite bushings
(C). Together with a hardened single-wheel axle/bogie link (B/E), the solution
reduces maintenance and increases the service life of the front linkage in the fork
carriage. Do not forget to refit the retaining ring (D) that locks the single wheel axle
(B) after fitting.
Note: Wheel fork (219144) with Ø 20 mm wheel axle with serial number 718954
- 6092450 is being discontinued. After wheel fork replacement, the entire
linkage must be replaced with the new wheel fork with composite bushings
and Ø 25 mm axle. See the table below for part number.
H
G
A
D
F
E
C
B
I
Pos. Description Part No Quantity per fork
A Wheel fork including bushing For P/N, see 1
C Composite bushing QP search.. 2
Single
wheel
B Single-wheel axle 1
D Retaining ring Ø 25 mm 1
G Std single wheel 1
G “Heavy duty” single wheel 1
Bogie
wheel
E Bogie link 2
F Screw with Tuflok® 60 Nm 2
H Standard bogie wheel 2
H Heavy duty bogie wheel 2
© TMHE 16 – 12 T Code(s): 887, 888

16.2.5 Install fork carriage OSE250, OSE250P
Method
1. Thoroughly clean dirt and old grease from all parts. Apply grease as per
specification. See section "22.3 Oil and grease specification".
2. Position the fork carriage just over the mast guides so that the lower
washer springs and guides can be fitted in place. 2-4 washer springs are
fitted as needed.
3. Lower the fork carriage some more so that the washer springs and
guides end up in their final position in the mast guide
4. Lower the fork carriage in the mast guide far enough to allow the lower
washer springs and guides to be fitted in position
5. Lower the fork carriage some more so that the springs and guides end up
in their final position in the mast guide
Note:
Minimise play between the guide and the beam with 2-4 washer springs.
6. Reinstall the lift cylinder. See section "15.14.5 Installing the lifting
cylinder OSE250".
7. Refit backrest components
8. Connect the battery and test-run the lift.
© TMHE 16 – 13 T Code(s): 887, 888

16.2.6 Roller replacement
q
r
s
Method
1. Remove the fork carriage from the mast. See section "16.2.7 Removing
the fork carriage OSE250, OSE250P".
2. Remove the guide (s)
3. Remove the washer springs (r)
4. Remove the circlip (q)
5. Remove the roller (p).
6. Clean dirt and old grease from the fork carriage
7. Fit a new roller
8. Lock the roller to the shaft using the circlip (q)
9. Apply grease as per specification. See section "22.3 Oil and grease
specification".
As washer the spring (r) and guide (s) are not locked in the fork carriage, they
are fitted at the same time as the fork carriage is fitted to the mast.
Note:
Minimise play between the guide and the beam with 2-4 washer springs.
© TMHE 16 – 14 T Code(s): 887, 888

16.2.7 Removing the fork carriage OSE250, OSE250P

An external lifting device, such as an overhead crane or another truck, is
required to remove the fork carriage from the truck.
Step 2 Step 3
Step 4 Step 5
© TMHE 16 – 15 T Code(s): 887, 888

Method
Note:
Oil leaking.
There is a risk of valve or cylinder failure if dirt enters the hydraulic
connections.
Plug all hydraulic connections when working with the hydraulic system.
1: Open the motor compartment and disconnect the battery
2: Place support under the chassis on both sides of the truck.
3: Remove backrest components.
4: Undo the banjo bolt (A) on the hydraulic connector and remove the
screws (B) and washers holding the lift cylinder in place.
Note:
It is safest to lift the fork carriage at its centre of gravity.
5: Lift out the fork carriage using a lifting device.
Note:
The guides and washer springs can be lost when the fork carriage is lifted
free from the truck.
6: When replacing the fork carriage, remove the lift cylinder.
© TMHE 16 – 16 T Code(s): 887, 888

16.3 Fork carriage – 7420
16.3.1 General - Fork carriage
Inspections and inspection intervals comply with ISO standard 5057.

Forks in operation must be inspected at intervals of no more than twelve
months and whenever a defect or permanent deformation is discovered. In
the case of demanding applications, more regular inspections may be
necessary.
Inspection
The forks must be carefully checked by trained personnel. The aim of an
inspection is to discover any damage, malfunctions, deformation or similar
that may impair safety. A fork with such defects must be taken out of service
and must not be used until it has been repaired in a satisfactory manner and,
where necessary, tested.

Lowered forks: min 80 mm and max 93 mm The fork must be clear of the
floor.
Lifted forks: min 220 mm and max 235 mm
Lowered forks: 85mm minimum and 93mm maximum. The fork must be clear
of the floor.
Lifted forks: 795mm minimum. The lift must stop 25 mm from the top of the
mast.
© TMHE 16 – 17 T Code(s): 887, 888

16.3.2 Removing the fork carriage

An external lifting device, such as an overhead crane or another truck, is
required to remove the fork carriage from the truck mast.
Step 1 Step 2
Step 4 Step 5
© TMHE 16 – 18 T Code(s): 887, 888

Method
1. For OSE120, detach and remove backrest components. Alternatively,
raise the operator platform for OSE120P.
DANGER!
Risk of crushing.
Make sure that the operator platform and fork carriage are securely
supported on trestles or securely anchored.
2. Use the truck’s hydraulics to raise the forks approx. 30 – 40 cm and
relieve the load on the lifting chains with lifting straps and a lifting device
3. Open the motor compartment and disconnect the battery
4. When the forks are raised, the chain attachments are accessible from the
operator side of the mast. Detach the lifting chain from the fork carriage
and move it aside
5. Unscrew the stop screws.
Note:
The guides and cup springs can be lost when the fork carriage is lifted free
from the mast.
6. Carefully lift the fork carriage out of the mast using a lifting device
Note:
It is safest to lift the fork carriage at its centre of gravity.
© TMHE 16 – 19 T Code(s): 887, 888

16.3.3 Install the fork carriage in the mast
Step 2 Step 5
Method
1. Thoroughly clean away all dirt and old grease from the mast guides, the
support arms’ upper shafts and associated bushings
2. Position the fork carriage just over the mast so that the lower washer
springs and guides can be fitted in place. 2-4 washer springs are fitted as
needed.
3. Lower the fork carriage some more so that the washer springs and guides
end up in their final position in the mast beam
4. Check the lateral play and adjust if necessary. See section
"16.3.5 Checking fork carriage lateral clearance".
5. Lower the fork carriage in the mast so far so that the lower washer springs
and guides can be fitted in position
6. Lower the fork carriage some more so that the springs and guides end up
in their final position in the mast beam
7. Check the lateral clearance and adjust if necessary. See section
"16.3.5 Checking fork carriage lateral clearance".
8. Lower the fork carriage so that the lifting chain may be fitted, the clamp is
tightened to 10Nm ±12.5%
9. Reinstall the stop screws
10. Refit backrest components
11. Grease the mast’s guides and the support arm’s bushings according to the
instructions for normal maintenance of the truck.
12. Connect the battery. Verify correct operation and adjust the chains if
necessary.
© TMHE 16 – 20 T Code(s): 887, 888

16.3.4 Replacing the mast rollers
q
r
s
Method
1. Remove the fork carriage from the mast. See section "16.3.2 Removing
the fork carriage".
2. Remove the guide (s)
3. Remove the washer springs (r)
4. Remove the circlip (q)
5. Remove the roller (p).
6. Clean dirt and old grease from the fork carriage
7. Fit a new roller
8. Lock the roller to the shaft using the circlip (q)
As washer the spring (r) and guide (d) are not locked in the fork carriage, they
are fitted at the same time as the fork carriage is fitted to the mast.
© TMHE 16 – 21 T Code(s): 887, 888

