Service Manual Spe160l 7SLL12.5 - 20F Sn.924454aa

Service Manual
en
7SLL12.5, 7SLL16, 7SLL20, 7SLL13.5S,

7SLL12.5F, 7SLL16F, 7SLL20F
Valid from serial number: 924454-
Order number: 230087-040

Issued: 2007-03-23 ITS
©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:
Issue date Order Changes

number
2004-12-20 222641-040 Completely new issue.
2005-12-02 230087-040 M4, P2, P3, P4, 0000 (new), 4300 (new), 5000, TruckCom
2006-03-06 230087-040 Updated chapters: Technical data, Maintenance (new chapter
replaces P1, P2 and P3), 0000 (spring replacement), 5000,
6000, 7000 (replaces 7120)
2007-03-23 230087-040 New truck model: 7SLL20, 7SLL20F
Updated chapters: Technical data, 1760, 2550, 5000.
This manual covers following truck models:
T-code Model Serial number

789 7SLL12.5, 924454-
7SLL16
790 7SL13.5S 924454-
791 7SL12.5F, 924454-
7SLL16F
817 7SLL20 955093-
818 7SLL20F 955093-
© TIEE SARL Service Manual 7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F Approved by: L-G A
Table of contents
Order number Date Valid from serial number T-code
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
1- Table of contents
2- Technical data ..................................................................................... 2-1
2.1 General tightening torques............................................................. 2-7
2.1.1 Galvanised, non-oiled bolts ............................................. 2-7
2.1.2 Untreated, oiled bolts ....................................................... 2-7
3- Maintenance ........................................................................................ 3-1

3.1 Safety rules during maintenance work ........................................... 3-1
3.2 Cleaning and washing.................................................................... 3-3
3.2.1 External cleaning ............................................................. 3-3
3.2.2 Cleaning the motor compartment .................................... 3-3
3.2.3 Electric components ........................................................ 3-3
3.3 Safe lifting ...................................................................................... 3-4
3.4 Lifting the truck............................................................................... 3-5
3.5 Maintenance schedule ................................................................... 3-6
3.6 Lubrication chart .......................................................................... 3-12
3.7 Oil and grease specification ......................................................... 3-14
4- Tools ..................................................................................................... 4-1

4.1 Super Seal connectors................................................................... 4-1
4.2 AMP connectors............................................................................. 4-2
4.2.1 AMP Connectors, 040 series ........................................... 4-3
4.3 Molex connectors........................................................................... 4-3
4.4 Grease guns .................................................................................. 4-4
4.5 Other tools ..................................................................................... 4-5
5- Chassis – 0000 ..................................................................................... 5-1

5.1 Support arms ................................................................................. 5-1
5.1.1 General ............................................................................ 5-1
5.1.2 Main components ............................................................ 5-2
5.1.3 Maintenance .................................................................... 5-2
5.1.4 Adjusting the support arm width ...................................... 5-3
5.1.5 Support arm replacement ................................................ 5-4
5.2 Engine suspension......................................................................... 5-5
5.2.1 Components .................................................................... 5-5
5.2.2 Disassembly .................................................................... 5-5
5.2.3 Spring replacement ......................................................... 5-6
5.3 Platform ......................................................................................... 5-7
5.3.1 Components .................................................................... 5-7
5.3.2 Disassembly .................................................................... 5-7
6- Electric drive motor – 1760 ................................................................. 6-1

6.1 Included components..................................................................... 6-1
6.2 Disassembly/assembly of the truck motor...................................... 6-3
6.2.1 Disassembly .................................................................... 6-3
6.2.2 Assembly ......................................................................... 6-3
6.3 Service/repairs ............................................................................... 6-4
6.3.1 Disassembly of the motor ................................................ 6-4
6.3.2 Motor installation ............................................................. 6-4
6.3.3 Cleaning .......................................................................... 6-5
© TIEE SARL Service Manual 7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F 1- 1
Table of contents
T-code Valid from serial number Date Order number
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
7- Drive unit/gear – 2550 ......................................................................... 7-1

7.1 General .......................................................................................... 7-1
7.2 Included components..................................................................... 7-2
7.3 Disassembly of the drive unit from the truck................................... 7-4
7.4 Assembly of the drive unit in the truck............................................ 7-4
7.5 Oil inspection or changing oil ......................................................... 7-5
7.5.1 Oil inspection/replenishment ........................................... 7-5
7.5.2 Changing oil ..................................................................... 7-5
7.6 Replacing the gasket ring............................................................... 7-5
7.6.1 Disassembly .................................................................... 7-5
7.6.2 Assembly ......................................................................... 7-6
7.7 Leakage from top cover ................................................................. 7-6
8- Electromagnetic brake – 3370 ............................................................ 8-1

8.1 Main components of the brake ....................................................... 8-1
8.2 Maintenance .................................................................................. 8-2
8.2.1 Basic adjustment of the play ............................................ 8-2
8.2.2 Brake disc replacement ................................................... 8-3
9- Electrical steering system – 4300 ...................................................... 9-1

9.1 Electrical steering servo ................................................................. 9-1
9.1.1 General ............................................................................ 9-1
9.2 Steering servo components ........................................................... 9-2
9.3 Adjustment ..................................................................................... 9-3
9.3.1 Reference sensor ............................................................ 9-3
9.3.2 Calibration ....................................................................... 9-3
Parameter 36 ................................................................... 9-3
Parameter 37 ................................................................... 9-3
10- Electrical systems – 5000 ............................................................... 10-1

10.1 General ........................................................................................ 10-1
10.1.1 Part numbers ................................................................. 10-1
10.1.2 Nomenclature ................................................................ 10-2
10.2 Electrical equipment overview ..................................................... 10-3
10.2.1 Component placement .................................................. 10-3
10.2.2 Component list ............................................................... 10-5
10.3 Electrical wiring diagram .............................................................. 10-9
10.3.1 Symbol list ..................................................................... 10-9
10.3.2 Overview ...................................................................... 10-10
10.3.3 Detailed wiring diagram ............................................... 10-11
10.4 Functional description ................................................................ 10-27
10.4.1 Principle of operation ................................................... 10-27
10.4.2 Description of steering system .................................... 10-32
10.4.3 Spider expansion unit (SEU) ....................................... 10-32
10.4.4 Speed limitation ........................................................... 10-34
10.4.5 Hour meter and battery condition ................................ 10-35
10.4.6 TLS - Truck log system (optional) ................................ 10-36
General ........................................................................ 10-36
Registration ................................................................. 10-36
Logging in/out SD16 .................................................... 10-36
Logging in/out S16 ....................................................... 10-36
Collision sensor ........................................................... 10-37
Settings ........................................................................ 10-37
10.4.7 ID unit (optional) .......................................................... 10-37
1- 2 Service Manual 7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F © TIEE SARL
Table of contents
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.5 Parameters ................................................................................ 10-38

10.5.1 General ........................................................................ 10-38
10.5.2 Viewing parameters -CAN key not connected ............. 10-38
10.5.3 Viewing parameters - CAN key connected .................. 10-39
10.5.4 Setting Driver parameters ............................................ 10-40
10.5.5 Setting Service parameters ......................................... 10-40
10.5.6 Summary of driver parameters .................................... 10-41
10.5.7 Description of driver parameters ................................. 10-42
# 2 - Maximum speed, high range ............................... 10-42
# 3 - Maximum acceleration ........................................ 10-42
# 4 - Neutral braking effect .......................................... 10-42
# 6 - Maximum speed, low range ................................ 10-42
# 7 - Maximum speed, “Turtle” mode .......................... 10-42
10.5.8 Summary of service parameters .................................. 10-43
10.5.9 Description of service parameters ............................... 10-45
# 10 - PIN code ............................................................ 10-45
To enter a new PIN-code: ............................................ 10-45
To remove an existing PIN-code: ................................ 10-46
# 14 - Creep speed ...................................................... 10-46
#15 - Non-configurable options ................................... 10-46
Setting Non-configurable options ................................ 10-46
#16 - Configurable option #1 ....................................... 10-47
# 20 - Hour meter selection ......................................... 10-48
# 21 - Battery size ........................................................ 10-49
# 22 - Maximum fork lowering speed ........................... 10-49
# 23 - Fork lower stop ramp ......................................... 10-49
# 25 - Service interval .................................................. 10-49
# 35 - Log off ............................................................... 10-49
# 36 - Calibrate ............................................................ 10-50
# 37 - Steering offset ................................................... 10-53
# 38 - Steer servo activated ......................................... 10-53
# # 39 - Log-in method & operator parameter access . 10-53
Extended keypad - General ......................................... 10-54
Extended keypad - Programming ................................ 10-54
10.5.10 Configurable “Option” Parameters ............................... 10-57
General ........................................................................ 10-57
Parameter #16 to #19 Configurable options ................ 10-58
10.6 Diagnostic and troubleshooting.................................................. 10-71
10.6.1 General ........................................................................ 10-71
10.6.2 Fault code history ........................................................ 10-72
10.6.3 List of fault codes ......................................................... 10-73
10.6.4 Transistor regulator ..................................................... 10-80
General ........................................................................ 10-80
Transistor regulator errors ........................................... 10-81
Resetting errors ........................................................... 10-82
Safety .......................................................................... 10-82
10.6.5 Built-in Test Function ................................................... 10-83
Digital inputs/outputs test mode .................................. 10-85
10.6.6 Display test mode ........................................................ 10-88
10.7 Technical specifications – Curtis 1243 ....................................... 10-89
Table of contents
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
11- Hydraulic system – 6000 ................................................................. 11-1

11.1 Hydraulic diagram ........................................................................ 11-1
11.1.1 With height-adjustable support arms ............................. 11-1
11.1.2 Without height-adjustable support arms ........................ 11-2
11.2 Main Components........................................................................ 11-3
11.3 Description ................................................................................... 11-4
11.3.1 Lifting system ................................................................. 11-4
11.3.2 The PowerTrak system .................................................. 11-4
11.3.3 Working pressure .......................................................... 11-5
11.3.4 Overflow valve ............................................................... 11-5
11.3.5 Pressure sensor ............................................................ 11-5
12- Lift mast – 7000 ............................................................................... 12-1

12.1 Mast incline .................................................................................. 12-1
12.2 Main lift chain system................................................................... 12-2
12.2.1 Checking the chain setting ............................................ 12-2
12.2.2 Chain inspection ............................................................ 12-2
Noise ............................................................................. 12-2
Surface rust ................................................................... 12-2
Rusty links ..................................................................... 12-2
Stiff links ........................................................................ 12-2
Bolt rotation ................................................................... 12-3
Loose bolts .................................................................... 12-3
Outline wear .................................................................. 12-3
Stretching ...................................................................... 12-4
Damage ......................................................................... 12-5
Damaged discs .............................................................. 12-5
Damaged bolts .............................................................. 12-5
Dirty chain ...................................................................... 12-5
12.2.3 Cleaning ........................................................................ 12-5
12.2.4 Lubrication ..................................................................... 12-6
Table of contents
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13- TruckCom ........................................................................................ 13-1

13.1 General ........................................................................................ 13-1
13.2 Connection................................................................................... 13-1
13.3 Layout .......................................................................................... 13-2
13.3.1 Main program screen ..................................................... 13-2
13.3.2 Nodes ............................................................................ 13-2
13.3.3 Icons .............................................................................. 13-3
13.3.4 Tool buttons and menu bar ............................................ 13-3
13.3.5 Information window ........................................................ 13-4
13.3.6 Status bar ...................................................................... 13-4
13.4 Connection function .................................................................... 13-4
13.5 Disconnection function................................................................. 13-4
13.6 Downloading program function .................................................... 13-5
13.6.1 Normal downloading (truck with key) ............................. 13-5
13.6.2 Normal downloading (truck with keypad) ....................... 13-5
13.6.3 Emergency downloading (truck with keypad) ................ 13-6
13.6.4 Emergency downloading (truck with keypad) ................ 13-6
13.6.5 Downloading in old versions of logic card ..................... 13-6
13.7 Truck report function .................................................................... 13-7
13.8 Parameters function..................................................................... 13-8
13.9 Diagnostics function..................................................................... 13-8
13.9.1 Representation of signal colours ................................... 13-9
13.9.2 “Tiller arm” tab ............................................................... 13-9
13.9.3 “Drive Controller” tab (transistor regulator driving) ..... 13-10
13.9.4 “Pump controller” tab (transistor regulator pump) ....... 13-11
13.9.5 “EPS” (steering servo tab) ........................................... 13-12
13.9.6 SEU tab (Extra I/O module) ......................................... 13-13
13.10 Other menu functions................................................................. 13-13
13.10.1 Save to file ................................................................... 13-13
13.10.2 Download from file ....................................................... 13-13
13.10.3 Reset CAN adapter ..................................................... 13-14
13.10.4 Delete error code log ................................................... 13-14
13.10.5 Reset hour meter ......................................................... 13-14
13.10.6 Read error code log ..................................................... 13-14
13.10.7 Adjust date and time .................................................... 13-14
13.10.8 Adjusting the hour meter on older cards ...................... 13-14
13.10.9 Help ............................................................................. 13-14
About the TruckCom application ................................. 13-14
13.10.10 Exit ............................................................................. 13-14
13.11 Specifications............................................................................. 13-15
13.12 Installation.................................................................................. 13-15
13.12.1 Installation on a PC with Windows® 95/98 .................. 13-15
13.12.2 Installation on a PC with Windows XP/2000 ................ 13-16
Changes in Windows® Control Panel ......................... 13-18
13.12.3 Installation on a PC with Windows NT ......................... 13-21
13.12.4 In case of communication problems with CAN ............ 13-21
13.12.5 To uninstall .................................................................. 13-21
Table of contents
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14- Destruction instructions ................................................................. 14-1

14.1 General ........................................................................................ 14-1
14.2 Procedure .................................................................................... 14-1
14.3 Abbreviations ............................................................................... 14-2
14.4 Sorting ......................................................................................... 14-2
14.5 Chassis (0300)............................................................................. 14-3
14.5.1 Dismantling .................................................................... 14-3
14.5.2 Material handling ........................................................... 14-3
14.6 Hoods, covers (0340)................................................................... 14-4
14.6.1 Dismantling .................................................................... 14-4
14.7 Fork structure (low-lifter) (0380)................................................... 14-5
14.7.1 Dismantling .................................................................... 14-5
14.8 Travel platform including mount (0560)........................................ 14-6
14.8.1 Dismantling .................................................................... 14-6
14.9 Overhead guard (option) (0810)................................................... 14-7
14.9.1 Dismantling .................................................................... 14-7
14.10 Operator protective device (0840)................................................ 14-8
14.10.1 Dismantling .................................................................... 14-8
14.11 Electric pump motor (1710).......................................................... 14-9
14.11.1 Dismantling .................................................................... 14-9
14.12 Electric travel drive motor (1760) ............................................... 14-10
14.12.1 Dismantling .................................................................. 14-10
14.12.2 Material handling ......................................................... 14-10
14.13 Drive unit/gear (2550) ................................................................ 14-11
14.13.1 Dismantling .................................................................. 14-11
14.14 Wheels (3500)............................................................................ 14-12
14.14.1 Dismantling .................................................................. 14-12
14.15 Steering arm (4110) ................................................................... 14-13
14.15.1 Dismantling .................................................................. 14-13
14.16 Steering arm (4110) ................................................................... 14-14
14.16.1 Dismantling .................................................................. 14-14
14.17 General electric equipment (5100)............................................. 14-15
14.17.1 Dismantling .................................................................. 14-15
14.18 Cabling (5590) ........................................................................... 14-16
14.18.1 Dismantling .................................................................. 14-16
14.19 Steering and protective electronics (5700)................................. 14-17
14.19.1 Dismantling .................................................................. 14-17
14.20 Lift/lowering sensor (5820) and safety sensor (5830) ................ 14-18
14.20.1 Dismantling .................................................................. 14-18
Table of contents
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
14.21 Hydraulic unit (6100) .................................................................. 14-19

14.21.1 Dismantling .................................................................. 14-19
14.22 Main mast (7100) ....................................................................... 14-20
14.22.1 Dismantling .................................................................. 14-20
14.23 Chassis-mounted hydraulic oil lines (6230)
(and main lift cylinder (6610))..................................................... 14-21
14.23.1 Dismantling .................................................................. 14-21
14.24 Battery charger connector (9380) .............................................. 14-22
14.24.1 Dismantling .................................................................. 14-22
Table of contents
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
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Technical data
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
2- Technical data
Table 1: Technical data