16.3.5 Checking fork carriage lateral clearance
To adjust the play, the fork carriage must be lifted up from the truck.
Clearance is most easily checked and adjusted when the fork carriage is
being refitted in the truck.
1. Check the fork carriage guides for uneven or abnormal wear.
2. Check the wear on the inside of the mast.
3. Minimise clearance between the guide and the mast beam using 2 – 4
spring washers (r). Maximum clearance is 2 mm.
© TMHE 16 – 22 T Code(s): 887, 888

17. Options - C9000

17.1 Spider expansion unit
The spider expansion unit, called SEU, allows the main logic card to handle
a greater number of inputs and outputs. The SEU does not have its own truck
controller logic, which means that a defective SEU can be replaced without
the replacement affecting any truck functions.
The SEU is used for modification of the truck to meet special customer
requirements. .
Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector
Motor
Controller
The picture above shows how the SEU is used to allow a greater number of
functions to be controlled via the CAN bus. SEU has a 42-pin, multi-pin
contact that manages all inputs, outputs, CAN and power supply signals.
© TMHE 17 – 1 T Code(s): 887, 888

17.2 Component overview, T.W.I.S. (Toyota Wireless Information

System)
T.W.I.S is a system that collects data from the trucks.
T.W.I.S is available in two different versions:
• T.W.I.S including a DHU/DHU2 and an antenna.
• T.W.I.S including a DHU/DHU2, an antenna and a collision sensor.
The data handling unit (DHU) receives data from the truck and transfers it to
a central server at a set interval. The data is then accessible to users with an
authorised code via a website. No hardware installation is required at the
customer site. Communication is via the GSM 900/1800 network for the DHU.
DHU2 is also approved for UMTS FDDI/ VIII 900/ 1900/ 2100 MHz.
Reports can be viewed showing information such as the following:
• Truck usage
• Operator utilisation
• Battery consumption and charging behaviour
• Hour meter readings
If the system includes a collision sensor, the following collision data can be
viewed:
• Operator involved in collision
• Severity of collision
• Error codes generated by a collision
• When the collision occurred and how long the truck had been in use before
the collision
Collision sensitivity and the post-collision resetting procedure can be
programmed separately for each individual truck.
For instructions on installation, configuration, setup and troubleshooting, see
the separate T.W.I.S. manual.
© TMHE 17 – 2 T Code(s): 887, 888

17.2.1 Overview OSE120
17.2.2 Component list
Pos. Description Quanti

ty
a T.W.I.S main unit 1
b Shocksensor 1
c Sticker 1
d Wiring harness 1
e T.W.I.S antenna 1
© TMHE 17 – 3 T Code(s): 887, 888

17.2.3 Overview OSE120P
17.2.4 Component list T.W.I.S

ty
b Shocksensor 1
c Sticker 1
d Wiring harness 1
e T.W.I.S antenna 1
© TMHE 17 – 4 T Code(s): 887, 888

17.2.5 Overview OSE250/250P
d
e
17.2.6 Component list T.W.I.S

ty
b Shocksensor 1
c Sticker 1
d Wiring harness 1
e T.W.I.S antenna 1
© TMHE 17 – 5 T Code(s): 887, 888

17.3 E-bar
17.3.1 Overview
© TMHE 17 – 6 T Code(s): 887, 888

17.3.2 Component list E-bar
Pos. Description Quantity

A Screw 2
B Washer 2
C Roller bearing 2
D Bracket 1
E Bracket 2
F Screw 3
G Profile 1
H Nut 3
I Cover /Electric socket (When connecting to an electric socket, the 1
wiring harness is connected to X44 on the electric panel)
J Bracket 1
I Screw 1
L Spring 1
M Nut 1
N Washer 2
O Bracket 1
P Screw 2
Q Washer 2
R Washer 8
S Screw 8
© TMHE 17 – 7 T Code(s): 887, 888

17.3.3 Replacement/installation method
1. Remove the cover.

2. Remove the pump if it is obstructing.
3. Fit the lower screws (P) and washers (Q) to the motor wall.
4. Fit the brackets (D, J) to the lower screws (P, Q).
5. Fit screw and washer (R, S) to the bracket. Also fit the bracket (E).
6. Make sure everything is parallel to the motor wall. Tighten the screws.
7. Fit the profile bracket and fittings. See the illustration for more
information.
8. When the opening bracket (O) is mounted the screw must be tightened,
but not so much that you cannot open and close the arm without
problems. (K,M). Make sure to fit the spring on the arm (L).
9. If the arm does not fit, adjust the brackets (D, J).
10. Fit the pump.
11. Fit a cover that suits the E-bar.
17.3.4 E-bar accessories

Use the E-bar profile for quick and easy installation of optional accessories,
such as a computer equipment, scanner, writing tablet, etc. The accessories
are then easily accessible from the operator's position.
Accessories can be fixed with standard brackets. The brackets can be used
on all trucks with E-bar profile, making it easy to move equipment between
the trucks.
© TMHE 17 – 8 T Code(s): 887, 888

• Use the screws on the brackets of each accessory to adjust the

accessories for the most comfortable operating position.
NOTE:
To prevent accidents, make sure all fastening screws are securely tightened.
DANGER!
To prevent accessories from coming loose and eliminate the risk of
accidents, only use specially approved mounting brackets for the E-bar.
DANGER!
Never mount accessories where they will reduce safety.
© TMHE 17 – 9 T Code(s): 887, 888

© TMHE 17 – 10 T Code(s): 887, 888

18. Instructions for disposal

18.1 General
The disposal instructions were developed to support our company's objective
of protecting the environment. By recycling materials, resources can be
utilised more efficiently, while reducing emissions.
The following instructions specify the sorting category of the materials used
in the various truck components. To achieve optimum sorting, all components
should be disassembled to a level corresponding to the sorting categories.
18.2 Marking of plastics
18.2.1 General marking of products and packaging

Markings on plastics consist of three arrows, a number and usually also a
designation of the plastic material used. This example shows the marking for
polypropylene.
• 01: PET – Polyethylene terephthalate
• 02: PE-HD – Polyethylene with high density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with low density
• 05: PP - Polypropylene
• 06: PS – Polystyrene
• 07: O – Other
© TMHE 18 – 1 T Code(s): 887, 888

18.2.2 Marking according to the manufacturer’s standards

Standards: 58-02-001, 58-02-003 and 58-02-004.
A few examples of markings are given here. For more information, please
refer to the standards above.
The product material and trade name of each item are indicated between
arrows. Example: >PP<.
Abbreviations
• ABS: acrylonitrile/butadiene/styrene
• HDPE: High Density Polyethylene
• LDPE: Low Density Polyethylene
• PA: Polyamide
• PA6: Amide resin 6
• PA66: Amide resin 66
• PBT: Polybutylene terephtalate
• PC: Polycarbonate
• PET: Polyethylene terephtalate
• PMMA: Plexiglas
• POM: Polyoxymethylene, Polyformaldehyde
• PP: Polypropylene
• PUR: Polyurethane
Marking examples
Products made from a single substance
ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and carbonate
plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<
© TMHE 18 – 2 T Code(s): 887, 888

18.3 Pressure vessels

Pressure vessels sent for recycling/destruction must have been
depressurised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas struts and accumulators used
in hydraulic systems.
18.3.1 Gas struts

DANGER!
Gas struts have extremely high internal pressure. To prevent injury, always
follow the instructions of the manufacturer.
Wear safety goggles when disassembling struts.
To allow the gas to escape, only open and disassemble gas struts as
recommended by the manufacturer. An example of how to perform this is
given for "Stabilus Lift-O-Mat/Inter-stop":
2 1
ca 20 mm
1: Drill or cut a hole in the cylinders, approximately 20 mm from the bottom.