Drive motor
Type TSL140B-DS41
Output 1,7 kW
Duty cycle S2, 60 min
Minimum carbon brush length 13 mm
Nominal commutator diameter Ø63 mm
Minimum commutator diameter Ø60 mm
Resistance, shunt field winding, at 25 C° 0,498 Ω (26C°)
Resistance armature winding, at 24 °C 0,0161 Ω (26C°)
Insulation resistance between the windings and >= 1 Mohm
motor casing
Weight 17 kg
Brake
Type BFK458-12
Braking force 32 Nm
Output 40 W
Resistance coil 14,4 Ω
Nominal play in actuated position 0,3-0,5 mm
Minimum thickness brake disc 8,8 mm
Thickness of a new brake disc 10,0 mm
Transmission/drive gear
Type 2-stage angle transmission
Gear ratio 16,29:1
Oil volume 1,0 litre
Oil type Hypoid oil
Oil type at normal temperature SAE 80W/90
Oil type at temperature < -15oC SAE 75W
Technical data
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

Wheels (See note 1) 7SLL12.5 7SLL12.5F 7SLL13.5S
Drive wheel Ø215x70 mm Ø215x70 mm Ø215x70 mm
Axle pressure without load 390 kg 390 kg 390 kg
Axle pressure at rated load 530 kg 530 kg 530 kg
Tightening torque for wheel bolts 65 Nm 65 Nm 65 Nm
Fork wheel Ø85x75 mm Ø85x75 mm Ø85x75 mm
Ø140x60 mm
Support castors Ø125x50 mm Ø125x50 mm Ø125x50 mm
7SLL16 7SLL16F 7SLL20
Drive wheel Ø215x70 mm Ø215x70 mm Ø215x70 mm
Tightening torque for wheel bolts 65 Nm 65 Nm 65 Nm
Fork wheel Ø85x75 mm Ø85x75 mm Ø85x75 mm
Support castors Ø125x50 mm Ø125x50 mm Ø125x50 mm
7SLL20F
Drive wheel Ø215x70 mm
Axle pressure without load 400 kg
Axle pressure at rated load 595 kg
Tightening torque for wheel bolts 65 Nm
Fork wheel Ø85x75 mm
Support castors Ø125x50 mm
Technical data
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

Hydraulic system
Output 3,0 kW
Duty cycle 11 %
Minimum carbon brush length 10 mm
Minimum commutator thickness/diameter 47 mm
Pressure at rated load 110 bar
Overflow pressure 200 bar
Pump flow, at rated load 13 litre/min
Tank volume 12 litre
Oil type Hydraulic oil
Oil type at normal temperature ISO-L-HM32
Oil type at temperature < -15oC ISO-L-HV32
Fuses
Drive motor circuits 130 A
Pump motor circuits 175 A
Control circuits 7,5 A
Battery compartment, Batteries
Dimensions LxWxH, small/large 168x763x660/264x763x660 mm
Capacity 250/450 Ah
Weigh, max./min. 200/320 kg
Driving speed 7SLL20,
7SLL20F
Without load 8,0 km/h (2,22 m/s) 6 km/h
With rated load 7,0 km/h (1,94 m/s) 5 km/h
Technical data
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

Lift/lowering speed (see note 2 & 3) 7SLL12.5 7SLL12.5F 7SLL13.5S
Lifting without load, above free-lift 0,32 m/s 0,32 m/s 0,32 m/s
Lifting without load, under free-lift 0,28 m/s 0,28 m/s 0,28 m/s
Lifting with rated load, above free-lift 0,19 m/s 0,19 m/s 0,19 m/s
Lifting with rated load, under free-lift 0,17 m/s 0,17 m/s 0,17 m/s
Lowering without load, above free-lift 0,44 m/s 0,44 m/s 0,44 m/s
Lowering without load, under free-lift 0,16 m/s 0,16 m/s 0,16 m/s
Lowering with rated load, above free-lift 0,57 m/s 0,57 m/s 0,57 m/s
Lowering with rated load, under free-lift 0,43 m/s 0,43 m/s 0,43 m/s
Lifting without load, above free-lift 0,26 m/s 0,26 m/s 0,26 m/s
Lifting without load, under free-lift 0,24 m/s 0,24 m/s 0,24 m/s
Lifting with rated load, above free-lift 0,15 m/s 0,15 m/s 0,13 m/s
Lifting with rated load, under free-lift 0,14 m/s 0,14 m/s 0,13 m/s
Lowering without load, above free-lift 0,36 m/s 0,36 m/s 0,35 m/s
Lowering without load, under free-lift 0,15 m/s 0,15 m/s 0,13 m/s
Lowering with rated load, above free-lift 0,45 m/s 0,45 m/s 0,44 m/s
Lowering with rated load, under free-lift 0,37 m/s 0,37 m/s 0,35 m/s
7SLL20F
Lifting without load, above free-lift 0,26 m/s
Lifting without load, under free-lift 0,24 m/s
Lifting with rated load, above free-lift 0,13 m/s
Lifting with rated load, under free-lift 0,13 m/s
Lowering without load, above free-lift 0,35 m/s
Lowering without load, under free-lift 0,13 m/s
Lowering with rated load, above free-lift 0,44 m/s
Lowering with rated load, under free-lift 0,35 m/s
Technical data
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

Power consumption 7SLL12.5 7SLL12.5F 7SLL13.5S
Driving without load 30 A
Driving with rated load 50 A
Lifting without load, above free-lift 100 A
Lifting without load, under free-lift 80 A
Lifting with rated load, above free-lift 215 A
Lifting with rated load, under free-lift 170 A 170 A
Driving without load 55 A
Driving with rated load 70 A
Lifting without load, above free-lift 100 A
Lifting without load, under free-lift 80 A
Lifting with rated load, above free-lift 215 A
Lifting with rated load, under free-lift 170 A 170 A
7SLL20F
Driving without load
Driving with rated load
Lifting without load, above free-lift
Lifting without load, under free-lift
Lifting with rated load, above free-lift
Lifting with rated load, under free-lift
Incline climbing ability
With rated load 10%
Technical data
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

Measurement, L2 7SLL12.5 7SLL12.5F 7SLL13.5S
Small battery compartment 880 mm 921 mm 1370 mm
Large battery compartment (see note 1) 978 mm 1019 mm 1468 mm
Turning radius WA (see note 1) 1716 mm 1696 mm 1633 mm
Max. lifting height (depends on the mast type) 2350- 2350- 2350-
5400 mm 5400 mm 5400 mm
Small battery compartment 907 mm 948 mm 882 mm
Large battery compartment (see note 1) 1005 mm 1046 mm 980 mm
Turning radius WA (see note 1) 1716 mm 1696 mm 1681 mm
Max. lifting height (depends on the mast type) 2350- 2350- 2150-
5400 mm 5400 mm 3950 mm
7SLL20F
Small battery compartment 923 mm
Large battery compartment (see note 1) 1021 mm
Turning radius WA (see note 1) 1709 mm
Max. lifting height (depends on the mast type) 2150-
3950 mm
Weight 7SLL12.5 7SLL12.5F 7SLL13.5S
Truck without battery, max./min. 960/1220 kg 940/1200 kg 1040/1250 kg
Truck without battery, max./min. 1056/1340 kg 1030/1320 kg 1050/1090 kg
7SLL20F
Truck without battery, max./min. 1030/1170 kg
Note 1 applies to the specification: Triplex mast 415, fork length 1150, small
battery compartment, battery weight 220 kg, truck width 850.
Note 2 applies to the specification:Duplex hilo 415 mast.
Note 3 applies to the specification:Duplex hilo 335 mast.
Technical data
General tightening torques
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
2.1 General tightening torques

Millimetre thread M3 to M24.
The following applies under ideal conditions, e.g. steel against steel.
2.1.1 Galvanised, non-oiled bolts

Tightening torques (Nm)
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
2.1.2 Untreated, oiled bolts

Tightening torques (Nm)
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
NOTE:
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will achieve the correct torque value for
galvanised bolts. Do not tighten more than the values set out in the ta-
ble, as the bolts may otherwise be destroyed.
Technical data
General tightening torques
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Maintenance
Safety rules during maintenance work
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
3- Maintenance
To assure maximum safety and minimum downtime, all items in the
service programme should be covered. The service intervals are only
guidelines and need not be strictly followed. The operator of the truck
should adapt these to local requirements, however, it is important that
the minimum requirements as stated by TOYOTA are observed.
The service intervals are based on truck operating hours and can be
adapted to most common 8-hour shifts. When calculating the service
intervals, the following operating hours have been used:
Day time: 08.00-17.00 (20 hours/week)
Double shift: 06.00-14.00, 14.00-22.00 (40 hours/week)
Triple shift: 06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hours/week)
Make sure the truck receives the necessary regular maintenance serv-
ice according to the maintenance schedule. The truck's safety, efficien-
cy and service life rely on the service and maintenance the truck
receives.
For service and repairs, only use spare parts approved by TOYOTA.
3.1 Safety rules during maintenance

work
Only technicians who have received the necessary training for service
and repairs of this truck type may carry out service and repair work.
• Do not perform any repair work on the truck unless properly trained
and possessing the necessary skills to perform such work.
• Keep the service site clean. Oil and water on the floor could make it
slippery.
• Never wear loose items and jewellery when working on the truck.
WARNING!
Short-circuiting/Burn injuries.
When working on the truck's electrical system, short-circuiting/burn
injuries may occur if metal objects come into contact with live electri-
cal connections.
Remove any watches, rings and other metal jewellery.
• Unless otherwise indicated in this service handbook, always discon-
nect the battery connector prior to performing maintenance work on
the truck.
• Prior to opening any covers to the drive unit and the electrical sys-
tem, be sure to disconnect the power supply to the truck.
Maintenance
Safety rules during maintenance work
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
• Prior to commencing any work on the hydraulic system of the truck,

be sure to slowly depressurize the system.
• Use paper or a thick paper board to inspect possible hydraulic oil
leaks. Do NOT use your hand.
• Keep in mind that the transmission oil and hydraulic system oil may
be burning hot.
WARNING!
Risk of burn injuries.
Hot transmission and hydraulic oil.
Allow the truck to cool down prior to replacing the oil.
• Use only new and clean oil when refilling the hydraulic oil system
WARNING!
Risk of damaging the hydraulic system.
If the oil is contaminated, the hydraulic system components will be
damaged.
Always use new and clean oil in the hydraulic system.
• Store and transport replaced oil in accordance with local regulations.
• Do not flush solvents, etc. used for cleaning into drains that are not
specifically suited for this. Follow local regulations with regards to
destruction of oil, solvents, etc.
• Disconnect the battery prior to performing welding work on the truck.
NOTE!
The battery could become damaged.
When using an electric welding system, the welding current could
reach the battery.
Be sure to first disconnect the battery.
• Prior to welding or grinding on painted surfaces, be sure to scrape
off the paint at least 100 mm around the welding/grinding site using
blasting or a paint remover.
CAUTION!
Unhealthy gasses.
Paint, which is heated, generates unhealthy gasses.
Remove the paint 100 mm around the working place.
Maintenance
Cleaning and washing
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3.2 Cleaning and washing

Cleaning and washing of the truck is important to assure a high level of
reliability.
• Clean and wash the truck once a week.
NOTE!
Risk of short-circuiting.
The electrical system can become damaged.
Prior to washing, be sure to disconnect the battery by disconnecting
the battery connector.
3.2.1 External cleaning

• Remove dirt, chips, etc. from the wheels daily.
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion.
• Wash off loose dirt using lukewarm water.
NOTE!
Seizure, corrosion.
Mechanical parts could become damaged.
Following washing of the truck, lubricate it according to the lubrica-
tion schedule in the Maintenance section.
3.2.2 Cleaning the motor compartment

• Prior to washing, cover all electric motors, connectors and valves.
NOTE!
The electrical system can become damaged.
Electric components must not be washed with a high-pressure jet.
• Wash the motor compartment with a well-known degreasing agent
diluted to a suitable concentration.
• Wash off loose dirt using lukewarm water.
3.2.3 Electric components

• Use compressed air to blow clean the electric motors.
• Clean electric panels, logic cards, connectors, valves, etc. with a rag
moistened with water and a suitable detergent.
NOTE!
Electric components can become damaged.
Avoid breaking the warranty seals on the logic cards.
Maintenance
Safe lifting
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
3.3 Safe lifting

Perform all lifts on level, slip-proof and firm surfaces. Avoid newly laid
asphalt on warm summer days.
• Always apply the parking brake to prevent the truck from moving
during lifting. If the brake wheel needs to be lifted, be sure to block
the other wheels to make sure the truck will stand still.
• Select a lifting point that will make the lift as light as possible (one
corner at a time). If the lifting point on the truck are indicated on the
lower part of the chassis, be sure to use this to assure balanced lift-
ing.
• Ensure that the surface where the jack is placed is clean and free
from oil.
• Use clean hands and make sure the jack handle is free from grease
and oil.
• Use the handle supplied with the jack. Too short a handle will require
more strength than necessary. Too long a jack may result in over-
loading of the jack.
• Secure the truck with trestles, etc.:
- As close to the lifted part of the chassis as possible in order to re-
duce the falling height if the truck should collapse.
- To prevent the truck from rolling.
- Never chock up the jack in order to achieve a higher lifting height.
- Never work under a lifted truck unless it has been securely
chocked up.
WARNING!
Risk of crushing.
A poorly chocked up truck may fall down.
Never work under a truck unless it has been securely chocked up us-
ing trestles or other safe hoisting gear.
Maintenance
Lifting the truck
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3.4 Lifting the truck
600+-100
600+-100
• Lift the truck at its centre of gravity using another fork lift truck.
• Fasten 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 lift-
ing 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 at the indicated lifting points.
Maintenance
Maintenance schedule
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
3.5 Maintenance schedule
Table 2: Maintenance schedule

I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.
M:Control measurement, rectify if necessary
Pos. Work to carry out
no. Interval in hours - may vary due to applica- 5 20 500 1000 3000
tion
Interval in days/weeks/months - may vary 1d 1w 6m 12m 36m
due to application
0000 Chassis
0000.1 Inspect all shafts, links and clamping pins I
0000.2 Inspect possible damage on the chassis; open the I
battery cover and use it as an aid
0000.3 Check the cover locks I
0000.4 Check finger guard I
0000.5 Check signs and stickers I
0000.6 Inspect the operator platform I
0350 Support arm
0350.1 Tightening torque inspection of the cap bolts (Note T
7)
0380 Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
0380.3 Press grease into grease nipples (Note 6) I/L
0380.4 Check the lift limit switch I
0380.5 Inspect the guides for wear and lubricate them (Note I/L
6)
0380.6 Inspect the load support (Option) I
0450 Frame-mounted components
0450.0 Inspect the motor plate links and turning pipe I
Maintenance
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

tion
due to application
1700 Drive motors
1700.1 Check clearance in connections I/T1 I/T
1700.2 Inspect the carbon brushes in the drive motor and lift M
motor
1700.3 Clean the drive motor and lift motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing I
2550 Drive unit
2550.1 Check for leakage I3 I
2550.2 Check the oil level I
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steering I
bearing
2550.5 Change the oil in the drive gear L4 L
2550.6 Lubricate the gear rim L
3100 Brake
3100.1 Clean and verify correct operation of the service C/I
brake and parking brake
3100.2 Inspect brake disc weak and verify correct tightening M
torque (32 Nm)
3100.3 Check the clearance in disengaged position. (0,2-0,3 M
mm)
Maintenance
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

tion
due to application
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tightening M
torque on bolts
New wheel: Tread thickness = 30 mm
Tightening torque = 65 Nm) (3500,2)
3500.3 Check whether the castor wheel rotates and swings I
freely; lubricate the horizontal bearing. Inspect the
castor wheels for wear and correct installation. New
wheel: Tread thickness = 10 mm)
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Inspect the steering couplings for excessive play and I
the return spring
4110.3 Inspect the gear of the steering servo unit. (Option) I
5000 Electrical functions
5000.1 Inspect brake switch operation I I
5000.2 Inspect correct operation of the emergency stop I I
switch
5000.3 Check the function of the collision safety switch I I
5000.4 Inspect lifting/lowering operation of the forks (and I I
support arms 7SLL12.5F, 7SLL16F)
5000.5 Inspect correction operation of the platform switch I I
5000.6 Inspect the side guard switch for correct operation I I
5000.7 Check the function of the horn I I
5000.8 Check for wear on cabling I I
5000.9 Check the function of the driver’s control I I
5000.10 Inspect the error code log, operating hours and all I I
segments in the display panel
Maintenance
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

tion
due to application
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over the cell M
plates
5110.2 Check connections to battery, truck and charge I
5110.3 Check that the cell and pole guards are undamaged I
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery locking I
5400 Power system
5400.1 Clean and inspect the mounting devices C/T
5400.2 Re-tighten cable connections T
5400.3 Check the contactor points on K10 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
6000 Hydraulic system
6000.1 Check hoses and connections for wear I
6000.2 Check hoses for wear and damage I
6000.3 Check the oil tank for cracks, leakage and damaged I
mountings
6000.4 Check that the oil level is correct I I
6000.5 Replace the oil and clean the reservoir L5 L
Maintenance
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tion
due to application
6600 Lift cylinder
6600.1 Check for leakage I
6600.2 Check the mountings I
7100 Mast
7100.1 Check for any cracks and other damage I
7100.2 Tighten the mast mounting bolts (tightening torque = T
197 Nm)
7100.3 Inspect the play between the mast member and the I
mast stabiliser rollers inside the mast
7100.4 Inspect lateral play in the mast stabiliser I
7100.5 Inspect the lifting chains and chain rollers for wear I
7100.6 Inspect correct adjustment of the lifting chains I
7100.7 Inspect the chain pin shafts and split cotters I
1 = The connections are re-tightened for the first time after 500h and
then every 1000 /h.
2 = The attachment bolts are re-tightened after 500h to 45 Nm.
3 = Check for leakage in conjunction with the first oil change
4 = The oil is changed for the first time after 500h/6 month and then
every 3000 h/36 months.
5 = Replace the oil and clean the reservoir the first time after 500 hours/
1 month, and then every 1000 hours/12 months.
6 = If the truck is used in cold stores or other severe conditions, perform
this item every 250 hours.
7 = Tightening torque of 110 Nm (+/- 12 Nm).
When points with higher hour intervals are carried out the points with
lower hour intervals should also be carried out unless otherwise speci-
fied above.
Maintenance
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5000
7100
6600
0350
4110
5000
5000
3500 3100
1700
0450
5100 6000
2550
5400
3500
Maintenance
Lubrication chart
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3.6 Lubrication chart
Table 3: Lubrication chart

Pos no Service point Interval/Running hours Lubricant
500h 1000h 3000h
1 Wheel bearing, bushings L A
2 Mast beam L F
3 Lifting chains L D
4 Hydraulic system C O B
5 Steering bearings L G
6 Drive gear C O C
7 Bushings L A
L= Lubrication
C = Check
O= Oil change
Maintenance
Lubrication chart
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Maintenance
Oil and grease specification
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3.7 Oil and grease specification
Table 4: Oil and grease specification

Lubricant Specification Application area
> - 15°C < - 15°C
A Grease 223690 223690 Bearings and bushings
Q8 Rembrandt EP2 Q8 Rembrandt EP2
B Hydraulic oil ISO-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease See table below See table below Chains
F Grease 055-70111 055-74320 Mast
G Grease Staburags Staburags Steering bearings
NBU 8EP NBU 8EP
Ambient temperature Viscosity Recommended products (Similar products from

class other manufacturers may be used)
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
Anticorit LBO 160 TT, Fuchs DEA
< + 5° C
> + 5° C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
Anticorit LBO 160, Fuchs DEA
< +45°C
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
<+ 80°C
Tools
Super Seal connectors
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4- Tools
4.1 Super Seal connectors
3
3
Figure Number Application

159232 Tools for fitting pins/sleeves
159229 Tools for loosening locks (1)
159230 Tool for fitting secondary locks

1-2 poles (2)
159231 Tool for fitting secondary locks

3-6 poles (2)
159228 Tools for removing pins/sleeves (3)
Tools
AMP connectors
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4.2 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) Tools for removing pins/sleeves
213296 (JPT) Tools for removing pins/sleeves
213298 (MPT) Tools for removing pins/sleeves
1=163787 Tools for fitting sleeves

2=163788
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2
Tools
Molex connectors
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4.2.1 AMP Connectors, 040 series

213130 Pin removal tool
213129 Tools for fitting pins
4.3 Molex connectors

16
9
8
1
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins
Tools
Grease guns
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4.4 Grease guns
Figur Nummer Användning

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-hand grease gun with angled dis-

fif
charge pipe and nozzle.
755152 Two-hand grease gun with hose and

nozzle.
755146 Grease hose 450 mm.

Grease hose 750 mm.
Grease hose 1500 mm.
202154PM Pointed nozzle for grease guns used

to apply grease in recessed nipples.
Fits grease guns with hose and dis-
charge pipe. Length 125 mm.
755140 Nozzle for neck nipples. Fits grease
guns with hose and discharge pipe.
Tools
Other tools
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
4.5 Other tools

179915 Service instrument (CAN)
1=163793 Service instrument for pro-

2=163792 gramme changes
08-13022 Driving gear puller
Tools
Other tools
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Chassis – 0000
Support arms
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5- Chassis – 0000
5.1 Support arms
5.1.1 General
Only available on straddle version.
The truck has been assembled to a single unit by bolting the support
arm chassis and the separate mast and support arm mounting loca-
tions to the drive unit.
The support arms of the support arm chassis can be adjusted to differ-
ent support arm widths ranging from 900 mm to 1300 mm to enable
handling of different pallet sizes. Normally, the support arm width has
been preadjusted prior to delivery.
Chassis – 0000
Support arms
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5.1.2 Main components
6 7
5
4
Pos. no. Designation

1 Support arm wheels, bogie type
2 Support arm wheels, single type (option)
3 Support arms
4 Cap, screws and nuts, support arms
M6S M16x110
5 Safety catch, support arms
6 Drive unit
7 Mast mount
8 Locking screws and locking nuts, support
arms
M6S M12x60
5.1.3 Maintenance
Proper fixing of the support arms must be inspected at the regular
500 hour service interval. Inspect the tightening torque (pos. no. 4 in
the section ”Main components”) using a torque wrench set to 110 Nm.
Chassis – 0000
Support arms
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5.1.4 Adjusting the support arm width

B
3
6
2b 2a
5 4
1b 1a
Proceed as follows when adjusting the A measure between the support

arms:
• Lift one side of the truck.
WARNING!
The truck can topple over.
Do not lift both support arms at the same time.
Lift one side at a time and arrange sufficient support under the truck
during this work procedure.
• Loosen the locking nuts and locking screws on the front of the cross
member (1a,1b, 2a and 2b).
• Loosen the cap screws and nuts (3, 4, 5, 6).
• Pull out (or retract) the support arm. To obtain the A measure, the B
measure must equal A/2 - 374 mm. Make sure the B measure is
identical on both sides.
If the support arm is pulled too far out, the safety catch (7) will lock
the support arm to prevent it from falling out of the cross member.
• Following adjustment of the support arm width, tighten the screws
and nuts (1a,1b, 2a, 2b) by hand.
Tightening order: 1a, 1b, 2a, 2b
• Finger tighten the nuts (3, 4, 5, 6) and then tighten them to a torque
of 55 Nm.
Tightening order: 3, 4, 5, 6
Chassis – 0000
Support arms
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
• Slightly loosen 1a and 2a. Then tighten the nuts to a torque of

110 Nm +- 12 Nm.
Tightening order: 3, 4, 5, 6
5.1.5 Support arm replacement
2b 2a
7
1b 1a
3
6
5 4
Replacement of a support arm is a more comprehensive task than sim-

ply adjusting the width.
• Lift out the battery.
• Disassemble the safety catch (7) from the support arm cap.
• Lift up the truck side on which the support arm shall be replaced.
• Loosen the locking bolts on the front of the cross member (1a,1b, 2a
and 2b).
• Loosen the cap bolts (3, 4, 5, 6).
• Pull out the support arm.
• Insert the new support arm and adjust the width as explained in the
section “Adjusting the support arm width”.
• Lower the truck to the floor.
• Install the safety catch (7) once the cap bolts have been tightened.
• Reinstall the battery.
Chassis – 0000
Engine suspension
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5.2 Engine suspension
5.2.1 Components
2 3 4
Pos. Description
1 Axle for torsion tubes
2 Threaded hole
3 Washer
4 Screw
5.2.2 Disassembly
Remove the power unit as follows:
• Unscrew the four screws (4) holding the power unit in place.
• Insert the screws (4) in the threaded holes (2). The torsion tube ax-
les (1) will then be pulled out automatically.
Chassis – 0000
Engine suspension
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5.2.3 Spring replacement

• A = 85 mm
• B = 274 mm
Chassis – 0000
Platform
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5.3 Platform
5.3.1 Components
5
3
Pos. Description
1 Gas damper
2 Screws
3 Compression springs
4 Inductive sensor S19
5 Inductive sensor S59
5.3.2 Disassembly
The platform can be removed to allow easy access to the drive wheel,
for example. This is done by removing the two screws (2) holding the
platform in place. The platform is then loose and can be removed.
Chassis – 0000
Platform
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Electric drive motor – 1760
Included components
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
6- Electric drive motor – 1760
6.1 Included components
18
24
23
22
16 21
15 20
14 19
13
17 10
12
11
7
8
6
5
4
3
2
Included components
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Table 5: Included components

Pos. Name Notes
1 Screw M6x25
2 Bearing plate
3 Locking ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20
8 Carbon brush
9 Rotor
10 Wedge
11 Plug
12 Armature
13 Cable
14 Cable
15 Adjuster bush
16 Fan
17 Bearing plate
18 Screw M6x25
19 Seal
20 Bearing
21 Washer
22 Locking ring
23 Washer
24 Locking ring
Disassembly/assembly of the truck motor
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
6.2 Disassembly/assembly of the truck

motor
6.2.1 Disassembly
• Switch off the truck and disconnect the battery connector.
• Remove the motor compartment covers.
• Disconnect the cables from the motor and the tiller arm.
• Loosen the four nuts from the motor mounts on the driving gear.
• Disconnect the cables for the start switch and the emergency stop
switch. At the same time, remove all cables from the cable recess in
the cover.
• Remove the cover that covers the motor compartment and the tiller
arm mount from the motor. Remove the cover that covers the motor
compartment together with the tiller arm.
• Carefully lift the motor straight up while being careful not to damage
the driving gear sealing surfaces, and place the motor on a clean
surface.
• Protect the driving gear against contamination by covering all ports
with suitable means, e.g. a plastic sheet.
It is now possible to commence with the necessary service and repairs
of the motor.
6.2.2 Assembly
• Assembly is done in reverse.
• Carefully lower the motor into the drive gear while making sure the
seals and gear wheels are not damaged.
• Tighten the pin bolt nuts to the prescribed torque of 27 Nm.
• Install and adjust the brake according to the instructions. Secure the
cover and tiller arm with screws and connect the cables that were
previously disconnected. Verify that the polarity is correct.
• Following completed installation, perform operational testing of the
brake before the truck is operated again.
Service/repairs
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6.3 Service/repairs
6.3.1 Disassembly of the motor

• Loosen the brake disc tappet by first removing the groove ring to-
gether with the washer at the end of the rotor shaft. It is then possible
to remove the tappet by lifting it. It may be necessary to use a suita-
ble tool to free it.
• Us the four plugs that cover the carbon brushes, fold away the car-
bon brush springs and pull out the carbon brushes.
• Disassemble the bearing plate at the end of the commutator togeth-
er with the carbon brush bridge and the carbon brushes by removing
the eight screws. Then set down the motor, arrest it properly to the
edge of the bearing plate and carefully knock at the end of the rotor
shaft with a rubber mallet.
• Disassemble the drive end of the bearing plate together with the ro-
tor. Be careful not to damage the motor windings when the rotor is
remove from the motor cover.
• Once the motor bearing plates have been disassembled and the ro-
tor has been removed from the motor cover, loosen the gear wheel
at the rotor drive end. This is done by loosening the gear wheel nut
and then pulling out the gear wheel with a puller. Please note that the
gear wheel has been secured to the rotor shaft with Loctite.
• Then loosen the inner groove ring together with the washer below
the ring. Pull out the rotor shaft from the bearing.
• Loosen the outer groove ring together with its washer, and remove
the bearing from the bearing plate.
• Remove the bearing plate seal and carefully clean the bearing plate.
• Install a new seal in the bearing plate.
6.3.2 Motor installation

Install the motor in reverse.
• Carefully check whether the rotor can move freely when rotating and
that the carbon brushes press against the commutator.
• Check the insulation resistance of the motor (between each winding
and the motor cover). On a new motor, the measured value should
be 2 - 3 MOhm. When the motor has become dirty, an insulation re-
sistance down to approx. 1 MOhm is acceptable.
• Install a new O-ring on the bearing plate at the drive shaft end and a
new seal on the bearing plate collar.
Service/repairs
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
6.3.3 Cleaning
Keep the motor as clean as possible since this is a decisive factor for
correct operation. Regularly inspect the motor and motor compartment
for build-up of dust, oil and other contaminants.
If the motor windings and internal compartments are dry, use a vacuum
cleaner with a suitable nozzle to clean the motor. Compressed air can
be used together with a vacuum cleaner for cleaning. If this is the case,
make sure the compressed air is clean and dry.
If deposits have formed on the windings, use a lint-free cloth to remove
them. If required, moisten the cloth with an organic, volatile grease sol-
vent that will not damage the windings. However, do not use too much
cleaning agent as it could penetrate into the motor parts.
If grease deposits are left on the surface, use a suitable solvent to
remove cleaning agent remains.
If the motor components are heavily contaminated, it may be necessary
to use a solvent that is sprayed onto the parts. It is especially important
for the rotor that the cleaning agent is applied in a manner that avoids
contaminants from penetrating into the motor section.
One method to clean the rotor is to submerge it in solvent. If this meth-
od is used, be sure to later dry the motor using a heat source. During
the drying process, arrange good ventilation and allow the components
to dry until repeated insulation resistance measurements show similar
and approved values.
Service/repairs
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Drive unit/gear – 2550
General
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
7- Drive unit/gear – 2550
7.1 General
These service instructions cover descriptions of service performed at
the customer site. Complete reconditioning of the driving gear must be
performed in the workshop by trained technicians.
Included components
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
7.2 Included components
2
3
5
16
15
14
13
9
8
7
6
12
11
10
Included components
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
Pos. Designation Note

1 Bleeder valve
2 Cover
3 Dip stick
4 Seal
5 Screw Upper cover and gear housing
Tightening torque 26.6 Nm
Secure with Loctite 242.
6 Nut Tightening torque 300 Nm
Lock with centre punch
7 Washer
8 Conical roller
bearing
9 Shims
10 Bolt Lower cover and gear housing
Tightening torque 25 Nm
Secure with Loctite 242.
11 Cover
12 Seal
13 Conical roller
bearing
14 Shims
15 Sealing
16 Drive shaft
Nuts (assembly of Tightening torque 26.6 Nm
motor - gear hous-
ing)
Wheel nuts Tightening torque 65 Nm
Disassembly of the drive unit from the truck
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
7.3 Disassembly of the drive unit from

the truck
1. Jack up the truck until the wheel clears the floor. Support the truck
with trestles in a safe manner.
2. Disassemble the drive wheel.
3. Drain all oil from the driving gear.
4. Disconnect the motor cables.
5. Disconnect the cables to the brake.
6. Loosen and remove the drive motor bolts and lift away the drive
motor.
7. Secure the drive unit from below.
8. Loosen and remove the nuts securing the drive unit to the chassis.
9. Lower the drive unit enabling removal from under the truck.
10. Place the drive unit on a workbench or similar.
7.4 Assembly of the drive unit in the

truck
1. Lift the gear unit into place in the chassis.
2. Fit a new O-ring on the drive motor bearing cage.
3. Assemble the drive motor and gear case.
Proceed with caution to prevent damage to the O-ring.
4. Tighten the nuts to the torque indicated in the table.
Prior to assembly, apply grease on the nuts.
5. Connect the motor cables.
6. Connect the cable to the brake unit.
7. Fill the driving gear with oil.
8. Assemble the drive wheel.
Tighten the wheel nuts diagonally to the torque indicated in the ta-
ble.
9. Lower the truck to the ground and assemble the motor cover.
Oil inspection or changing oil
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
7.5 Oil inspection or changing oil
7.5.1 Oil inspection/replenishment

Inspect the oil level in the gear case according to the maintenance
chart.
1. Check the oil level in the gear case by removing the oil filling plug
on the upper part of the gear housing.
2. Fill up with oil according to the indication on the dip stick.
7.5.2 Changing oil

Change the gear case oil in accordance with the maintenance chart.
1. Drain the old oil by removing the lower cover.
Use a new seal and apply Loctite when refitting the cover.
2. Fill with oil according to the oil filling instructions.
7.6 Replacing the gasket ring