2: Drill or cut a hole in the recess at the piston rod end.
© TMHE 18 – 3 T Code(s): 887, 888

18.4 Sorting categories

• Plastic and rubber material
• Iron/steel (including bolts, washers and nuts)
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Wires
• Hazardous waste
• Complex materials - large amounts in several categories but non-
combustible and not hazardous
• Combustible material (including small plastic and rubber parts)
• Please return batteries to the manufacturer.
Component Category Comments
Chassis Iron/steel
Iron/steel
Inspection covers, sheet metal
Handle: >ABS<
Sort according to the material
Inspection covers, plastic Plastic
marking
Forks and frames Iron/steel
Iron/steel, including any gas
Operator's platforms dampers Be sure to depressurise dampers
Mats, cushions: combustible
Roofs and overhead guards Iron/steel
Iron/steel
Gates and operator protective
Plastic handles: >PA<
devices
Crush protectors: >PMMA<
Oil
Hydraulic hoses: Oil-polluted Ensure that the system has been
material depressurised.
Oil tank: >PP< Carefully drain all oil.
Hydraulic unit
Motor, valves: Electronic Any accumulators should be
components emptied of gas and if possible
Pump: Iron/steel opened.
Accumulator: Iron/steel
Motor: Electronic components
Travel motors Wires
Parking brake: Hazardous waste
Iron/steel Carefully drain all oil
Drive gears
Oil Hazardous waste
If the tread and hub cannot be
Tread: Plastic according to marking
Wheels separated, then sort the wheel as
Hub: Iron/steel
complex material
© TMHE 18 – 4 T Code(s): 887, 888

Component Category Comments

Electronic components
Tiller arms Wires Be sure to depressurise dampers
Iron/steel, also gas dampers
PCBs, transistor regulators,
Expansion unit SEU, contactors:
Electrical system Hazardous waste
Wires
Small batteries Hazardous waste
Hazardous waste.
Because of the chemical content in
fluorescent tubes, do not break
Fluorescent tubes them.
Obsolete fluorescent tubes must be
packaged and transported according
to local regulations.
Mast beams, rollers, cylinders,
hydraulic pipes: Iron/steel
Hydraulic hoses: Oil-polluted ()
Wires Oil-polluted components should be
Mast
Sensors/switches: Electronic handled as hazardous waste
components
Plastic components: According to
marking or as combustible waste
Chargers and connectors
Wires
© TMHE 18 – 5 T Code(s): 887, 888

© TMHE 18 – 6 T Code(s): 887, 888

19. Electrical components and electrical diagram

19.1 Electric components
The following table shows a summary of the electrical components in this
truck.
Designation Function Component type Other Notes
Electronic circuit
A2 Control of truck functions (ICH) 1
board
Electronic circuit
A5 Steering servo 2
board
A6 Display of truck functions Display 1
A17 Login with PIN code Keypad 1
Electronic circuit
A20 Data Handling Unit (DHU)
board
A23 Collision registration Collision sensor
Electronic circuit
A36 Expansion unit (SEU)
board
Drive motor
B1 Temperature sensor
temperature sensor
B10 Load detection Pressure sensor
B12 Pulse transformer Speed sensor
F1 Main fuse + drive motor protection Fuse 200 A
F2 Protection for the SEU Fuse 3 A
F 50 Protection for A5, A2 Fuse 3 A
F 51 T1 protection Fuse 7.5 A
F52 Sensor protection Fuse 3 A
F 53 Steering servo motor protection Fuse 30 A
F54 Protection, 24V socket Fuse 7.5 A OME, OSE100
F55 Protection, DC/DC converter Fuse 7.5 A Option
G1 Main power source Battery 24 V
Automatic height
H97 Automatic mode Lamp adjustment
(option)
Automatic height
H98 Automatic mode Lamp adjustment
(option)
L1 Speed control and travel direction selector Hall element 3, 4
M1 Truck traction Motor
M3 Pump motor Motor
M6 Steering motor Motor 2
M12 Transistor regulator cooling Fan
M13 Transistor regulator cooling Fan
P4 Horn Horn
© TMHE 19 – 1 T Code(s): 887, 888


Electromagnetic
Q1 Mechanical brake 4
brake
Q4 Fork lowering – hydraulic control Proportional valve
Q10 Main contactor Contactor
OSE120P
Q22 Fork lifting/lowering – hydraulic Solenoid valve
OSE250P
OSE120P
Q23 Platform lifting/lowering – hydraulic Solenoid valve
OSE250P
Q30 Fork lifting (Pump motor activation) Contactor OSE250
R2 Steering signal Potentiometer
Inductive limit
S10 Mechanical brake activation 4
switch
Inductive limit
S12 Forks > 500 mm OSE120P
switch
S18:1 / S18:2 Button for sound signal (left/right) Switch
Inductive limit
S19 Presence check (operator on platform) switch 4, 5
Contact carpet
S21 Emergency switch off Switch
Automatic height
S22 Emergency stop Switch adjustment
(option)
Automatic height
S23 Emergency stop Switch adjustment
(option)
Inductive limit
S31 Fork lift limiter 4
switch
Inductive limit
S32 Forks < 200 mm OSE120P
switch
Inductive limit
S65 Drive wheel centring reference
switch
Inductive limit OSE120P
S103 Platform >500 mm
switch OSE250P
Inductive limit OSE120P
S107 Platform lift limiter
switch OSE250P
Automatic height
Optional button Automatic height
S114 Switch preselector
preselection. Up
(option)
Automatic height
Optional button Automatic height
S115 Switch preselector
preselection. Down
(option)
Platform lowering activation (via button in OSE120P
S214 Contact sheet 5
floor mat) OSE250P
S215/216 Walkie button – left/right Switch Walkie button
S217/218 Safety stop (all lateral functions) Switch Walkie button
S219/220 Fork lifting from side – left/right Switch Walkie button
© TMHE 19 – 2 T Code(s): 887, 888


S221/222 Fork lowering from side – left/right Switch Walkie button
Deadmans handle, driving from side – left/
S223/ S224 Switch OSE120/P
right
Automatic height
S225 Load height monitoring Photocell preselector
(option)
T1 Lift, drive and peripherals control Transistor regulator
01X Battery connection / isolation Connector
Port for additional I/
X29 External CAN communication
O units
X41 External CAN communication Connection point
Notes to the table above:

1. Situated in the tiller arm handle and communicates via the CAN bus.
2. The steering servo, servo motor and mechanics are integrated into one
single unit.
3. Speed control signals from L1 are controlled by the Hall element
mounted on the A2 card. Sensors A2:S300-308 control speed control
signals for driving in fork direction. Sensors A2:S310-318 control speed
control signals for driving in the drive wheel direction.
4. Signals to/from these elements can be checked using the built-in test
function. See section "8.5 Built-in test function for the tiller arm".
5. S19 & S214 are integrated in the mat on OSE120P, OSE250P
© TMHE 19 – 3 T Code(s): 887, 888

6. Automatic height adjustment show below. A = Black wire, B = Blue wire.

S22 A
B
H97
S115
S114
H98
S23
© TMHE 19 – 4 T Code(s): 887, 888

19.1.1 Electric component overview
A17
A6
S18:1
S115
A2 S114
S18:2
L1
© TMHE 19 – 5 T Code(s): 887, 888

S10
S21
R2
© TMHE 19 – 6 T Code(s): 887, 888

S31
S12
S32
S107
S103 S214
S19
© TMHE 19 – 7 T Code(s): 887, 888

01X
M3
Q4
Q22
Q23
B10
X41
G1
M6 A36
A5 B12
Q1
M1
S65
© TMHE 19 – 8 T Code(s): 887, 888

T1
M12
M13
F50
F51
F52
F53
Q30 F55
F1
X4
Q10
X2
X3
P4
X1
© TMHE 19 – 9 T Code(s): 887, 888

19.2 Electrical wiring diagrams
19.2.1 List of symbols
Symbol Description Symbol Description

Truck battery Horn
Fuse Emergency switch off NC
Sensor, inductive NO Switch, pressure (weight)

operated
DC motor Sensor, inductive NC
Contactor Variable resistor (potentiometer)
Brake coil (normally applied) Pressure switch NO
Coil for hydraulic solenoid valve Multi-pin connect
Pressure sensor, analogue NO = Normally open

P NC = Normally closed
© TMHE 19 – 10 T Code(s): 887, 888

© TMHE
Publication Number: 7536388-040

Repair manual:
M3
5
OUT. P- M 28
S103 +24 VDC (1)
22 49 (82)PLATFORM > 500mm
6
F1 A36 40
(+) B+ 6 0 VDC (29)
9
F2
S107 F51
85 (88)INP. PLATFORM LIFT LIMIT 21 S21 24
OPTION
EMERGENCY AUT. HEIGHT
SWITCH OFF ADJUSTMENT
Q10
19.2.2 Wiring diagram 250P - Overview

CONTACT MAT 20
ENABLE (84) 1 200
S19 65 (95) DRIVER ON PLATFORM M12 M13 CONTROL (5) INP.DIGITAL 1
35
OUT. FAN (119) M M BOX.MAST 210 (16) OUT.DIGITAL 1
Q10 X1
32
S10 MAIN CONTACTOR (118)
57 (87) INP. TILL ARM 46 (33) INP.DIGITAL 3
+
T1 PROP. VALVE (108) 38 Q4 G1 - 47
(19) INP.DIGITAL 2
S32
47 (86) FORKS < 200mm X1
31 Q1 8
BRAKE (117) 40
OPTION
30 F55 27 DHU/SHOCK
+24V (115) 1 SENSOR
S12
Date: 2016-12-01
48 (96) FORKS > 500mm 40
F52
Q22 A20
19 – 11
36
S31 OUT. FORK VALVE (120) 22 F53 F50
46 (94) LIFT LIMIT Q23
37
OUT. PLATFORM VALVE (121) A23
20 40
EXT. (27/42)
24 CAN H/L
INP. +24 V (114) EQUIP.
FOOTSWITCH,
24 S214 80
(83)LOWER PLATFORM
Model(s): OSE120, OSE120P, OSE250, OSE250P

26
(93) OUT. +5V extern
B10
P 66 (X100:3/7) CAN H/L
(101) LOAD WEIGHT
20 (X100:6) +24VDC
41
(113) INP. ANALOGE GND DISPLAY
(X300)
Applies from serial number: 6192021-

A2:S320
U Hall (X1) A6
M1 V DRIVE MOTOR
W A2:S321
B12 Hall
23 20
61 (104) CH A, SPEED SENSOR
62 (103) CH B, SPEED SENSOR (8/16) (6) A2:S322 A2
+24V ENABLE Hall
A5
B1 63 (92) THERMAL SENSOR A2:S323
(X204)
KEYBOARD
(DRIVE MOTOR) Hall
A17
64 (105) OUT. NEGATIVE
60 (85) OUT. +11V SPEED SENSOR A2:S300-S308 A2:S310-S318
Hall Hall (X2:2/2)
40 95 INP.AUTO UP
(3) SUPPLY +12V
T Code(s): 887, 888
S65
(99/100) CAN H/L 96 (X200:1) HORN 1
(11) REF. SWITCH (2/10) (X2:2/3) 0VDC
S114
CAN H/L
97 0V 40 (X2:2/4)
(12) SUPPLY 0V (7/15) S18:1 INP.AUTO
(X200:2)
LOWER
(X201:1) HORN 2
119/120 M M6 S115
(X2:2/5) 0VDC
S18:2 (X201:2) 40
(X100:2) 0VDC
X41 CAN
X29 CAN
19.2.3 Wiring diagram 250P
7519505
1 11
© TMHE 19 – 12 T Code(s): 887, 888

© TMHE 19 – 13 T Code(s): 887, 888

7519505
3 11
© TMHE 19 – 14 T Code(s): 887, 888

7519505
4 11
© TMHE 19 – 15 T Code(s): 887, 888

7519505
5 11
© TMHE 19 – 16 T Code(s): 887, 888

7519505
6 11
A2:S300-S308-
A2:S310-S318
A2:S321
A2:S323
A2:S320
A2:S322
© TMHE 19 – 17 T Code(s): 887, 888

7519505
7 11
© TMHE 19 – 18 T Code(s): 887, 888

7519505
8 11
© TMHE 19 – 19 T Code(s): 887, 888

7519505
9 11
© TMHE 19 – 20 T Code(s): 887, 888

7519505
10 11
© TMHE 19 – 21 T Code(s): 887, 888

7519505
11 11
© TMHE 19 – 22 T Code(s): 887, 888

© TMHE

Repair manual:
S21 24 S22 24 S23 24
M3
5 EMERGENCY
OUT. P- M SWITCH OFF 28
S103 +24 VDC (1)
22 49 (82)PLATFORM > 500mm F1 A36
(+) B+
6 6 0 VDC (29) 40
9
F2
S107 F51
85 (88)INP. PLATFORM LIFT LIMIT 21 S21 24
OPTION
SWITCH OFF ADJUSTMENT
20 Q10
CONTACT MAT 1
19.2.4 Wiring diagram 120P - Overview

ENABLE (84) 200
S19 65 (95) DRIVER ON PLATFORM M12 M13 CONTROL (5) INP.DIGITAL 1
35
OUT. FAN (119) M M BOX.MAST 210 (16) OUT.DIGITAL 1
Q10 X1
MAIN CONTACTOR (118) 32
S10 46 (33) INP.DIGITAL 3
57 (87) INP. TILL ARM +
T1 PROP. VALVE (108) 38 Q4 G1 - 47 (19) INP.DIGITAL 2
S32
47 (86) FORKS < 200mm 8 X1
31 Q1
BRAKE (117) 40
OPTION
30 F55 27 DHU/SHOCK
+24V (115) 1 SENSOR
S12
48 (96) FORKS > 500mm 40
Date: 2016-12-01
F52
Q22 A20
36
19 – 23
S31 OUT. FORK VALVE (120) 22 F53 F50

46 (94) LIFT LIMIT Q23
37
OUT. PLATFORM VALVE (121) A23
20 40
EXT. (27/42)
24 CAN H/L
INP. +24 V (114) EQUIP.
S214 FOOTSWITCH, STOP
24 80
(83)LOWER PLATFORM L 74 R

S217 S218
26
B10 AUX SW,
66 70 S215
P GO/WALK (90) (X100:3/7) CAN H/L
(101) LOAD WEIGHT
20 (X100:6) +24VDC
41 S216
(113) INP. ANALOGE GND DISPLAY
S223 A2:S320 (X300)