It is easiest to replace the drive shaft gasket ring when the drive unit
has been disassembled from the truck.
If oil leaks from the drive shaft, follow the instructions below.
7.6.1 Disassembly
1. Disassemble the drive unit from the truck.
2. Remove the lower cover.
3. Loosen the nut. Remove the nut and washer.
4. Press out the drive shaft.
5. Pull of the bearing from the drive shaft is a bearing remover.
6. Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing remover, then measure the to-
tal thickness of the spacing washers and replace them prior to as-
sembly.
7. Remove the gasket ring from the drive shaft.
Leakage from top cover
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
7.6.2 Assembly
Following replacement of the gasket ring, follow the instructions below.
1. Position the outer bearing of the drive shaft in the gear housing.
2. Press the new gasket ring into the gear housing.
When pressing the gasket ring into place, exercise care to make
sure it is correctly positioned.
3. Press the drive shaft into the gear.
Check to make sure the drive shaft splines interconnect with the
drive wheel splines.
4. Screw on the nut and tighten to the torque indicated in the table.
Be sure to always to use a new nut. Prior to assembly, apply
grease on the nut.
5. Before fitting the lower cover, assemble a new seal and apply Loc-
tite.
6. Replace the cover and tighten the bolts to the torque indicated in
the table.
Make sure the seal is not damaged. Prior to assembly, apply
grease on the bolts.
7. Fill with oil.
8. Assemble the drive wheel and tighten the wheel nuts diagonally to
the torque indicated in the table.
Prior to assembly, apply grease on threads.
9. Install the drive unit in the truck.
7.7 Leakage from top cover

Follow the instructions below in case of leakage from the gear case top
cover.
1. Disassemble the gear case from the truck.
2. Loosen all bolts securing the top cover to the gear housing and re-
move the cover.
3. Carefully clean the sealing surfaces of the cover and gear housing.
4. Apply Loctite on the sealing surfaces.
5. Insert the bolts in the cover and tighten the bolts to the torque indi-
cated in the table.
Prior to assembly, apply grease on the bolts.
6. Fill with oil.
7. Assemble the gear case and drive motor. Install the drive unit in the
truck.
Electromagnetic brake – 3370
Main components of the brake
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
8- Electromagnetic brake – 3370
8.1 Main components of the brake

9 1
8
2
6
4
Table 6: Main components of the brake

Pos. no. Description
1 Magnet coil
2 Electric cable
3 Pressure plate
4 Pressure spring
5 Friction plate
6 Adjusting locking nut
7 Brake disc
8 Mounting bolts
9 Hub
Maintenance
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
8.2 Maintenance
In normal use, the brake should not require any maintenance. The pre-
ventive maintenance diagram, however, recommends regular inspec-
tion of the brake disc for wear and also to ensure the play between the
magnet coil housing and pressure plate is correct.
8.2.1 Basic adjustment of the play
9,5 Nm
0,3
The specified play between the magnetic coil housing and the pres-
sure plate should be 0.3 mm when applying the brake. The maximum
play prior to adjustment becoming necessary is 0.8 mm.
Adjustment
• Slightly loosen the tightening of the three mounting bolts.
• Turn the locking nuts counter-clockwise and lightly tighten the bolts
while at the same time checking the play in three places using a 0.3
feeler gauge.
• Tighten the mounting bolts to a torque of 9.5 Nm and reverify the
play using the feeler gauge.
Maintenance
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
8.2.2 Brake disc replacement

Replace the brake disc when its entire thickness has become 8,8 mm.
• Disconnect the electric cables from the brake.
• Loosen and remove the three mounting bolts and the brake coil.
• Replace the brake disc on the hub and inspect the friction plate for
wear. If the surface is uneven, then replace the friction plate.
• Unscrew the locking nuts on the coil at least 6 mm to assure there is
a large play between the coil and the pressure plate when the coil is
later reinstalled.
• Attach the coil to the motor end and adjust the play as described in
the section ”Basic adjustment of the play”.
• Reconnect the electric cables.
Maintenance
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Electrical steering system – 4300
Electrical steering servo
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
9- Electrical steering system – 4300
9.1 Electrical steering servo

NOTE:
Steering servo is an option.
9.1.1 General
The electrical steering servo consists of twin potentiometers connected
to an electronic module in the motor compartment. The electronic mod-
ule, which is also referred to as the EPS (Electrical Power Steering), is
directly mounted on a Brush-Less Permanently Magnetised servo
motor (BLPM). The motor has a power amplifier that consists of 2-stage
planetary gearing with a gear wheel mounted on a trailing journal and
locked with a nut. The gear wheel is meshed with the gear ring on the
driving wheel gear, and as such the drive unit also handles steering of
the truck.
The steering system is electric and uses a "Steer-By-Wire" design. This
means there is no mechanical contact between the steering unit and
the truck's steering wheel.
The electronic module monitors all electrically connected components.
Monitoring is continuous enabling instant detection of possible cable
interruptions. Electrical faults detected in potentiometers, cables and
the electronic module result in automatic switch-off of the truck's drive
mode and application of the electromechanical brake.
An automatic drive reference measurement is performed at each start-
up after a no-voltage state. During this calibration, the truck cannot be
driven. The drive reference mode safety-checks the system and simul-
taneously calibrates the wheel position.
Steering is progressive, implying slow-down of the travel speed at large
steering angle throws. This promotes safe and efficient truck travel.
Maximum acceleration depending on steering angle

Transport mode Transport mode Steering mode
Steering High-speed range Low-speed range Safety mode
angle
<20° 100%, approx. 8 km/h 100%, approx. 6 km/h 100%, approx. 5 km/h
20° to 90° Linear from 100% to 62% Linear from 100% to 83% 100%
>90° 62%, approx. 5 km/h 83%, approx. 5 km/h 100%, approx. 5 km/h
A certain steering response from the steering arm results in an increas-

ingly greater steering response in the steering wheel. This is because
the arm can turn maximum 70°, while the wheel can turn 90°.
Steering servo components
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
9.2 Steering servo components
Pos. Designation
1 Following tightening of the locking nut (2), the torque
when rotating the securing plate should be 6.5 +/-0.5 Nm.
2 Tighten the nut so that the above applies.
Adjustment
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
9.3 Adjustment
9.3.1 Reference sensor

If replacement or adjustment of the reference sensor should be
required, screw it all the way down until it touches the highest part of the
gear ring (12). Then unscrew it 2 turns and lock it with the nut. Calibrate
the system using parameters 36 and 37.
9.3.2 Calibration
Calibration and adjustment of the steering servo is accomplished using
parameters 36 and 37.
Parameter 36
Parameter 36 calibrates the steering servo and must be adjusted when
the following components are replaced.
• Complete steering servo assembly or parts of the steering servo as-
sembly.
• Reference sensor.
• Potentiometer.
• Following any work on the steering unit.
Detailed instructions as to the function of parameter 36 are presented in
C code 5000.
Parameter 37
Parameter 37 adjusts the drive wheel centre position. The wheel can be
adjusted 30 degrees to either side. Prior to adjustment of parameter 37,
parameter 36 must be adjusted to ascertain the wheel's zero position.
Detailed instructions as to the function of parameter 37 are presented in
C code 5000.
Adjustment
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Electrical systems – 5000
General
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10- Electrical systems – 5000
10.1 General
The electrical system of the truck is based on the PowerDrive platform.
• The main energy source comprises a 24 V DC truck battery.
• The traction drive motor is a separate excitation type (SEM). The
travel drive motor is operated by an enclosed transistor regulator re-
lying on pulse width modulation (PWM) technology.
• The lift unit motor is a conventional DC motor without any external
field winding connections. Switch-on of the hydraulic unit's electric
motor is achieved using a contactor.
• All electric units communicate via a CAN bus with an IC card in the
steering unit handle. This card contains a processor and software
that controls and monitors truck functions. A set of parameters used
to adjust truck functions and characteristics is stored in the card. The
card also monitors error conditions that may occur.
10.1.1 Part numbers

To select part number display mode carry out the following procedure:
• Ensure the battery is connected.
• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid
PIN-code and then press on the keypad.

• Hold [S18] depressed until “Pn” is displayed, then release [S18]. Fig.
1
Fig. 1 The display will now show the part numbers for the control program, the
hardware part number and hardware serial number.
The part numbers are displayed by repeatedly operating speed control
[L1]. The display will first show the starting portion of the number then
the ending portion.
General
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.1.2 Nomenclature
[ ] = reference to electrical component in the wiring diagram.
Table 7: Part numbers

Display Meaning
Software (Control program) part number
Hardware part number
Hardware serial number
Electrical equipment overview
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.2 Electrical equipment overview
10.2.1 Component placement

S53 S56
S90
S31
S10
S33
S21
M3
Y59 X1
Y58 B4
Y41
B5 G1
Y52
X41
Y10 A3
F3
A1
S19
S59
F50
R2 F52
F53
K10
M1 A36 F1
H1
S65
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
A2:S17
A17
A6
S18:1 S18:2
A2
A2:S20
A2:S19
R14
L1
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.2.2 Component list

The following table shows a summary of the major electrical compo-
nents of this truck.
Table 8: Electrical equipment list summary

Sym- Function Description Associated signal Inf.
bol names
Energy and main power isolation
G1 Main electrical power source Traction battery
24 V
X1 Battery connection / isolation Connector
K10 Main contactor Contactor A1:OUT MAIN CON- 7
TACTOR
Equipment protection
F1 Drive motor protection Fuse 130 A
F3 Pump motor protection Fuse 175 A
F 50 Operating circuit protection, A2 Fuse 7,5A A5:INPUT ENABLE B+
F 51 Operating circuit protection A1 Fuse 7,5 A
F 52 Steer servo motor protection Fuse 30 A A5:POWER SUPPLY
24VDC
F 53 Operating circuit protection, A5 Fuse 3 A 3
Control and Signal processing
A1 Traction and peripherals power Transistor regula-
control tor
A2 Control of truck functions Electronic card 1
A3 Lift power and signal control Transistor regula-
tor
A5 Steering servo Electronic card 3, 2
A6 Display of truck functions Display unit 1
A17 PIN log in and data entry Keypad 1
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

bol names
Braking, Safety & Supervision
S21 Emergency switch-off Switch A1:INP.SUPPLY
24VDC
S10 Tiller arm in drive position Inductive proxi- A1:INP.TILLER ARM I 7, 10
(Mechanical brake activation) mity switch N DRIVE POS
Y1 Mechanical brake Electromechani- A1:OUT.BRAKE A 7
cal brake
A2:S17 Emergency reverse Hall sensor A2:BELLY BUTTON 5
S19 Platform staying down supervi- Inductive proxi- A1:INP.MAN ON PLAT- 7, 3
sion mity switch FORM
S59 Platform not up supervision Inductive proxi- A1:INP.PLATFORM N 7, 10
mity switch OT FOLDED UP
S53 Gates up supervision Inductive proxi- A1:INP GATES UP 7, 10
mity switch
S56 Gates down supervision Inductive proxi- A1:INP GATES DOWN 7, 10
mity switch
S33/1 Supervision -Max. permitted lift Magnetic switch A1:INP LIFT LIMIT 7,9
height for powertrak POWER TRAC 1,<
1.8M
S33/2 Supervision -Max. permitted lift Magnetic switch A3:INP.LIFT LIMIT <1, 7,9
height with gates up 8M
H1 Audible warning signal -Horn Horn A1:OUT.SIGNAL 7
HORN
S18:1 Horn activation Switch A2:INP.HORN1 7, 4
S18:2 Horn activation Switch A2:INP.HORN2 7, 4
Traction & traction control
L1 Speed control and travel direc- Hall sensor 6, 7
tion selector (butterfly)
S113 “Turtle” function Switch A2:TURTLE 3
M1 Truck traction Motor
Y58 Powertrak drain-hydraulic control Magnetic valve A1:OUT.POWER- 7
TRAK DRAIN VALVE
Y59 Powertrak open-hydraulic control Magnetic valve A1:OUT.POWER- 7
TRAK FILL-UP VALVE
B5 Powertrak pressure supervision Pressure sensor A3:INP.PRESSURE PT 7
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

bol names
Steering
R2 Steering angle signal Potentiometer A5:A_IN0 , A_IN1 3
S65 Drive wheel in centre reference Inductive proxim- A5:REF 3
ity switch
M6 Drive wheel steering Motor 3,2
Forks lift
R14 Fork lift/ lower control Hall sensor unit A2:A_IN 7
Y10 Fork lower -hydraulic control Proportional mag- A3:OUT MAGNET 7,8
netic valve VALVE PWM
B4 Load supervision Pressure sensor A3:INP.PRESSURE 7
LIFT
M3 Hydraulic pressure Motor
Support arm lift
A2:S19 Support arm lift control Hall sensor 5,7,8
A2:S20 Support arm lower control Hall sensor 5,7.8
Y41 Support arm lower -hydraulic con- Magnetic valve A3:OUT.SUPPORT 7,8
trol ARM LOWER VALVE
Y52 Support arm / fork lift selection Magnetic valve A3:OUT. FORK/ 7,8
SUP.ARM VALVE
S31 Support arms at top supervision Inductive proxi- A1:INP.SUPPORT 7,8 10
mity switch ARM AT TOP
S90 Support arms at bottom supervi- Inductive proxi- A1:INP.SUPPORT 7,8,10
sion mity switch ARM AT BOTTOM
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

bol names
Other
R1 Power supply PTC-resistor 10
Ohm
X41 CAN communication (external) Connection point
X9 CAN communication (extra I/O) Connection point
Y16 Hydraulic control of special func- Magnetic valve A3:OUT.3 HYD. FUNC 3
tion. 1A
tion. 1B
tion. 2A
tion. 2B
S114 Activation of special function. Switch 3
S115 Activation of special function. Switch 3
Footnotes to the table above:

1. Situated in the tiller arm handle and communicates via the CAN bus
2. The steering servo controller, servo motor and mechanics are inte-
grated into one single unit.
3. Optional function
4. [S18:1] represents the left side button and [S18:2] represents the
right side button.
5.These inputs signals are processed directly via Hall effect sensors
mounted on the A2 card and are handled via the CAN bus.
6. Speed control signals from [L1] are processed by Hall element sen-
sors mounted on the A2 card. Sensors [A2:S1-9] control speed control
signals for driving in fork direction. Sensors [A2:S10-18] control speed
control signals for driving in drive wheel direction.
7. Signals to/ from these elements can be checked via the Built-in Test
function. See “10.6.5 Built-in Test Function” on page 83
8. Only valid for truck with support arm lift
9. Output is low when sensor is activated.
10. Output is high when sensor is activated.
Electrical wiring diagram
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.3 Electrical wiring diagram
10.3.1 Symbol list
Table 9: Symbol list

Symbol Description Symbol Description
Truck battery Horn
Fuse Emergency stop switch NC
Resistor (PTC)1 Brake coil (normally applied)
DC motor2 (SEM type)3 Sensor, inductive NO

A1 A2
M
E1 S E2
Contactor Coil for hydraulic magnetic valve
Switch, NO Pressure sensor

P
Magnetic switch, NC Connector
NO = Normally Open, NC = Normally closed

1. PTC = Positive Temperature Coefficient (resistance increases as temperature increases)
2. DC = Direct Current
3. SEM = Separately Excited Motor
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.3.2 Overview
A1 M1 F1 R1
24 (+) POWER 24VDC A2 A2 A1 X1
(16) SUPPLY 24VDC ARMATURE (M) M
40
PLATFORM SPECIFIC (-) POWER 0VDC S2/E2 E2 S G1
+
E1
FIELD (S2)
56
-
(13) MAN ON PLATFORM S1/E1
S19 X1
FIELD (S1) 2
57
(14) PLATFORM NOT FOLDED UP
S59 40
58 50 K10
(10) GATES UP MAIN CONTACTOR (4)
S53
60 Y58 F51
59 21
(11) GATES DOWN DRAIN VALVE (2)
S56
S21
A1
54 Y59
FILL-UP VALVE (3) F3
H1
52 53
S10 (12) TILLER ARM SIGNAL HORN (7)
78 51
(15) FORKS<1,8M BRAKE RELEASE (5) Y1
S33/1 (1/8) CAN H/L
24 24
A1
M3 F
79 (+) POWER +24VDC A2 A2
M
A1
(15) FORKS<1,8M ARMATURE (M)
40
S33/2 (-) POWER 0VDC S2/F1 F1 S EXT. EQUIP.
F2
119/120 FIELD (S2) S1/F2