U AUX SW,
S219 Hall (X1) A6
M1 V DRIVE MOTOR LIFT FORKS (110) 72
W S224
A2:S321
S220 Hall
B12 23 20
62 (103) CH B, SPEED SENSOR AUX SW,LOWER
S221
(8/16) (6) A2:S322 A2
FORKS (107) 73 +24V ENABLE Hall
A5
B1 63 (92) THERMAL SENSOR S222 A2:S323
(X204)
KEYBOARD
(DRIVE MOTOR) Hall
A17
64 (105) OUT. NEGATIVE AUX SW, STOP (111) 71
OPTION W. BUTTONS A2:S300-S308 A2:S310-S318
60 (85) OUT. +11V SPEED SENSOR Hall Hall (X2:2/2)
40 95 INP.AUTO UP
(3) SUPPLY +12V
T Code(s): 887, 888
S65
(99/100) CAN H/L 96 (X200:1) HORN 1
(11) REF. SWITCH (2/10) (X2:2/3) 0VDC
S114
CAN H/L
97 0V 40 (X2:2/4)
(12) SUPPLY 0V (7/15) S18:1 (X200:2) INP.AUTO
LOWER
(X201:1) HORN 2
119/120 M M6 S115
(X2:2/5) 0VDC
S18:2 (X201:2) 40
(X100:2) 0VDC
X41 CAN
X29 CAN
19.2.5 Wiring diagram 120P
J
1/15
© TMHE 19 – 24 T Code(s): 887, 888

J
2/15
© TMHE 19 – 25 T Code(s): 887, 888

J
3/15
© TMHE 19 – 26 T Code(s): 887, 888

J
4/15
© TMHE 19 – 27 T Code(s): 887, 888

J
5/15
© TMHE 19 – 28 T Code(s): 887, 888

© TMHE 19 – 29 T Code(s): 887, 888

J
7/15
A2:S300-S308-
A2:S310-S318
A2:S321
A2:S323
A2:S320
A2:S322
© TMHE 19 – 30 T Code(s): 887, 888

J
8/15
© TMHE 19 – 31 T Code(s): 887, 888

J
9/15
© TMHE 19 – 32 T Code(s): 887, 888

J
10 /15
© TMHE 19 – 33 T Code(s): 887, 888

J
11 /15
© TMHE 19 – 34 T Code(s): 887, 888

J
12 /15
© TMHE 19 – 35 T Code(s): 887, 888

J
13 /15
© TMHE 19 – 36 T Code(s): 887, 888

J
14/15
© TMHE 19 – 37 T Code(s): 887, 888

© TMHE

Repair manual:
44 F54
S21 24 S22 24 S23 24

EMERGENCY
M3 SWITCH OFF
5
OUT. P- M A36
0 VDC (29) 40
6 F1
(+) B+ 6
9 F2
F51
19.2.6 Wiring diagram 120 - Overview

21 S21 24 OPTION
S19 SWITCH OFF 1 ADJUSTMENT
20 Q10 200
44 65 (95) INP. DRIVER ON PLATFORM ENABLE (84) (5) INP.DIGITAL 1
CONTROL 210 (16) OUT.DIGITAL 1
X1 BOX.MAST
M12 M13
35 46 (33) INP.DIGITAL 3
OUT. FAN (119) M M
S10 +
24 57 (87) INP. TILL ARM G1 - 47 (19) INP.DIGITAL 2
Q10
S32 MAIN CONTACTOR (118) 32 8 X1
47 (86) FORKS < 200mm
40
T1 PROP. VALVE (108) 38
Q4 OPTION
DHU/SHOCK
Date: 2016-12-01
1 F55 27
SENSOR
31 Q1 40
19 – 38
S12 BRAKE (117)

48 (96) FORKS > 500mm F52
A20
30
+24V (115)
22 F53 F50
S31
46 (94) LIFT LIMIT A23
20 40
EXT. (27/42)
24 CAN H/L
INP. +24 V (114) EQUIP.

STOP
L 74 R
26 S217 S218
B10
P 66 AUX SW, 70 S215
(101) LOAD WEIGHT GO/WALK (90) (X100:3/7) CAN H/L
20 (X100:6) +24VDC
41 S216

(113) INP. ANALOGE GND
DISPLAY
S223 A2:S19 (X300)
U AUX SW, S219
Hall (X1) A6
M1 V DRIVE MOTOR 72
LIFT FORKS (110) S224
W A2:S20
S220 Hall
B12 23 20
62 (103) CH B, SPEED SENSOR AUX SW,LOWER
S221
(8/16) (6) A2:S21 A2
+24V ENABLE
FORKS (107) 73 Hall
A5 KEYBOARD
B1 63 (92) THERMAL SENSOR S222 A2:S22
(X204)
(DRIVE MOTOR) Hall
A17
64 (105) OUT. NEGATIVE AUX SW, STOP (111) 71
60 (85) OUT. +11V SPEED SENSOR OPTION W. BUTTONS A2:S1-S9 A2:S10-S18
Hall Hall (X2:2/2)
95
T Code(s): 887, 888
40 (3) SUPPLY +12V INP.AUTO UP

S65
(99/100) CAN H/L 96 (X200:1) HORN 1
(11) REF. SWITCH (2/10) (X2:2/3) 0VDC
S114
CAN H/L
97 0V 40 (X2:2/4)
(12) SUPPLY 0V (7/15) S18:1 INP.AUTO
(X200:2)
LOWER
(X201:1) HORN 2
119/120 M M6 S115
(X2:2/5) 0VDC
S18:2 (X201:2) 40
(X100:2) 0VDC
X41 CAN
X29 CAN
19.2.7 Wiring diagram 120
7519483
1 13
© TMHE 19 – 39 T Code(s): 887, 888

PROD I
7519483
2 13
B12
B12
B12
B12
B12
© TMHE 19 – 40 T Code(s): 887, 888

PROD I
7519483
3 13
© TMHE 19 – 41 T Code(s): 887, 888

PROD I
7519483
4 13
22
44
1
1 12
© TMHE 19 – 42 T Code(s): 887, 888

© TMHE 19 – 43 T Code(s): 887, 888

PROD I
7519483
I
6 13
A2:S300-S308-
A2:S310-S318
A2:S321
A2:S323
A2:S320
A2:S322
© TMHE 19 – 44 T Code(s): 887, 888

PROD I
7519483
7 13
© TMHE 19 – 45 T Code(s): 887, 888

© TMHE 19 – 46 T Code(s): 887, 888

7519483
9 13
© TMHE 19 – 47 T Code(s): 887, 888

© TMHE 19 – 48 T Code(s): 887, 888

PROD I
7519483
11 13
© TMHE 19 – 49 T Code(s): 887, 888

PROD I
7519483
12 13
© TMHE 19 – 50 T Code(s): 887, 888

PROD I
7519483
13 13
© TMHE 19 – 51 T Code(s): 887, 888

© TMHE

Repair manual:
44 F54
Q30
M3
40 10
M
6 F1
(+) B+ 6
9
F51
21 S21
EMERGENCY 24
19.2.8 Wiring diagram 250 - Overview

SWITCH OFF Q10
20
S19 ENABLE (84) 1
M12 M13
44 (95) DRIVER ON PLATFORM 35
65 OUT. FAN (119) M M
Q10 X1
MAIN CONTACTOR (118) 32
S10 +
24 57 (87) INP. TILL ARM T1 PROP. VALVE (108) 38
Q4 G1 -
Q1 8 X1
31
BRAKE (117) 40
OPTION
F55 27 DHU/SHOCK
Q30 1
Date: 2016-12-01
45 SENSOR
PUMP CONTACTOR (116)
40
+24V (115) 30
19 – 52
F52
A20
S31
46 (94) LIFT LIMIT F53 F50
22
20 A23
EXT. 40
INP. +24 V (114) 24 EQUIP.