(1/8) CAN H/L FIELD (S1)
24 73
(16) SUPPLY +24V M.VALVE PWM (9)
55 Y10
P (10) PRESSURE ONLY INITIAL LIFT
B5 70
SUP.ARM LOWER (5) Y41
75
P (11) PRESSURE L.
B4 72
FORK/SUP.ARM (6) Y52
A3
ONLY 3 & 4 HYD. FUNC.
80
3 HYD.FUNC. 1A (2) Y16
81
ONLY INITIAL LIFT 3 HYD.FUNC. 1B (3)
76 Y17
S31 (13) SUP.ARM 82
AT TOP 4 HYD.FUNC. 2A (4)
77 Y18
S90 (14) SUP.ARM 83
AT BOTTOM 4 HYD.FUNC. 2B (7) Y19
F50 1
40
ONLY 3 & 4
CAN CAN 20 (X3:6) 0VDC (X3:3/7) ONLY STEER SERVO
X41 X9 (X3:2) +24VDC CAN F53 F52
HYD. FUNC. BLUE2 A2:S17 STEER R2
(X2:2/5) Hall ANGLE 22 23
BLACK2 SENSOR
(X2:2/3) (2/10) (6) (8/16)
(X2:1/2) TURTLE A2:S19 CAN H/L ENABLE +24V
S115 91/93/92/94
(X1:1) HORN 2 Hall (4/13/5/14)
S114 95
(X4:1) HORN 1 (3) +12V
S113 A2:S20 96
(11) REF.
A5
S18:2 A2 Hall 40
(7/15) 0V (12) 0V
S18:1
(X4:2) A2:S1-S9 A2:S10-S18 S65 97
(X1:2) Hall Hall M M6
(X2:1/3)
BLACK1
(X2:2/2) 5VDC (X8:1)
BLUE1 R14
(X2:2/4) DISPLAY
KEYBOARD (X11) (X12) (X1)
A6
A17 (X8:2) A_IN 0VDC (X8:4)
© TIEE SARL
230087-040
Order number
40
Sh. 3
F EXTERNAL EQUIPMENT
TRANSISTOR REGULATOR
A1
Date
X1 G1 24V X1
1 + - 40
- INP. POWER SUPPLY 0V DC
2007-03-23
1
Sh. 9 R1 F1
2 A1
+ INP. POWER SUPPLY +24V DC
DRIVE MOTOR
PTC 10~E 130A
F50 M1
20 2 1 A1 A2 A2
Sh. 5 M M OUT ARMATURE
7,5A
924454-
Service Manual
E1 E2 S2/E2
4 3 S2 OUT. FIELD
F51 S1/E1
21 S1 OUT. FIELD
Sh. 2
7,5A
2
Sh. 3
Valid from serial number
K10
24 A1 A2 50
Sh. 2 4 OUT. MAIN CONTCTOR
S10
1 2 52
12 INP. TILLER ARM IN DRIVE POS.
3
10.3.3 Detailed wiring diagram
T-code
X5 Y1 X5
1 2 51
5 OUT. BRAKE RELEASE
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

H1
- +
53
7 OUT. SIGNAL HORN
789, 790, 791, 817, 818
1/16 PROD G
220241
10- 11
10- 12
T-code
789, 790, 791, 817, 818
924454-
A1
EMERGENCY SWITCH OFF

S21
21 1 2 24
Sh. 1 16 INP. SUPPLY +24V DC
Service Manual
Y58
24 1 2 60
Sh. 1 3 2 OUT. POWER TRAK DRAIN VALVE
Y59
1 2 54
3 OUT. POWER TRAK FILL-UP VALVE
S33/1
3 2 78
15 INP. LIFT LIMIT POWER TRAK 1, <1.8M
Date
S33/2
1 4
2007-03-23
79
Sh. 4
119 119
Sh. 3 1 CAN HIGH
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

120 120
Sh. 3 8 CAN LOW
230087-040
Order number
2/16 PROD G
220241
© TIEE SARL
© TIEE SARL
230087-040
Order number
Date
2007-03-23
A3
40 40
Sh. 1 4 - INP. POWER SUPPLY 0V DC
924454-
Service Manual
F3
2 A1
Sh. 1 9 + INP. POWER SUPPLY +24V DC
175A PUMP MOTOR
M3
A1 A2 A2
M M OUT. ARMATURE
S
F2 F1 S2/F1
S2 OUT FIELD
S1/F2
S1 OUT FIELD
119 119
Sh. 2 5 1 CAN HIGH
120 120
Sh. 2 5 8 CAN LOW
T-code
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

24 24
Sh. 2 4 16 INP. SUPPLY +24V DC
789, 790, 791, 817, 818
3/16 PROD G
220241
10- 13
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
220241
4/16 PROD G
OUT. MAGNET VALVE PWM
INP. LIFT LIMIT, <1.8M

INP. PRESSURE LIFT
INP. PRESSURE PT
10
15
11
A3
9
73
55
75
79
2
Y10
1
79
24
Sh. 2
40
Sh. 3 8
Sh. 3 5
© TIEE SARL
230087-040
Order number
Date
ELECTRONIC CARD TILLER ARM

A2
2007-03-23
X3
20 20
Sh. 1 X3:2 INP. +24V DC
X3
119 119
Sh. 3 9 X3:3 CAN HIGH
X3
924454-
120 120
Service Manual
Sh. 3 9 X3:7 CAN LOW
X3
40 40
Sh. 4 8 X3:6 INP. OV DC
X9
20 1 A2:S17
BELLY BUTTON
40 2
X41 A2:S1-S9 A2:S10-S18

1 20 119 3 SPEED REF. VALUE
2 40 120 4
A2:S19 A2:S20
3 119 CAN CONNECTION SUPPORT ARM
LIFT/LOWERING
4 120
T-code
CAN, SERVICE CONNECTOR
X8:1 OUT. +5V DC

FORK LIFT/LOWER
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

X8:2 INP. A_IN
789, 790, 791, 817, 818
X8:4 OUT. 0V DC
5/16 PROD G
220241
10- 15
10- 16
T-code
DISPLAY ELECTRONIC CARD TILLER ARM
A6 A2
X1 1 X12:1 +5V DC
789, 790, 791, 817, 818
X1 2 X12:2 SI
X1 3 X12:3 SCK
8 8 8 8
X1 4 X12:4 ENABLE
924454-
X1 5 X12:5 LCLK
Service Manual
X1 6 X12:6 0V DC
S18:1
1 2
X4:1 INP. HORN 1
X4:2 OUT. OV DC HORN 1

Date
S18:2
1 2
X1:1 INP. HORN 2
2007-03-23
X1:2 OUT. 0V DC HORN 2
S113
1 2
X2:1/2
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

TURTLE
OPTION
230087-040
X2:1/3 TURTLE
Order number
6/16 PROD G
220241
© TIEE SARL
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
7/16 PROD G
220241
ELECTRONIC CARD TILLER ARM
LED_GREEN
LED_RED
2580
369#
0V DC
147-
123
456
789
-0#
X11:10
X11:1
X11:2
X11:3
X11:4
X11:5
X11:6
X11:7
X11:8
X11:9
A2
3
6
9
I
2
5
8
0
1
4
7
KEY BOARD
A17
10- 18
T-code
789, 790, 791, 817, 818
924454-
Service Manual
ONLY
TRUCKS WITH SUPPORT ARM LIFT TRANSISTOR REGULATOR
A3
Y41
24 1 2 70
Sh. 4 5 OUT. SUPPORT ARM LOWERING VALVE
Y52
1 2 72
6 OUT. FORK/SUP. ARM VALVE
X2
S31
Date
X2
1 2 76
13 INP. SUPPORT ARM AT TOP
X2
3
40
2007-03-23
Sh. 5 9
S90
X2
1 2 77
14 INP. SUPPORT ARM AT BOTTOM
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

8/16 PROD G
220241
230087-040
Order number
© TIEE SARL
© TIEE SARL
230087-040
Order number
ONLY ELECTRONIC CARD STEER SERVO

TRUCKS WITH SERVO A5
40 40
Sh. 8 10 7 POWER SUPPLY OV DC
Date
40
15 POWER SUPPLY 0V DC
F52 X7
2007-03-23
2 23
Sh. 3 8 POWER SUPPLY +24V DC
30A
23
16 POWER SUPPLY +24V DC
X6
119 119
Sh. 5 2 CAN HIGH
924454-
Service Manual
X6
120 120
Sh. 5 10 CAN LOW
STEER ANGLE SENSOR
R2
X10
Rd 1 91
4 OUT. SUPPLY +5V DC
M6
X10
Gn 2 93 M
A 13 INP. A_IN0
X10
Wh 3 92
B 5 INP. A_IN1
X10
Bu 4 94
14 OUT. SUPPLY 0V DC
95
3 OUT. SUPPLY +12V DC
T-code
S65
1 2 96
11 INP. REFERENCE SWITCH
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

97
12 OUT. SUPPLY 0V DC
F53 X7
1 22
789, 790, 791, 817, 818
Sh. 1 6 INP. ENABLE

3A
9/16 PROD G
220241
10- 19
10- 20
T-code
789, 790, 791, 817, 818
924454-
PLATFORM FOLDING UP, WITH GATES
Service Manual
A1
X:S19 X:S19
24 56
Sh. 8 11 13 INP. MAN ON PLATFORM
S59
1 2 57
14 INP. PLATFORM NOT FOLDED UP
3
S53
1 2 58
10 INP. GATES UP
Date
3
2007-03-23
S56
1 2 59
11 INP. GATES DOWN
3
40
Sh. 9 11
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

OVERHEAD GUARD 10/16 PROD G
220241
230087-040
Order number
© TIEE SARL
© TIEE SARL
230087-040
Order number
Date
2007-03-23
PLATFORM STAYING DOWN, WITH GATES

924454-
Service Manual
A1
S19
24 1 2 56
3
S59
1 2 57
3
S53
1 2 58
10 INP. GATES UP
3
S56
1 2 59
11 INP. GATES DOWN
T-code
3
40
Sh. 10 12
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

11/16 PROD G
OVERHEAD GUARD 220241
789, 790, 791, 817, 818
10- 21
10- 22
T-code
789, 790, 791, 817, 818
924454-
Service Manual
BACK PROTECTION, WITH FIXED PLATFORM
SIDE PROTECTION, WITH FIXED PLATFORM
A1
S19
24 1 2 56
3
40
Sh. 11 14
X:S59 X:S59
57
Date
X:S53 X:S53
58
10 INP. GATES UP
2007-03-23
X:S56 X:S56
59
11 INP. GATES DOWN
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

12/16 PROD G
220241
230087-040
Order number
© TIEE SARL
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
220241
13/16 PROD G
INP. PLATFORM NOT FOLDED UP
INP. MAN ON PLATFORM
INP. GATES DOWN

INP. GATES UP
13
14
10
11
A1
59
NO PLATFORM, NO GATES
X:S56
X:S56
24
Sh. 12 14
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14/16 PROD G
220241
INP. GATES DOWN

INP. GATES UP
13
14
10
11
A1
56
57
59
PLATFORM STAYING DOWN, WITHOUT GATES
X:S56
2
S19
3
X:S56
1
2
S59
3
1
24
40
Sh. 13 15
Sh. 12 15
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
220241
15/16 PROD G
INP. GATES DOWN

INP. GATES UP
13
14
10
11
A1
56
57
59
PLATFORM FOLDING UP, WITHOUT GATES
X:S19
X:S56
X:S19
X:S56
2
S59
3
1
24
40
Sh. 14
Sh. 14 16
10- 26
T-code
789, 790, 791, 817, 818
924454-
Service Manual
OPTION
THIRD AND FOURTH HYD.FUNCTION
TRANSISTOR REGULATOR ELECTRONIC CARD TILLER ARM

A3 A2
X11 Y16 X11 S114

24 1 2 80 1 2 BLACK2
Sh. 15 2 OUT. THIRD HYD.FUNCTION (1A) X2:2/3 INP. OPTION BUTTON 4
Y17 X11
1 2 81 BLACK1
Date
3 OUT. THIRD HYD.FUNCTION (1B) X2:2/2 OUT. 0VDC
S115
1 2 BLUE2
X2:2/5 INP. OPTION BUTTON 5
2007-03-23
Y18 X11
1 2 82
4 OUT. FOURTH HYD.FUNCTION (2A)
BLUE1
X2:2/4 OUT. 0VDC
Y19 X11
1 2 83
7 OUT. FOURTH HYD.FUNCTION (2B)
16/16 PROD G
7SLL12.5, 16, 20, 13.5S, 12.5F, 16F, 20F

220241
230087-040
Order number
© TIEE SARL
Functional description
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.4 Functional description
means constantly on means flashing.

This section gives basic electrical descriptions of the truck’s main func-
tions in tabular form. It describes, in simple terms, what happens when
performing any of the truck’s main operations.
• Event - The main stages in performing any of the truck’s main func-
tions are referred to as “Events”. Each event is numbered.
• Prior events - Indicates the event number which must have taken
place immediately before in order for current event function correct-
ly.
• Action(s) - A required action from the operator for the event to occur
• Influencing elements - conditions which must be fulfilled in order for
the event to occur. Certain parameter settings may also affect the
outcome of the event.
• Resulting conditions - Describes key occurrences which can be
checked to confirm operation.
Note that “resulting conditions” show what is expected when no error
conditions are present. Items shown in square brackets [ ] refer to elec-
trical component designations as stated in the electrical wiring dia-
grams.
Unless otherwise stated, high ≈ 24 V and low ≈ 0 V
10.4.1 Principle of operation
Table 10: Principle of operation

Event: 1. Battery connected
Action(s) Connect the traction battery [X1, G1]
Influencing Main power fuses ok [F1, F3]
elements Operating circuit fuses ok [F50, F51, F52, F53]
PTC resistor ok [R1]
Resulting 24V (control) supplied directly to [A2], [A5] and via R1 to [A1], [A3], [A5]
conditions Curtis status LED blinks once every 5 seconds.[A1]
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

Event: 2. Switch on (PIN-code entry)
Prior event(s) 1
Action(s)
Enter valid PIN-code and press [A17]
Influencing Emergency switch-off closed [S21] [INP.SUPPLY +24V] high
elements Tiller arm in drive not activated [S10] [INP.TILLER ARM IN DRIVE POS] low
Resulting
conditions Power lamp lights. Main display shows hour meter reading
and for 4 seconds followed by battery condition as a per-
centage of full charge and [A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE] high
Main contactor output remains high [A1:OUT.MAIN CONTACTOR] and Main
contactor remains open [K10]
Event: 3. Tiller am lowered for driving
Prior event(s) 2
Action(s) Lower tiller arm handle
Influencing Tiller arm in drive sensor [S10]
elements
Resulting Tiller arm in drive sensor activates [S10] [INP.TILLER ARM IN DRIVE POS.]
conditions high
Brake solenoid control [A1:OUT.BRAKE] remains high
Brake remains on [Y1]
Main contactor output [A1:OUT.MAIN CONTACTOR] goes low
Main contactor closes [K10]
24V (power) supplied to [A1],[A3] & [A5]
Event: 4. Traction, forks first
Prior event(s) 3
Action(s) Move butterfly [L1] in forks drive direction.
Influencing Butterfly Hall sensors [A2:S10-18]
elements Platform staying down sensor [S19]. Platform not up sensor [S59]
Gates up sensor [S53], Gates down sensor [S56]
Fork load supervision sensor [B4]
Parameter settings. See “10.4.4 Speed limitation” on page 34
Resulting [A1:OUT.BRAKE A] goes low
conditions Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises,
mechanical brake releases
Current fed to traction motor field winding (S2 +ve and S1 -ve)
Pulsed current fed to traction motor armature proportional to butterfly deflection
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

Event: 5. Traction, drive wheel first
Prior event(s) 3
Action(s) Move butterfly [L1] in drive wheel drive direction.
Influencing Butterfly Hall sensors [A2:S1-9]
elements Platform staying down sensor [S19]. Platform not up sensor [S59]
Fork load supervision sensor [B4
See “10.4.4 Speed limitation” on page 34
Resulting [A1:OUT.BRAKE A] goes low
conditions Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises
Current fed to traction motor field winding (S2 -ve and S1 +ve)
Pulsed current fed to traction motor armature proportional to butterfly deflection
Event: 6. Neutral braking
Prior event(s) 4 or 5
Action(s) Let butterfly [L1] return to neutral position.
Influencing Fork load supervision sensor [B4]
elements Parameter settings
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] converts
conditions the trucks energy of motion into electrical energy thus reducing the truck’s
speed. The excess electrical energy is fed back to the battery helping to
recharge it [G1].
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes
to a complete stand still
Event: 7. Reverse braking
Action(s) Move butterfly [L1] so as to reverse the direction of travel
Influencing Man-on platform switch [S19]
elements Fork load supervision sensor [B4]
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] converts
conditions the trucks energy of motion into electrical energy thus reducing the truck’s
speed. The excess electrical energy is fed back to the battery helping to
recharge it [G1]. The braking effect increases the more the butterfly is
deflected
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes
to a complete stand still
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