26
B10
P 66
(101) LOAD WEIGHT (X100:3/7) CAN H/L
20 (X100:6) +24VDC
41
(113) INP. ANALOGE GND
DISPLAY

A2:S320 (X300)
U Hall (X1)A6
M1 V DRIVE MOTOR
W A2:S321
B12 Hall
23 20
62 (103) CH B, SPEED SENSOR (8/16) (6) A2:S322 A2
+24V ENABLE Hall
A5 KEYBOARD
B1 63 (92) THERMAL SENSOR A2:S323
(X204)
(DRIVE MOTOR) Hall
A17
64 (105) OUT. NEGATIVE
60 A2:S300-S308 A2:S310-S318
(85) OUT. +11V SPEED SENSOR Hall Hall
95
T Code(s): 887, 888
40 (3) SUPPLY +12V

S65
(99/100) CAN H/L 96 (X200:1) HORN 1
(11) REF. SWITCH (2/10)
CAN H/L
97 0V 40
(12) SUPPLY 0V (7/15) S18:1 (X200:2)
(X201:1) HORN 2
119/120 M M6
S18:2 (X201:2) 40
(X100:2) 0VDC
X41 CAN
X29 CAN
19.2.9 Wiring diagram 250
7519504
1 11
© TMHE 19 – 53 T Code(s): 887, 888

7519504
2 11
© TMHE 19 – 54 T Code(s): 887, 888

7519504
3 11
© TMHE 19 – 55 T Code(s): 887, 888

7519504
4 11
© TMHE 19 – 56 T Code(s): 887, 888

7519504
5 11
© TMHE 19 – 57 T Code(s): 887, 888

7519504
6 11
A2:S300-S308-
A2:S310-S318
A2:S321
A2:S323
A2:S320
A2:S322
© TMHE 19 – 58 T Code(s): 887, 888

7519504
7 11
© TMHE 19 – 59 T Code(s): 887, 888

7519504
8 11
© TMHE 19 – 60 T Code(s): 887, 888

7519504
9 11
© TMHE 19 – 61 T Code(s): 887, 888

7519504
10 11
© TMHE 19 – 62 T Code(s): 887, 888

7519504
11 11
© TMHE 19 – 63 T Code(s): 887, 888

© TMHE 19 – 64 T Code(s): 887, 888

20. Hydraulics schematics

20.1 Schematics OSE120P
p
a o
p
q B10
F SA
b
c
n
Max190 Bar
m
g
h i
Pos. Type of component Designation Remarks

a Lift cylinder Fork operation
b Solenoid valve Q23 Platform operation
c Solenoid valve Q22 Fork operation
d Proportional valve Q4 Lift/platform lowering
e Non-return valve
Limitation of max. hydraulic
f Pressure limiting valve
pressure, 190 bar
g Pump Hydraulic pressure
h Tank 2 litres
Coarse filtering of oil, pump suction
i Filter
side
© TMHE 20 – 1 T Code(s): 887, 888


m Air filter Tank ventilation
n Flow regulator valve 10 l/min
o Lift cylinder Platform operation
p Non-return valve Closes upon hose rupture
Load monitoring For reducing the
q Analogue pressure sensor B10
truck speed with certain loads.
© TMHE 20 – 2 T Code(s): 887, 888

20.2 Schematics OSE120
a
m
n B10
Max190 Bar
i
e
g
f
b Proportional valve Q4 Lift lowering
c Non-return valve
Limitation of max. hydraulic pressure,
d Pressure limiting valve
190 bar
e Pump Hydraulic pressure
f Tank 2 litres
g Filter
side
i Air filter Tank ventilation

k Flow regulator valve 10 l/min
m Non-return valve Closes upon hose rupture
Load monitoring For reducing the
n Analogue pressure sensor B10
truck speed with certain loads.
© TMHE 20 – 3 T Code(s): 887, 888

20.3 Schematics OSE250P
p
a o
q B10
F
b
c
n
Max190 Bar
m
g
h i

b Solenoid valve Q23 Platform operation
c Solenoid valve Q22 Fork operation
d Proportional valve Q4 Lift/platform lowering
e Non-return valve
Limitation of max. hydraulic pressure,
f Pressure limiting valve
190 bar
g Pump Hydraulic pressure
h Tank 2 litres
i Filter
side
© TMHE 20 – 4 T Code(s): 887, 888


m Air filter Tank ventilation
n Flow regulator valve 10 l/min
o Lift cylinder Platform operation
p Non-return valve Closes upon hose rupture
Load monitoring For reducing the truck
q Analogue pressure sensor B10
speed with certain loads.
© TMHE 20 – 5 T Code(s): 887, 888

20.4 Schematics OSE250
m B10
Max185 Bar
c
g
f e

b Flow regulator valve 5 l/min
c Air filter Tank ventilation
e Filter Hydraulic pressure

f Tank 1 litres
g Pump
Limitation of max. hydraulic
h Pressure limiting valve
pressure, 185 bar
i Non-return valves
k Solenoid valve Q4 Lowering the forks
Load monitoring For reducing
m Analogue pressure sensor B10 the truck speed with certain
loads.
© TMHE 20 – 6 T Code(s): 887, 888

21. Tools
21.1 Super Seal connectors
Tools Part number Use

159232 Crimping tool for fitting sleeves/pins
159229 Tool for removing locks (1)
159230 Tool for fitting secondary locking, 1-2

pins (2)
159231 Tool for fitting secondary locking, 3-6

pins (2)
159228 Removal tool for pins/sleeves (3)
© TMHE 21 – 1 T Code(s): 887, 888

21.2 AMP connectors

PT = Power Timer (4.8. 5.8. 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)

151080 (PT) Removal tool for pins/sleeves
213296 (JPT) Removal tool for pins/sleeves
213298 (MPT) Removal tool for pins/sleeves
1=163787 (JPT) Crimping tool (sleeves only)

2=163788 (JPT)
1=213336 (MPT)
1 2=213337 (MPT)
2
1=213336 (JPT) Tool for crimping pins
2=213549 (JPT) For 0.5–2.5 mm2
1
2
© TMHE 21 – 2 T Code(s): 887, 888

21.3 AMP connectors, Multilock series 040

213130 Pin removal tool
213129 Crimping tool for pins
© TMHE 21 – 3 T Code(s): 887, 888

21.4 Molex connectors
16
9
8
1
Part number
Classification
Tools Use
Inspection
interval
156937 Crimping tool for pins
156936 Crimping tool for fitting sleeves/pins
© TMHE 21 – 4 T Code(s): 887, 888

21.5 CPC contacts
Tools Number Use

1=213336 (CPC) Crimping tool (sleeves only)
2=213338 (CPC)
1
2
183593 Pin/sleeve removal tool
© TMHE 21 – 5 T Code(s): 887, 888

21.6 MQS contacts
Tools Number Use

257841 MQS Basic toolbox.
The box contains:

1 pair crimping pliers
1 pair stripping pliers
25 x splice sleeves 0.5-1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
connectors (male and female) with
prewired cables and splicing sleeves.
Please use to replace damaged connectors
on the truck.
© TMHE 21 – 6 T Code(s): 887, 888