Event: 8. Mechanical brake operation
Action(s) Move tiller arm handle to upper or lower position
Influencing Tiller arm in drive sensor goes low [S10]
elements
Resulting The mechanical brake [Y1, A1:OUT.BRAKE A] activates
conditions
Event: 9. Steering
Prior event(s) 3
Action(s) Steer tiller unit handle to left or right
Influencing Steering angle potentiometer [R2]
elements Steering reference switch [S65, A5:INP.REFERENCE SWITCH]
Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]
Resulting Steer servo motor positions drive wheel according to tiller handle’s deflection
conditions [A5, M6] (See section “10.4.2 Description of steering system”.)
Event: 10. Fork lifting

Prior event(s) 2
Action(s) Operate fork lift control [R14] in lifting direction
Influencing Forks lift control [R14]
elements Battery status ok (>20% charge left)
Max permitted lift height with gates up sensor [S33/2]
Support arms at bottom sensor [S90]
Resulting Current fed to lift motor [M3] field winding (S2 -ve and S1 +ve)
conditions Pulsed current fed to lift motor armature proportional to lift control deflection
Pump motor [M3] operates
Event: 11. Fork lowering
Prior event(s) 2
Action(s) Operate fork lift control [R14] in lowering direction
Influencing Forks lift control [R14]
elements
Resulting [A1:OUT.MAGNET VALVE PWM] sends pulsed signal to fork lowering hydrau-
conditions lic valve [Y10]. Valve opens proportionally to signal allowing a variable lower
speed.
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818

Event 12. Support arms lifting
Prior event(s) 2
Action(s) Operate support arm lift button [A2:S19] i
Influencing Support arm lift button [A2:S19]
elements Battery status ok (>20% charge left)
Support arm at top sensor [S31]
Resulting [A3:OUT.FORK/SUP:ARM VALVE] goes low & valve Y52 operates
conditions A set current is fed to lift motor [M3] field winding (S2 -ve and S1 +ve)
Pulsed current fed to lift motor armature
Pump motor [M3] operates & hydraulic pressure fed to support arm lift circuit
Event 13. Support arms lowering
Prior event(s) 2
Action(s) Operate support arm lower button [A2:S20] i
Influencing Support arm lower button [A2:S19]
elements Support arm at bottom sensor [S90]
Resulting [A3:OUT.SUPPORT ARM LOWERING VALVE] goes low & valve Y41 operates
conditions support arm lift circuit pressure is drained to tank and support arms lower.
Event 14. Powertrak operation

Prior event(s) 10 / 11 / 12 / 13
Action(s) Lift a load on forks and/or support arms
Influencing Max permitted lift height for PowerTrak sensor [S33/1]
elements Signal from pressure sensor [B4] and [B5]
Resulting System monitors pressure differences between [B4] [A3: INP. PRESSURE
conditions LIFT] and [B5] [INP. PRESSURE PT] and switches [Y58] [OUT. POWER TRAK
DRAIN VALVE] and [Y59] [OUT POWER TRAK FILL-UP VALVE] to maintain a
similar pressure in PowerTrak circuit.
[A1:OUT POWERTRAK FILL-UP VALVE] low & [A1:OUT POWERTRAK
DRAIN] high while fork lift height <1,8 m
Lift pressure applied to PowerTrak cylinder.
Fork lift height goes over 1.8m and [S33/1] [A3INP LIFT LIMIT POWER TRAK
1, <1,8M] goes low
[A1:OUT POWERTRAK DRAIN VALVE] then goes low and valve [Y58] opens
thus draining pressure from Powertrak cylinder
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.4.2 Description of steering system

The servo steering system on this truck comprises a synchronous DC
motor [M6] with permanently magnetized rotor which is also brushless.
This type of motor is ideal for truck steering applications due to light
weight and high torque even from stand still. The motor directly drives
the drive wheel gear unit, via an integrated 2 stage planetary gear. The
steer motor is controlled by a fully electronic 4-quadrant regulator [A5]
which is mounted directly in the servo motor casing. Hall sensors (H) in
the servo motor provide timing information for commutation control.
The sensors also provide the steer servo with position information.
A double potentiometer [R2] situated below the tiller arm mounting pro-
vides steer angle information from the operator. Every time the traction
battery is connected and the truck switched on the steer system per-
forms a reference search for "straight ahead" position. An inductive
proximity switch [S65] mounted in the final drive gear mounting plate
registers a change in state (either ON to OFF or OFF to ON depending
on drive wheel's initial position) and feeds this signal back to the steer
servo. From this point on, the steer servo "knows" the position of the
drive wheel. Only after the traction battery is next disconnected, is a
new reference search carried out.
The steer servo communicates fully via the CAN bus. All steer servo
errors codes are transmitted to the truck's control system and displayed
on the tiller unit's display.
10.4.3 Spider expansion unit (SEU)

The Spider expansion unit ,referred to as the SEU, allows the main con-
trol card to handle a greater number of inputs & outputs. The SEU
allows up to 8 extra digital inputs and 4 digital outputs which can be
addressed and controlled via the CAN bus. The SEU contains firmware
but this is only for internal configuration. No truck control logic is
present in the SEU. This means a faulty SEU can be exchanged with-
out affecting the truck’s functions in any way.
There are 3 cases covering the usage of SEU:
a) The SEU can be fitted if the truck is modified according to a customer
special request. In this case, correct operation of the modification is
acheived by adjustment of service parameters 16 to 19.
b) The SEU is fitted as standard in certain truck models, to allow control
of standard features. Such trucks do not require that service parame-
ters 16 to 19 be activated. (parameters 16 to 19 shall be set to “0”.)
c) Trucks fitted with an SEU as standard can also have additional mod-
ifications using “configurable options”. These additional modifications
are controlled by the setting of service parameters 16 to 19.
Refer to section Parameter #16 to #19 Configurable options on page 58
for more detailed information.
.
Fig. 2 shows how the SEU is used to allow a greater number of func-
tions to be controlled via the CAN bus. The SEU has one 42-pin mul-
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
A2
Electronic
card
TLS
A36 Extra / Customised
A5 SEU function(s)
Steer servo
CAN bus
A3
Pump
controller
X41
CAN service
connector
A1
Traction
controller
Fig. 2 Connection architecture for SEU
tipin connector which handles all inputs, outputs, CAN and supply sig-
nals.
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.4.4 Speed limitation

The truck’s maximum speed is limited by a combination of, fork lift
height, fork load and operator’s driving position. Driver parameter set-
tings also affect maximum speed. See “10.5.6 Summary of driver
parameters” on page 41 for more information. The table below summa-
rises the speed limitations and assumes that all relevant driver param-
eters are set to 100%. Note that the speeds given are nominal.
Table 11: Summary of speed limitations

Load Fork lift Driver position or mode Max.
(kg) height speed
(mm) (km/h)
<800 <1800 Platform down, gates up (transportation mode) 8
Platform down, gates down1 6
Platform up, gates down (pedestrian mode)1 6

Platform up, gates up 0
<800 >1800 Platform down, gates up 0

>800 <1800 Platform down, gates up (transportation mode) 8 - 72

>800 >1800 Platform down, gates up (transportation mode) 0

- - Turtle mode is controlled by parameter # 7
- - Snail speed mode ≈ 1,6
- - Error / Warning code mode ≈ 2,5
1.The 7SLL20 & 7SLL20F do not have side guards; from an electric viewpoint, the side
guards are considered to be in the lowered position.
2.Max. speed determined by actual load and will ramp between 8 & 7 km/h
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.4.5 Hour meter and battery condition

At switch on, the hour meter is displayed and the hour meter symbol
lights for 4 seconds. Fig. 3
The display will then change to show the battery’s remaining capacity
Fig. 3 expressed as a percentage of full charge and the battery symbol lights.
Fig. 4
The truck’s control system stores 5 different elapsed time values in
units of hours. The time value normally shown depends on the setting
of service parameter #20. (See “ # 20 - Hour meter selection” on
page 48). However, any of these time values can be temporarily dis-
played on the hour meter. To choose which value to display carry out
the following procedure:
Fig. 4


• Hold [S18] depressed until “H” is displayed, then release [S18]. Fig. 5
Hour meter symbol lights.

Fig. 5
The different hour meter modes are displayed by repeatedly operating
speed control [L1]. The actual time value will be displayed momentar-
ily after the mode is selected.
Table 12: Hour meter modes

Description Display
Key time:
Total time truck has been switched on
Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
Drive motor time:
Total time drive motor has been in operation
Pump motor time:

Total time pump motor has been in operation
Remaining time to next service

(Parameter #25 controls the initial value) See “ # 25 - Service interval”
on page 49 for more information.
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.4.6 TLS - Truck log system (optional)

General
The truck log system, which is CAN based, is either an integrated sys-
tem (SD16) or a freestanding supplementary system (S16). A collision
sensor can also be connected.
The TLS communicates wirelessly with a base station (RG3) once the
truck is within range. The base station then receives information on
what the truck has done since they last communicated with one anoth-
er.
Built-in system PC
A2 RG3
Electronic card
Add-on system
CAN bus
TLS SD16
TLS S16
CAN bus
Shock sensor
Shock sensor
A1
Traction controller I/O-unit
Registration
To register the truck with the base station, follow the instructions below:
• Position the truck close to the base station.
• Press and hold the green button for approx. 5-10 seconds until
three LEDs on the base station start flashing at the same time.
The base station can now communicate with the truck whenever it is
within range.
Logging in/out SD16

Logging in and out is performed as usual via the keyboard on the han-
dle (or by using an ID unit). The difference is that communication pass-
es through the TLS, which makes all the decisions.
Logging in/out S16

Logging in and out is performed using the keyboard on the TLS.
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
Collision sensor
If there is a collision sensor installed on the CAN bus, it registers when
the truck bumps into something. If the impact exceeds a certain level, it
is classified as a collision and the truck comes to a halt. It can be reset
by entering the PIN code for “resetting the collision sensor” (see table
below).
Settings
Additional equipment (software and wiring) from Davis Derby is
required to change the TLS settings.
Table 13: Settings TLS

Function Description Default setting
PIN code PIN code for different driver pro- 00001 (profile 1)
files. 00002 (profile 2)
00003 (profile 3)
11111 (resetting the collision sensor)
Logoff time Time in minutes (1-254) that the 255 (not switched off)
truck is inactive before it is
switched off.
Impact level Determines how sensitive the 5 % (sideways)
truck is to an impact. 5 % (forwards/backwards)
Department Only applies when ID unit is 14
installed.
Type of truck Only applies when ID unit is 16
installed.
10.4.7 ID unit (optional)

See the separate manual that is included with the software.
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.5 Parameters
10.5.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Driver parameters and Service parameters.
• Driver parameters (1 to 9) - These parameters are used to tailor the
driving characteristics of a truck for a specific driver or operation. Up
to 10 sets of driver parameters can be stored. Driver parameters can
be adjusted directly without the requirement for a suitable CAN serv-
ice key.1
• Service parameters (10 to 39) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as driver parameters. Service pa-
rameters can ONLY be adjusted when a suitable CAN service key is
plugged into the truck.2
10.5.2 Viewing parameters -CAN key not

connected
To select Parameter display mode carry out the following procedure:


• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig. 6
Parameters symbol lights.

Fig. 6
The different parameters are now displayed by repeatedly operating
speed control [L1]. Driver parameters can be both viewed and
changed.1
1.Driver parameters can only be set without a CAN key if parameter

#39 is set to value 3. See “ # # 39 - Log-in method & operator param-
eter access” on page 53
2.Service parameters can be viewed without a CAN key being
plugged in but they cannot be adjusted.
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.5.3 Viewing parameters - CAN key

connected
• Connect a suitable CAN-service key to [X41].

• Press and hold horn button [S18] for at least 1 second and then
press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig. 7

Fig. 7
Operating speed control [L1] in the forward direction causes the display
to show the first set of driver parameters. Continued operation of speed
control [L1] in the forward direction will then cause display to show the
next set of driver parameters (for driver no.2) and so on, up to the last
driver (Driver no. 10). See Fig. 8
Driver parameter no.
After the ten sets of driver parameters have been displayed, the trucks
Parameter set no.
service parameters will be displayed when operating the speed control
Fig. 8 [L1] in the forward direction
The truck’s service parameters can be displayed first by operating
speed control [L1] in the backward direction. This will cause parameter
#40 to be displayed and then parameter #39 etc.1
1.Certain parameters numbers displayed are not active in this truck

model.
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.5.4 Setting Driver parameters

To change the value of a particular driver parameter carry out the fol-
lowing:
• Switch on the truck and log in with the appropriate PIN-code. This is
important if the truck has more than one set of Driver parameters ac-
tive. Any changes made will only be in effect when that particular
“driver” is logged in.
• Select the required parameter using [L1].
• Press Horn button [S18].
Parameter symbol flashes. .
• Set parameter value by repeatedly operating speed control [L1] up

or down
• Press Horn button [S18] once to confirm the new setting.
Parameters symbol lights. (stops flashing).
• Switch off the truck by pressing on the keypad

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
For detailed descriptions and effects of these parameters.see the sec-
tion “10.5.6 Summary of driver parameters” on page 41
10.5.5 Setting Service parameters

To set any of the Service parameters, a suitable CAN service key must
be plugged into the truck’s external CAN connector [X41]. Service
parameters are not driver specific. When a CAN service key is plugged
in, it is not necessary to enter a PIN-code prior to pressing on the

key pad. Once the CAN service key is plugged in, the procedure is the
same as setting Driver parameters.
For detailed descriptions and effects of these parameters see the sec-
tion “10.5.8 Summary of service parameters” on page 43.
NOTE!
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necessary know how.
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.5.6 Summary of driver parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in sections
“10.5.2 Viewing parameters -CAN key not connected” on page 38 and
“10.5.6 Summary of driver parameters” on page 41
See also section “10.4.4 Speed limitation” on page 34 for information
regarding the maximum speeds of the truck.
Table 14: Summary of driver parameters

Name Unit Min. Max. Step Std. Note
Parameter
02 Maximum speed, high % 10 100 5 100

range S
10: 100:
S= maximum speed
03 Maximum acceleration % 10 100 5 80
A
10: 100:
A= maximum acceleration
04 Neutral braking effect % 5 100 5 70
F
5: 100:
F= neutral brake force
06 Maximum speed -low % 10 100 5 100
range S
10: 100:
S= maximum speed
07 Maximum speed- “Tur- % 10 100 5 60
tle” S
10: 100:
S= maximum speed
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.5.7 Description of driver parameters

# 2 - Maximum speed, high range
Allows adjustment of the maximum speed of the truck in the high speed
range. The high speed range is active when the gates are folded out,
the platform is down and the forks are below 1,8 m.
# 3 - Maximum acceleration
Allows adjustment of the truck’s maximum acceleration. The lower the
value of the parameter the longer it takes to accelerate the truck to the
demanded speed control lever position [L1].
# 4 - Neutral braking effect

Allows adjustment of the neutral braking force applied when speed con-
trol lever [L1] returns to the neutral position. The lower the value of the
parameter the longer it takes to bring the truck to a standstill.
# 6 - Maximum speed, low range

Allows for adjustment of the maximum speed of the truck in the low
speed range. The low speed range is active when the gates are folded
down and ptatform folded up. This parameter also affects the stacking
speed mode when the forks are above 1,8 m.
# 7 - Maximum speed, “Turtle” mode

Allows for adjustment of the maximum speed of the truck in the “Turtle”
mode.
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.5.8 Summary of service parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in sections
“10.5.3 Viewing parameters - CAN key connected” on page 39 and
“10.5.8 Summary of service parameters” on page 43
Service Manual The CAN service key must be connected to the exter-
nal CAN connector [X41] before adjusting any Service parameters
Table 15: Summary of service parameters

Parameter
10 PIN-code - 0 9999 1 1 PIN code assignment.