Tools Number Use

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

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

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

female connectors.
© TMHE 21 – 7 T Code(s): 887, 888

21.7 Grease guns

24981 A tool with a pointed nozzle used to
apply grease. Length 170 mm.
755132 Single-hand grease gun with straight

discharge pipe and nozzle.
755142 Two-handed grease gun with angled

fif
discharge pipe and nozzle.
755152 Two-handed grease gun with hose and

nozzle.
755146 Lubricating hose 450 mm

Lubricating hose 750 mm
Lubricating hose 1500 mm
202154PM Pointed nozzle for grease guns used to

apply grease in recessed nipples.
Fits grease guns with hose and
discharge pipe. Length 125 mm.
755140 Nozzle for necked nipples. Fits grease
guns with hose and discharge pipe.
© TMHE 21 – 8 T Code(s): 887, 888

21.8 Other tools

7516708 Service instrument (CAN)
1=7521083 Service instrument

1 2=163793 (CASTOR USB)
for programming
1=163793 Service instrument for

(connecting wire) program changes
2=163792
(Adapter for
connection to PC
parallel printer
port)
© TMHE 21 – 9 T Code(s): 887, 888


08-13022 Drive gear puller
680832 Chain gauge
N/A Removing or fitting the hydraulic

12 unit’s pressure limiting valve:
A 22 mm standard socket is machined
down to the values shown in the
26,5
illustration.
N/A Slacken or tighten the locking nut

8 for the adjuster screw on the
hydraulic unit’s pressure limiting
valve:
13,5
A 10 mm standard socket is machined

down to the values shown in the
illustration.
© TMHE 21 – 10 T Code(s): 887, 888

22. Service data and grease specifications

22.1 General tightening torques
Millimetre threads M3 to M24. The following applies in the case of good
conditions, e.g. steel against steel.
22.1.1 Galvanised, non-oiled screws
Strength class:
8.8 10.9 12.9
M3 1.1 1.6 2.0
M4 2.8 3.8 4.7
M5 5.5 7.7 9.3
M6 9.5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075
Tightening torque ‘T’ (Nm)
22.1.2 Untreated, oiled screws
Strength class:
8.8 10.9 12.9
M3 1.2 1.7 2.1
M4 2.9 4.0 4.9
M5 5.7 8.1 9.7
M6 9.8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
Tightening torque ‘T’ (Nm)

NOTE:
Experience has shown that if the torque wrench is adjusted to the values for untreated
screws, the correct torque value for galvanised screws will also be obtained. Do not
tighten more than the values indicated in the table, otherwise the screws can be
destroyed.
© TMHE 22 – 1 T Code(s): 887, 888

22.2 Lubrication chart

Lubrication chart
Interval/Operating hours
Service point Lubricant*
500 h 1000 h 3000 h
Wheel bearings, bushes L A
Mast beam L F
Lifting chains L D
Hydraulic system C O B
Steering bearing L G
Drive gear C O C
Gear ring L E
Grease nipples L A
Guides C A
L = Lubrication
C = Check
O= Oil change
* See section "22.3 Oil and grease specification".
Note:
Change the oil in the drive gear for the first time at 500 hours and then every
3000 h/36
months.
Change the oil and clean the tank for the first time at 500 hours and then
every 1000 h/12 months.
© TMHE 22 – 2 T Code(s): 887, 888

22.3 Oil and grease specification
Specification Usage
Lubricants
> -15 °C < -15 °C
223690 223690
A Grease (Q8 Rembrandt (Q8 Rembrandt Bearings and bushings
EP2). EP2).
B Hydraulic oil See table below Hydraulic system
Mineral oil based hypoid oil
C Transmission oil SAE 80W-90 Gear wheel
Class API-GL5
D Grease See table below Chains
Grafloscon Grafloscon
E Grease Gear ring
A-G1 (Klüber) A-G1 (Klüber)
223690
755784-040
F Grease (Q8 Rembrandt Mast
Q8 Rubens LT
EP2).
Staburags Staburags
G Grease Steering bearing
NBU 8EP NBU 8EP
Ambient
Pos. Viscosity class Usage
temperature
ISO VG32
B 0°C-40°C ISO 6743-4 category HM Hydraulic system
DIN 51524 part 2 = HLP
ISO VG 27.5
B -35°C-40°C ISO 6743-4 category HV Hydraulic system
DIN 51524 part 3 = HVLP
Ambient
Pos. Viscosity class Recommended products*
temperature
> -40°C
D VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< -30°C
> -30°C Klüberoil 4UH 1-68N, Klüber Lubrication
D VG 68
< +5°C Anticorit LBO 160 TT, Fuchs DEA
Klüberoil 4UH 1-150N, Klüber Lubrication
> +5°C
D VG 150 Anticorit LBO 160, Fuchs DEA
< +45°C Rexoil, Rexnord Kette
> +45°C
D VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
< +80°C
* Equivalent products from another manufacturer may be used.
© TMHE 22 – 3 T Code(s): 887, 888

© TMHE 22 – 4 T Code(s): 887, 888

23. Technical data

23.1 Basic data
Model OSE120 OSE120P OSE250 OSE250P

Truck traction
Type AC induction AC induction AC induction AC induction
motor motor motor motor
Output 2.8 kW 2.8 kW 2.8 kW 2.8 kW
Duty cycle S2, 60 min S2, 60 min S2, 60 min S2, 60 min
Weight 21 kg 21 kg 21 kg 21 kg
Transmission/gear
mechanism
Designation 2-stage drive unit 2-stage drive unit 2-stage drive unit 2-stage drive unit
Gear ratio 14.2:1 14.2:1 14.2:1 14.2:1
Oil volume, litres 1.8 1.8 1.8 1.8
Hydraulic system
Pump motor, type
Output 2.0 kW 2.0 kW 1.2 kW 2.0 kW
Duty cycle S3-7% S3-7% S3-4.5% S3-7%
Pressure at rated load 185 bar 185 bar 155 bar 155 bar
Overflow pressure 190 bar 190 bar 185 bar 190 bar
Pump displacement 1.6 CC 1.6 CC 1.25 CC 1.6 CC
Tank volume, litres 2 litres 2 litres 1 litres 2 litres
Brakes
Output 30 W 30 W 30 W 30 W
Resistance, coil 4.8 Ω 4.8 Ω 4.8 Ω 4.8 Ω
Nominal clearance in applied 0.2 – 0.4 mm 0.2 – 0.4 mm 0.2 – 0.4 mm 0.2 – 0.4 mm
position
Thickness of new friction disc 7 mm 7 mm 7 mm 7 mm
Wheels
Drive wheel 250x105 mm 250x105 mm 250x105 mm 250x105 mm
Wheel load unloaded, short/ 545/562 kg 545/562 kg 480/500 480/500
long chassis
Wheel load at rated load, 798/725 kg 798/725 kg 833/894 833/894
short/long chassis
Fork wheel, bogie 85 x 75 mm 85 x 75 mm 85 x 75 mm 85 x 75 mm
long chassis
short/long chassis
Castor wheel 150 x 75 mm 150 x 75 mm 150 x 75 mm 150 x 75 mm
© TMHE 23 – 1 T Code(s): 887, 888