NOTE: Not applicable if
Parameter #39 has been
set to the value 5, 6, 7 or 8.
14 Creep speed % -10 10 1 0
S
-10: +10:
S= Speed at first sensor

15 Non-configurable Standard value = “0”
options 0 to 9 See Service Manual“10.5.10 Configurable “Option” Parameters” on
page 57
16 Configurable option #1 These parameters provide correct operation of trucks which have
17 Configurable option #2 been modified with an approved special request modification. If no
such modifications are present on the truck, these parameters shall
18 Configurable option #3 all be set to “0”
19 Configurable option #4 See“10.5.10 Configurable “Option” Parameters” on page 57
20 Hour meter selection - 1 5 1 2 Select which hour meter is
normally displayed
21 Battery size - 1 20 1 5 Battery size selection
22 Maximum fork lower- - 64 255 5 180
ing speed L
1: 255:
L= max. lowering speed

23 Fork lower stop ramp - 1 20 1 7
T
1: 20:
T= Stop ramp time
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Table 15: Summary of service parameters

Parameter
25 Service interval h 0 2000 50 0 Setting of service interval-

timer.
35 Log off min. 0 20 1 20 Time interval to automatic
log off
36 Calibrate - 0 4 1 0 Calibrate fork lift OR steer
servo
37 Steering offset 1/10° -50 50 1 0 Trim steering
-300:30° to left
300:30° to right
38 Steer servo activated - 0 1 1 0 Activates steer servo,
when fitted
39 Access code - 1 12 1 3 State which level of authori-
zation the driver has to the
driver parameters. Odd val-
ues indicate open operator
parameters, while even
values indicate that the
operator parameters must
be opened with a CAN key.
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.5.9 Description of service parameters

# 10 - PIN code
NOTE:
On delivery of the truck, the PIN code for driver 1 must be changed to
a four-digit code to prevent unauthorised use.
NOTE:
The functionality of parameter #10 is ignored if the value of parameter
#39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the ex-
tended keypad. For detailed information, see the section Extended
keypad - General on page 54.
The parameter stores the truck’s active PIN-codes. The truck can store
up to ten PIN-codes. Each PIN-code has a set of parameters associat-
ed with it, called driver Parameters. Entering a particular PIN-code at
start-up will make the selected PIN-code’s driver parameters active.
This allows up to ten operators to individually adjust the characteristics
of the truck.
On delivery the truck has one default PIN-code stored which is “1“.
To enter a new PIN-code:

• Operate [L1] repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this
driver.
• Repeat the step above until parameter#10 for the next driver is dis-
played, the display will either show PIN-code for that driver OR
“0”(zero).
• Repeat the step above until the PIN-code displayed is “0”(zero)
• Press Horn button [S18]
• Operate [L1] to set the desired value of the new PIN-code.1

The new PIN-code has now been entered.
1.Operating [L1] lightly will step the value in increments of 1.

Operating [L1] fully will step the value in increments of 100
Valid values are 1 to 9999
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
To remove an existing PIN-code:

• Operate [L1] repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this
driver.
• Repeat the step above until the PIN-code to be removed is dis-
played.
• Operate [L1] to set the PIN-code value to “0”(zero).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in
Table 10, “Principle of operation,” on page 27 (Event 2 -Switch on (PIN
code entry)
Parameter #10 cannot be displayed without the CAN service key.
# 14 - Creep speed
This parameter allows adjustment of the initial speed when the first Hall
sensor is activated in the speed control [L1].
#15 - Non-configurable options

Up to 16 so called sub-parameters are stored and accessed via param-
eter #15. These options are either switched ON or switched OFF and
require no other adjustments. They are therefore called non-configura-
ble options. The number of available options is dependant on the truck
type. Consult table Parameter #15 Non-configurable options on page
47 for available options.
Setting Non-configurable options

• Ensure the truck is in the parameter mode.
The parameters symbol lights.
• Select parameter #15 using [L1].

The first sub-parameter will be displayed
Continued operation of the speed control [L1] will display the next sub-
parameter. Note also that only relevant sub-parameters will be dis-
played.
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
After 1 second the value of the sub-parameter will be displayed

• Press horn button [S18].
• Set the sub-parameter value by repeatedly operating speed control

[L1] up or down. See Table 21: for details.
• Press horn button [S18] once to confirm the new setting.
The parameters symbol lights. (stops flashing).
• Switch off the truck by pressing on the keypad.

The non-configurable option will now be activated.
• Ensure the option operates correctly before returning the truck for
normal use.
P
Table 16: Parameter #15 Non-configurable options

Option name Value NOTE!
Sub-parameter No.
Default setting
Function OFF
Function ON
1 to 9 N/A at present - - -
#16 - Configurable option #1

See “10.5.10 Configurable “Option” Parameters” on page 57.



Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
# 20 - Hour meter selection

This parameter determines which hour meter mode to display during
normal use.
Table 17: Hour meter parameter selection

Value Description Display
1 Key time:
Total time truck has been switched on
2 Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
3 Drive motor time:
Total time drive motor has been in operation
4 Pump motor time:

Total time pump motor has been in operation
5 Remaining time to next service

(Parameter #25 controls the initial value)
See “ # 25 - Service interval” on page 49 for more information
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
# 21 - Battery size
This parameter matches the discharge indication to the characteristics
of the battery fitted.
To adjust the disconnection point of the battery discharge indicator,
measure according to:
• Acid concentration when fully charged battery. To check quality of
battery. Shall be between 1,27-1,29.
• When you get lift cut-out (80% discharged of battery capacity) you
shall have close to 1,15 not less.
The acid concentration can vary depending on battery brand.
Table 18: Battery size parameter

Value Function Battery (Ah)
4 ↑
5 Less discharged 450 Ah
6
7 More discharged
8 ↓ 250 Ah
9
WARNING!
Ensure you have set the parameter correctly.
The battery may otherwise be irreparably damaged.
# 22 - Maximum fork lowering speed

This parameter allows adjustment of the maximum fork lowering speed
# 23 - Fork lower stop ramp

This parameter adjusts the time interval between releasing the fork lower
control and fork lower valve completely closing. Decreasing the parame-
ter value will shorten the time interval resulting in a “harder” fork stop.
Increasing the parameter value will make the fork stop more “gentle”
# 25 - Service interval
This parameter determines the time value in hours to the next service
from 0 to 2000 hours in steps of 50 hours. Whenever this value is
changed the timer is reset and will start counting activity time up to the
set value. On reaching the set value caution code 29 (C29) will be
shown on the display.
# 35 - Log off
This parameter determines the time interval before the truck automati-
cally logs off when truck has been idle. A value of “0”(zero) disables the
function.
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
# 36 - Calibrate
This parameter is used to perform calibration of fork lower start point,
automatic calibration of maximum load, manual calibration of maximum
load and steering servo:
NOTE: During calibration, the CAN key must have been connected and
the brake applied. The gates and support arms should be in the low-
ered position.
- Value 0 : No calibration value active (default value)
- Value 2 : Valve startpoint for fork lower
To optimize the fork lowering function it is necessary to “trim” the control
signal for the proportional lowering valve. The point when the valve just
starts to open is called the valve start point.
To calibrate the valve start point perform following procedure:
• Select parameter #36 and set its value to 2.
Press on the keypad. The display shows

• With a load on the forks (between 300 kg & max. load) lift to approx-
imately 1 m above the floor.
• Press and hold depressed the horn button [S18].
The display will show a counter value representing the valve control
signal. After a delay, the forks will begin to lower.
• Release the horn button [S18] immediately the forks begin to lower.
SAFETY NOTE!
Releasing the horn button [S18] before the calibration is complete
stops all truck’s functions and therefore functions as a “dead man’s
handle”
The display will show the calibration value for 3 seconds followed by
• Press on the keypad. Valve start point calibration is now complete

- Value 3 : Automatic calibration of maximum load
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
• Press on the keypad. The display shows

• With truck’s rated load + 100 kg on the forks, lift the forks above the
initial lift height.
• Press and hold depressed the horn button [S18].
The calibration sequence will now commence. The lift pump motor will
start and the forks will lift. During this procedure the system pressure is
analysed and the calibrated value is shown on the display. The whole
procedure lasts approximately 6 seconds. After the lift pump motor
stops the display will show the calibration value for 3 seconds followed
by .
• Release the horn button [S18].
SAFETY NOTE!
Releasing the horn button [S18] before the calibration is complete
stops all truck’s functions and therefore functions as a “dead man’s
handle”
Press on the keypad. Automatic max. load calibration is now complete

- Value 4 : Manual calibration of maximum load
SAFETY NOTE!
Under no circumstances shall the maximum load setting be increased
above the truck’s rated load capacity + 100 kg.
The maximum load can be set manually in this mode without the
requirement of a test load on the forks. It is necessary, therefore to
establish the correct value to be entered. See Table 19: below
• Press on the keypad. The display shows the present value

stored.
• Press the horn button [S18]
• Set parameter value by repeatedly operating speed control [L1] up
or down. See Table 19:
• Press the horn button [S18] to store the new value. The display will
show .
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Table 19: Man. max.load calibration values

Mast 1250 1600
DxTele ≈ 270-280 ≈ 270-280
DxHiLo ≈280-290 ≈280-290
TxHiLo ≈ 280-290 ≈ 280-290
NOTE!
The values given in the table above are nominal and based on brand
new, cold machines. Minor adjustment of these values may be neces-
sary to compensate for stiffness in mast guides, chains etc.
- Value 1 : Calibrate the steer servo.
The calibration establishes the steering centre position (straight
ahead). The system calculates the steering straight position by meas-
uring the difference between “steer full left” and “steer full right”.
Situations which may require that this calibration be performed are:
• The truck deviates from a straight line when tiller arm is in neutral po-
sition.
• Occurrences of error codes E121 or E135
Before performing this calibration, ensure the drive wheel in centre sen-
sor [S65] is functioning and correctly adjusted.
To calibrate the steer servo perform following procedure:
• Press on the keypad. The display shows

• Turn the tiller arm fully to the left until end stop is reached.
• Press horn button [S18]. Display now shows

• Turn the tiller arm fully to the right until end stop is reached.
• Press horn button [S18]. Display now shows .
• Press on the keypad. Steering calibration is now complete
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
# 37 - 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 tiller. It should only
be adjusted after having performed a steering calibration (parameter
#36)
A situation which may require that this parameter be adjusted is if the
truck tends to drift away from a straight ahead course when driving over
longer distances Many factors can contribute to this. It is therefore
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)
# 38 - Steer servo activated

If the truck is equipped with steer servo it must be activated by setting
this parameter.
Value 0 - Steer servo not activated (default)
Value 1 - Steer servo activated
# # 39 - Log-in method & operator parameter access

This parameter determines which function will used for log-in and
whether or not the operator is allowed to adjust the operator parameter
settings.
• Value 1 - Key switch installed - Operator parameters accessible
without CAN service key.
• Value 2 - Key switch installed - Operator parameters NOT accessi-
ble without CAN service key.
• Value 3 - Keypad (standard 10 PIN codes) - Operator parameters
accessible without CAN service key.
• Value 4 - Keypad (standard 10 PIN codes) - Operator parameters
NOT accessible without CAN service key.
• Value 5 - Extended keypad (100 PIN codes) - Operator parameters
accessible without CAN service key.
• Value 6 - Extended keypad (100 PIN codes) - Operator parameters
NOT accessible without CAN service key.
• Value 7 - Extended keypad (100 PIN codes) + TLS - Operator pa-
rameters accessible without CAN service key.
• Value 8 - Extended keypad (100 PIN codes) + TLS - Operator pa-
rameters NOT accessible without CAN service key.
• Value 9 – ID unit – Driver parameters accessible without CAN serv-
ice key.
• Value 10 – ID unit – Driver parameters NOT accessible without CAN
service key.
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
• Value 11 – ID unit + TLS – Driver parameters accessible without

CAN service key.
• Value 12 – ID unit + TLS – Driver parameters NOT accessible with-
out CAN service key.
Extended keypad - General

The truck can be programmed with a maximum of 10 operator profiles.
The extended keypad then enables a maximum of 10 PIN codes to be
assigned to each operator profile. This makes it possible to handle up
to 100 different PIN codes.
If the extended keypad is activated, handling of standard PIN codes
that are normally accessible via parameter #10 is ignored.
Extended keypad - Programming

A group of PIN codes can be made accessible by defining them as a
block. Block no. 0 is activated in the default setting. This means that 3
different operator profiles can be accessed from the very start. Activa-
tion of other blocks will make all the PIN codes for that block accessible
(see Table 21:). If all 10 blocks have been activated, then 10 PIN codes
will be accessible for the operator profile.
The truck firmware stores a standard PIN code set as depicted in Table
21:
These PIN codes can be adjusted to any value, however, it is advisable
to avoid identical PIN codes in different operator profiles.
Starting programming using the extended keypad:
• Connect a suitable CAN service key to [X41].
• Enter code 341671 and depress on the keypad.

• Select a programming command from Table 20:
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
Table 20: Programming commands - extended keypad

Programming Function Note
Reset to default settings Blocks 1 - 9 are dis-
Depress “1” + abled. The original
PIN codes are reset
according to Table
21:
The PIN codes in the block can B = Block no. 0 - 9
Depress “2” + B + be used
The PIN codes in the block B = Block no. 0 - 9
Depress “3” + B + cannot be used
Programming of a new PIN B = Block no. 0 - 9
Depress “4” + B + F + NNNN + code F = Operator profile
no. 0 - 9
NNNN = PIN code

Programming of the extended keypad is now complete.
Parameter #39 must be set to the value 5, 6, 7 or 8 in order for the new
PIN codes to take effect.
Perform a test by logging in with one of the new PIN codes. It is impor-
tant to verify that the correct operator profile is enabled when a specific
PIN code is entered, especially if an operator profile has been pro-
grammed for a specific application or special goods handling.
Table 21: The table shows the standard PIN codes in the firmware.
These can be activated for use or changed according to the preferenc-
es of the operator.
One or more of these blocks can be activated.
When logging in normally, an operator profile is activated when any of
the PIN codes in an activated block is entered.
The truck firmware will deny log-in if PIN code “0000” is used.
Service technicians are requested to keep notes on activated blocks,
PIN code changes and special operator profile settings.
NOTE:
If the extended keypad is reset, this does NOT affect the operator pro-
file settings.
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Table 21: Standard Pin-code assignment with extended keypad

Driver Pro- Pro- Pro- Profi Pro- Pro- Pro- Pro- Pro- Pro-
Pro- file 0 file 1 file 2 le3 file 4 file 5 file 6 file 7 file 8 file 9
file no
Block 0 0000 0001 0002 0003 0000 0000 0000 0000 0000 0000
Block 1 5421 7901 1437 3731 1049 9439 7265 1322 2869 1574
Block 2 1787 4854 2907 9175 5799 1490 3031 7392 5622 5023
Block 3 4659 3174 1026 3815 6703 1179 5152 7514 5668 3215
Block 4 9197 7110 5477 3846 9491 5918 8222 6923 8139 7025
Block 5 2549 6276 9879 9658 1690 4042 5201 9807 4332 9715
Block 6 7474 4142 8620 3754 8432 8788 7430 1948 2595 8527
Block 7 1930 1482 7135 2395 7365 7092 4611 2831 4185 6067
Block 8 2876 4731 1022 5377 3257 7334 9009 7881 8843 7436
Block 9 3242 3162 5878 2828 1910 6907 2136 5730 2957 7691
Parameters
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.5.10 Configurable “Option” Parameters

WARNING!
The information in this section is not intended as a programming ref-
erence and is included solely to allow the reader to gain a thorouth
understanding of parameter setting / checking.
Do not attempt to make any adjustments to these parameters unless
you have sufficient knowledge of the truck’s options/ modified func-
tions. This manual only covers the truck’s standard equipment. Spe-
cially modified trucks may require that you have access to special
service information. Improper adjustment of the option service pa-
rameters may compromise safe operation and / or result in a malfunc-
tion.
General
Parameters #16 to #19 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parame-
ters configure and control the behavior of the Spider expansion unit
(SEU) which must be fitted in the truck. See “10.4.3 Spider expansion
unit (SEU)” on page 32. This method of implementation allows the
standard software program to be used without the need for a special-
ised software. Normally, these parameters are configured by the manu-
facturer when the truck is modified or customized. It is advisable to up-
load the parameter settings from trucks which are modified. In the event
the main control card[A2] is changed, the original parameter settings
can then be transferred to the new card thus ensuring the special option
functions correctly.
Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a
maximum of 4 preprogrammed “base options” to be activated and con-
figured to suit a specific special option or customisation. See table
below.
Table 22: Summary of base options

Base Function Refer to..
option
no.
1 Pressing an option button controls a digital o/p table 23 on page 60
2 Activating a digital input will reduce maximum drive speed table 24 on page 61
3 Specific truck movement(s) activates a digital o/p table 25 on page 62
4 Activating a digital input causes main contactor to close table 26 on page 65
5 Activating digital inputs will operate lift /lower table 27 on page 66
6 Lift height can be restricted by activating a digital input + abil- table 28 on page 68
ity to override by pressing an option button
9 Single-acting hydraulic function table 29 on page 69
10 Double-acting hydraulic function table 30 on page 70
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Parameter #16 to #19 Configurable options

• Each parameter can be designated to hold a particular base option.
• Each designated option has up to 4 arguments associated with it.
• Each argument holds a value which configures that option.
Parameter no. (range 16-19)

Argument: #0 holds option designator (displayed for 2 s only)
Argument value (range 0 - 63)
0= no base option is activated for this parameter
1 to 6 = Base option no. See See separate tables)
16 - 0 - 1
OPTION ASSIGNATION
Argument: #1, #2, #3 & #4 hold configurable values for the option
Argument value (range depends on argument)
Value depends on option and argument selected
See separate table
16 - 1- 1
OPTION CONFIGURATION
Fig. 9 Configurable option layout
Setting Configurable options

To activate a configurable option the base option must first be assigned
to one of the parameters #16 to #19. This is achieved by setting argu-
ment #0 to the base option number. Once it is assigned, the option’s
arguments must be configured. This is achieved by setting a value for
arguments #1, #2, #3 and #4.
• Ensure the truck is in parameter mode.
• Select parameter #16, #17, #18 or #19 using [L1].