long chassis
short/long chassis
Battery compartment, Batteries
Battery compartment
Dimensions LxWxH
Short 212 x 790 x 775 212 x 790 x 775 212 x 790 x 775 212 x 790 x 775
Long mm mm mm mm
303 x 790 x 775 303 x 790 x 775 303 x 790 x 775 303 x 790 x 775
mm mm mm mm
Capacity -620 Ah -620 Ah 310-620Ah 310-620Ah
Maximum/minimum weight 239/501 kg 239/501 kg 239/501 kg 239/501 kg
Travel speed
Without load 12 km/h 12 km/h 12 km/h 12 km/h
With rated load 8 km/h 8 km/h 8 km/h 8 km/h
Lifting/lowering speed
Lift
with load 0.13 m/s 0.13 m/s 0.067 m/s 0.067 m/s
without load 0.15 m/s 0.15 m/s 0.094 m/s 0.094 m/s
Lowering
with load 0.22 m/s 0.22 m/s 0.06 m/s 0.06 m/s
without load 0.18 m/s 0.18 m/s 0.06 m/s 0.06 m/s
Gradient capability
Without load 5% 5% 13% 13%
With rated load 5% 5% 8% 8%
Truck weight without battery
Short chassis, 1184 kg 1184 kg 765 kg 765 kg
Long chassis, 1263 kg 1263 kg 897 kg 897 kg
Dimensions
Chassis
Short 2556 mm 2556 mm 2389 mm 2389 mm
Long 2642 mm 2642 mm 2574 mm 2574 mm
Chassis width 790 mm 790 mm 790 mm 790 mm
Turning radius with fork (Wa),
short chassis 2386 mm 2386 mm 2225 mm 2225 mm
Turning radius with fork (Wa),
long chassis 2472 mm 2472 mm 3090 mm 3090 mm
Lifting height 800 mm 800 mm 235 mm 235 mm
Power steering
© TMHE 23 – 2 T Code(s): 887, 888


Output 240 W 240 W 240 W 240 W
Voltage 24 V 24 V 24 V 24 V
Max. current, continuous 13 A 13 A 13 A 13 A
Max. current, momentary 45 A 45 A 45 A 45 A
Insulation class F F F F
Torque, continuous load 17 Nm 17 Nm 17 Nm 17 Nm
Torque, momentary 70 Nm 70 Nm 70 Nm 70 Nm
Max radial load 3500 N 3500 N 3500 N 3500 N
© TMHE 23 – 3 T Code(s): 887, 888

23.1.1 Speed limitation

The truck's maximum travel speed is limited depending on a combination of
factors, i.e. direction of travel, load, load lift height, steering angle, the
operator's driving position and the platform height. Operator parameter
settings also affect maximum speed. See section "5.2.3 Operator
parameters". for more information. The table below summarises the speed
limitations and assumes that all relevant operator parameters are set to
100%. Note that the speeds given are nominal.
© TMHE 23 – 4 T Code(s): 887, 888

Summary of speed limitations
OSE120, OSE120P
Platform Maximum speed km/h

Load lift height Operator position Steering
In drive Info
height above above and load (kg) [S19] angle In fork
wheel .
floor [S12] floor & [B10] degrees direction
[S103] direction
0 12 10.5
15 12 10
On platform &
25 11 9.6
0 to 300 kg last
60 8.7 7.6
85 7 6
< 0.5 m < 0.5 m
0 12 - 8 10.5 - 6
15 12 - 8 10 - 6
On platform &
25 11 - 8 9.6 - 6
300 to max. load
60 8.7 - 8 7.6 - 6
85 7 6
On platform &
> 0.5 m < 0.5 m 6 6
0 to max. load
On platform & < 700 kg 0 to 100 6 6
0 to max. load
> 0.5 m 2.3
height On platform and
6 - 2.5 6 - 2.5
700 kg to max. load
0 to 10 4 2.5
By side of truck and
< 0.5 m < 0.5 m 20 to 30 2.5 2.5
0 to max. load
>30 0 0
0 to 10 4 2.5
20 to 30 2.5 2.5 1
< 700 kg load
>30 0 0
> 0.5 m < 0.5 m
0 to 10 4 - 2.5 2.5
20 to 30 2.5 2.5
700 kg to max. load
>30 0 0
© TMHE 23 – 5 T Code(s): 887, 888

Summary of speed limitations
OSE250, OSE250P
Maximum speed km/h

Steering
Platform height above Operator position In drive Info
angle In fork
floor and load (kg) wheel .
degrees direction
direction
0 12 10.5
15 12 10
On platform &
25 11 9.6
0 to 500 kg load
60 8.7 7.6
< 0.5 m
85 7 6
0 12-8 10.5-7.5
On platform &
15 12-8 10.5-7.5
500 to max. load
85 7 6
On platform &
0.5 to max. height 0 to 100 6 6 2.3
0 to max. load
0 to 10 4 2.5
By side of truck and 0
< 0.5 m 20 to 30 2.5 2.5 1
kg to max. load
>30 0 0
1. In this mode, is displayed.
2. In this mode, is displayed.
3. In this mode, is displayed if the operator is not standing

on the platform. Neither the lift nor travel functions work in this condition.
© TMHE 23 – 6 T Code(s): 887, 888

TOYOTA MATERIAL HANDLING EUROPE, MANAGING THE TOYOTA AND BT MATERIALS HANDLING BRANDS IN EUROPE.

Repair Manual 7536388-040: OSE120, OSE120P, OSE250, OSE250P

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Repair Manual 7536388-040: OSE120, OSE120P, OSE250, OSE250P

Uploaded by

Copyright:

Available Formats

Repair manual 7536388-040

OSE120, OSE120P, OSE250, OSE250P.

Publishing Order Amendments

This manual contains information on the following trucks:

T-Code Model Serial number

© TMHE T Code(s): 887, 888

© TMHE 1– 1 T Code(s): 887, 888

6. Installation and commissioning ................................................................... 6–1

© TMHE 1– 2 T Code(s): 887, 888

9. Chassis – C0000............................................................................................. 9–1

© TMHE 1– 3 T Code(s): 887, 888

12.3 Drive wheel - C3530 ................................................................................ 12–5

© TMHE 1– 4 T Code(s): 887, 888

15. Hydraulic system – C6000......................................................................... 15–1

© TMHE 1– 5 T Code(s): 887, 888

16.1.2 Checking the chain ..................................................................... 16–1

© TMHE 1– 6 T Code(s): 887, 888

18.2.2 Marking according to the manufacturer’s standards .................. 18–2

© TMHE 1– 7 T Code(s): 887, 888

© TMHE 1– 8 T Code(s): 887, 888

© TMHE 2– 1 T Code(s): 887, 888

2.2 Warning symbols

© TMHE 2– 2 T Code(s): 887, 888

2.4 Abbreviations used in this manual

© TMHE 2– 3 T Code(s): 887, 888

© TMHE 2– 4 T Code(s): 887, 888

3. General safety rules

3.1 Work safety

© TMHE 3– 1 T Code(s): 887, 888

© TMHE 3– 2 T Code(s): 887, 888

3.2 Electrical system

© TMHE 3– 3 T Code(s): 887, 888

3.3 Safe lifting

© TMHE 3– 4 T Code(s): 887, 888

3.4 Truck modifications

© TMHE 3– 5 T Code(s): 887, 888

© TMHE 3– 6 T Code(s): 887, 888

4. Operation and connection sequences

Symbols on keypad and display

Battery charge as a percentage

© TMHE 4– 1 T Code(s): 887, 888

4.1 Battery is connected

Event Connection of battery

Action(s) Connect battery [X1, G1]

Event PIN code login

4.3 Basic conditions for driving

Event Steering unit lowered to drive position

Action(s) Lower the steering unit

© TMHE 4– 2 T Code(s): 887, 888

4.4 Driving in fork direction

Event Driving, fork direction

Action(s) Move the speed control [L1] in the fork direction.

4.5 Driving in the drive wheel direction

Event Driving, drive wheel direction

© TMHE 4– 3 T Code(s): 887, 888

4.6 Braking in neutral

Event Neutral braking

4.7 Reverse braking

Event Reverse braking

4.8 Brake operation via controls

Event Mechanical braking

© TMHE 4– 4 T Code(s): 887, 888

Event Mechanical braking