Argument #0 will be displayed
After 1 second the argument’s value will be displayed. A value of “0”

indicates no option is assigned to this parameter, in which case contin-
ued operation of the speed control [L1] will display the next parameter
Parameters
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• Set argument #0 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 22:
• Select argument #1 by operating speed control [L1].

After 1 second the value of argument #1 will be displayed.
• Set argument #1 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 22:
Adjust arguments #2, #3 and #4 using the same method as above.
• Switch off the truck by pressing on the keypad

The special option shall now be activated.
• Ensure the special option operates correctly before returning the
truck for normal use.
Parameters
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Table 23: Base option 1 - Option button controls SEU output

Argument #0 Option designator
Initial display Values Meaning
1 Sets relevant parameter to handle base option 1
(value shown after 2s)

Argument #1 Selection of SEU unit 1 or 2
0 option is handled by SEU unit 1 [A36]
1 option is handled by SEU unit 2 (second SEU unit)
Argument #2 Selection of SEU digital output
Initial display Values Meaning Pin no.
0 activate SEU digital o/p 1 (1,6A) 16
(value shown after 2s) 2 activate SEU digital o/p 3 (1,6A) 1
Argument #3 Selection of option button
1 activated by option button 1
(value shown after 2s) 3 activated by option button 3
Argument #4 Type of switching
0 activated when button is depressed
1 option is toggled when button is pressed
Parameters
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Table 24: Base option 2 - Reduced drive speed by SEU i/p

2 Sets relevant option parameter to handle base option
2
Argument #2 Selection of SEU digital input
0 activate SEU digital i/p 1 (1mA) 5
(value shown after 2s) 2 activate SEU digital i/p 3 (1mA) 33
Argument #3 Speed limitation as a percentage of max. speed
0-12 Max. speed adjustable from 40-100%
formula: =40+5*Arg.3
e.g. 40+5*4=60%
Argument #4 Speed range
0 Affects only high speed range
1 Affects only low speed range
(value shown after 2s) 2 Affects both speed ranges
Parameters
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Table 25: Base option 3 - Truck movement activates SEU O/P

3 Sets relevant option parameter to handle base
option 3

1 option is handled by SEU unit 2 (second SEU
unit)
Argument #2 Selection of SEU digital output
(value shown after 2s) 2 activate SEU digital o/p 3 (1,6A) 1
...table continued on next page
Parameters
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...continued from previous page
Argument #3 Selection of activating movement
Initial display Values Drive Drive Lift Lower Any
for- back- forks forks other
ward ward move-
ment
(value shown after 2s) 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 X
17 X X
18 X X
19 X X X
20 X X
21 X X X
22 X X X
23 X X X X
24 X X
25 X X X
26 X X X
27 X X X X
28 X X X
29 X X X X
30 X X X X
31 X X X X X
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040

Argument #4 Output switching mode
0 Output continuously on
1 Output switches at 1Hz
(value shown after 2s) 2 Output switches at 2Hz
Parameters
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Table 26: Base option 4 - Activate main contactor by SEU i/p

4 Sets relevant option parameter to handle base option 4

Argument #2 Selection of SEU digital input
0 activated by SEU digital i/p 1 (1mA) 5
(value shown after 2s) 2 activated by SEU digital i/p 3 (1mA) 33
Argument #3 Hold time in minutes
0-30 Contactor is held on from 0 to 30 minutes after digital i/p
is activated
Argument #4 Not used
Parameters
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Table 27: Base option 5 - Activate lift/lower by SEU i/p

5 Sets relevant option parameter to handle base option
5
Argument #2 Selection of SEU digital inputs
0 Lift - SEU digital i/p 1 5
Lower - SEU digital i/p 2 19
Lower inhibit - SEU digital i/p 3 33
Parameters
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Table 27: Base option 5 - Activate lift/lower by SEU i/p

Argument #3 Enable / Idisable lower inhibit
0 Lower inhibit disabled
1 Lower inhibit enabled
Argument #4 Selection of fork / support arm
0 Selects fork lift / Lower
1 Selects support arm lift / lower
Parameters
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Table 28: Base option 6 - Lift height restriction by SEU i/p &
override

Argument #2 Selection of SEU digital input for restriction switch
(value shown after 2s) 2 activate SEU digital i/p 3 (1mA) 33
Argument #3 Selection of option button to override
(value shown after 2s) 3 activated by option button 3
Argument #4 Not used
Parameters
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Table 29: Basic option 9 - Single-acting hydraulic function


Argument #1 Selection of output on A3 card.
0 this option is controlled via outputs A3:2 and A3:3.
Argument #2 Selection of option button for single-acting hydraulic function
0 activated with option button 2 and 5.
1 activated with option button 1.
(value shown after 2s) 2 activated with option button 2.
Argument #3 Pump motor power reduction
0-7 Max. pump power adjustable from 30 to 100%
formel: = 30 + 10*Arg.3
E.g. 30 + 10*4 = 70%
Argument #4 Pump motor current reduction
0-7 Max. current to pump motor adjustable from 30 to 100%
formula: = 30 + 10*Arg.4
E.g. 30 + 10*4 = 70%
Parameters
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Table 30: Basic option 10 - Double-acting hydraulic function


Argument #1 Selection of output on A3 card.
Argument #2 Selection of option button for double-acting hydraulic function
(value shown after 2s) 2 activated with option button 2.
Argument #3 Power motor power reduction
0-7 Max. pump power adjustable from 30 to 100%
E.g. 30 + 10*4 = 70%
Argument #4 Pump motor current reduction
0-7 Max. current to pump motor adjustable from 30 to 100%
E.g. 30 + 10*4 = 70%
Diagnostic and troubleshooting
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.6 Diagnostic and troubleshooting
means constantly on means flashing.
10.6.1 General
The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 10.
Fig. 10
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C51 to C99 will limit the truck’s maximum speed to creep-
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C1 to C50 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely. i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
10.6.2 Fault code history

Up to 50 of the most recently occurred fault codes will be stored in a log
along with the hour meter reading when the fault occurred. When the
fault code log is displayed, it shows the fault codes in chronological
order with the newest code first.
Carry out the following to display the fault code log:


• Hold [S18] depressed until “E” is displayed, then release [S18]. Fig.
11
Fig. 11 Fault symbol lights.
The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control [L1].
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
10.6.3 List of fault codes

NOTE!
The text “Restart the truck!” in the following tables always means
switching the truck off completely by removing the battery connector
[X1], reconnecting and then switching the truck on again.
Table 31: List of fault codes

Cod Description Possible cause / Hint or Solution
e
C3 TLS: Shock sensor val- A shock sensor has reported values above limit.
ues above limit Driving may be too tough
Make sure that the shock sensor limits are correct.
Make sure that the shock sensor is correct located./Brake acti-
vates and stops the truck. A TLS reset command activates the
truck.
C4 TLS: Truck set out of use Possibility to set the truck “out of use” with a TLS command. /
Truck can´t be used before a TLS command sets the truck “in
use”
C19 Default parameter value "Certain parameter value(s) may be outside their normal max-
warning min range. These parameter values will be reset to their default
values. / " It may be necessary to check the settings of all
parameters if this code is displayed
C20 Butterfly warning Problem with butterfly sensor [L1].
Butterfly may have been activated during start up or faulty sen-
sor(s).[A2] / Check action of butterfly
C21 Lift/Lower control warn- Lift / Lower control for the forks may have been activated dur-
ing ing start up or faulty sensor / Check action of Lift / Lower con-
trol
C28 Emergency switch warn- Emergency switch activated [S21]
ing No voltage supply to Traction transistor regulator [A1].
Harness problem. / Check emergency switch is not depressed.
Check wiring.
C29 Service time warning Next service is due / Check service counter. It may not be reset
after latest service See “ # 25 - Service interval” on page 49 for
setting of parameter #25.
C30 Max.fork load exceeded The load on the forks has exceeded the truck’s classified lift
capacity. / Ensure the load to be lifted does not exceed the
classified lift capacity
Check that lifting is not performed against the mechanical stop.
This applies to both fork lifting and support arm lifting.
Ensure the mast sections and lifting chains move freely
Check pressure sensor o/p [B1:INP.PRESSURE LIFT]
voltage ≈ 0,5V with no load & lowered forks / support arms
Perform a Max. load calibration See “ # 36 - Calibrate” on
page 50
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e
C35 Steer servo -Internal The internal temperature of the steer servo[A5] has exceeded
temperature warning +68° C / Steering may be too intensive
C41 Battery undervoltage Traction transistor regulator[A1] has detected battery voltage
war-ning -traction tran- < 17V
sistor re-gulator Battery parameter not correctly adjusted. See “ # 21 - Battery
size” on page 49 for setting of parameter #21
Battery due for charging
C42 Battery overvoltage war- Traction transistor regulator[A1] has detected battery
ning -traction transistor voltage > 33V /
regulator Can be caused by fully-charged battery and energy return feed
to the battery during heavy reverse braking
C43 Traction transistor regu- Driving may be too intensive
lator thermal cutback Defective Traction transistor regulator [A1]
C47 Battery under voltage Pump transistor regulator[A3] has detected battery
warning -pump transis- voltage < 17V /
tor regulator Battery parameter not correctly adjusted. See “ # 21 - Battery
size” on page 49 for setting of parameter #21
Battery due for charging
C48 Battery overvoltage - Pump transistor regulator[A3] has detected battery
pump transistor regulator voltage > 33V
C49 Pump transistor regulator Lifting may be too intensive
-thermal cutback Defective pump transistor regulator [A3]
C60 Pressure sensor error, Voltage at i/p [B4:INP.PRESSURE LIFT] outside range
Lift system +0,3V to +7,7V
/ Check pressure sensor [B4] wiring and function
Defective pressure sensor [B4]
C61 Pressure sensor error - Voltage at i/p [B5:INP.PRESSURE PT] outside range
powertrak +0,3V to +7,7V
/ Check pressure sensor [B5] wiring and function
Defective pressure sensor [B5]
C62 Powertrak error Unexpected pressure level in Powertrak system /
Check wiring & connections to Powertrak related components
[Y58], [Y59], [B4] & [B5]
Mechanical failure in powertrak valves
C63 Powertrak valve output Valve defective [Y59] or fault in o/p from traction transistor re-
error gulator [A1:OUT.POWERTRAK FILL UP VALVE]
C64 Powertrak valve output Valve defective [Y58] or fault in o/p from traction transistor re-
error gulator [A1:OUT.POWERTRAK DRAIN VALVE]
C 70 Pump motor field circuit Shunt field open [M3], harness broken, pump transistor regula-
open tor defective [A3]./ Check wiring and connections to shunt field
[M3]
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e
C 71 M minus error - Pump Problem with switch transistor in armature circuit inside Pump
transistor regulator [A3] transistor regulator [A3]
Defective Pump transistor regulator [A3].
C 72 Current sensor error - Armature current sensor fault in pump transistor regulator [A3]
Pump transistor regulator Defective pump transistor regulator [A3]
[A3]
C73 CAN timeout error - Pump transistor regulator [A3] reports unexpected loss of data
Pump transistor regulator flow from tiller head [A2]./ Check CAN bus signal cables and
[A3] connections.[A3, A2]
Restart the truck
C74 Data not received - Data from [A3] not received by [A2]
Pump transistor regulator Broken CAN wire
[A3] / Check CAN bus signal cables and connections.[A3, A2]
Restart the truck
C75 Transmission to Pump Data from [A2] not received by [A3]
transistor controller[A3] Broken CAN wire
failed Defective Pump transistor regulator [A3]
/Check CAN bus signal cables and connections.[A3, A2]
Restart the truck
C76 Pump transistor regulator Incorrect type of pump transistor regulator is fitted / Check cor-
[A3] incompatible with rect transistor regulator type is fitted
the type of truck
C77 Lift potentiometer [R14] Analogue potentiometer control not detected.
connection error / Check wiring & connections between potentiometer [R14] &
[A2]
C80 Steer servo - Reference Steer servo reference current < 0,1A
sensor current error Supply fault to home reference sensor [S65]
Defective home reference sensor [S65] / Check wiring to sen-
sor
C81 Steer servo - Reference Sensor supply from
sensor supply error Defective home reference sensor [S65] /
Check supply voltage is 12V between wires 95-97 / Check Wi-
ring to sensor
Check condition of [F50]
C82 Steer servo - drive cur- Steer servo drive current is exceeding 80% of maximum.
rent warning Steering activity may be too intensive
See also code E132
C90 Communication problem Verify the voltage supplied to the SEU 1 unit (A36 POWER
with the SEU 1 unit. SUPPLY 24 VDC) and check that the CAN cabling is OK
If no configurable option is fitted, ensure that service parame-
ter #16-#19 are set to “0”
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e
C91 Communication problem Verify the voltage supplied to the second SEU and check that
with the SEU 2 unit the CAN cabling is OK
If no configurable option is fitted, ensure that service parame-
ter #16-#19 are set to “0”
C92 Programming warning Incorrect programming of the SEU 1 unit 1 [A36]. The truck
SEU 1 unit (A36) travels at creep speed. / May have been caused by incorrect
allocation of an output during adjustment of the option parame-
ters (16 to 19). Verify all settings of any option parameters./ If
no configurable option is fitted, ensure that service parameter
#16-#19 are set to “0”
C93 Programming warning Incorrect programming of the SEU 2 unit. The truck travels at
SEU 2 unit creep speed. / May have been caused by incorrect allocation
of an output during adjustment of the option parameters (16 to
18). Verify all settings of any option parameters. If no config-
urable option is ffitted, ensure that service parameter #16-#19
are set to “0”
E100 Steer servo - configura- Presence of steer servo and parameter #38 setting do not
tion error match/ Ensure parameter #38 is set correctly
E101 Traction transistor regu- Incorrect type of traction transistor regulator is fitted / Check
lator [A1] incompatible correct transistor regulator type is fitted
with the type of truck
E104 Brake switch transistor Defective Traction transistor regulator [A1] / Check cables and
output in Traction transis- magnetic coil to the brake [Y1]
tor regulator [A1] shorted
E106 Digital output fault or field Attempting to drive more current than specified from outputs.
current limit OR problem regulating field current.
Internal Traction transistor regulator fault. [A1]
E107 Main contactor not acti- Problem with main contactor tips or cabling (open circuit).
vated [K10] Contactor control wire not connected.
Contactor drive output in controller faulty (off) / Check main
contactor tips. Check control wires to main contactor.
Check contactor drive output goes low. [A1]
E108 Main contactor tips Main contactor tips welded.
welded or open circuit in Contactor drive output in controller faulty (on) / Check main
coil.[K10] contactor tips Check contactor drive output goes high. [A1]
E110 Fault in armature current Possible defect in the transistor regulator [A1].
reading Can be caused by excessive moisture inside regulator. /
Restart the truck
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e
E112 Steer servo- wheel posi- Error when comparing actual wheel position (reference sensor
tion error signal) with steer servo’s calculated position.
/ Check reference sensor[S65] functions correctly
Check steer servo pinion is not loose and in contact with drive
unit’s gear ring
Restart the truck
E113 Unspecified steer servo Control system has detected a fault condition but is unable to
fault ascertain the exact cause. / Restart the truck
E114 Steer servo phase error Loss of motor phase to steer servo motor. / Check internal
[A5, M6] motor cable connections in steer servo[A5, M6]
E115 Steer servo initialisation Faulty Servo [A5]
error [A5] Internal logical fault
Wrong parameters / Restart the truck
E116 Steer servo checksum Can occur after new firmware has been loaded into truck /
error [A5] Restart the truck
E117 Steer servo communica- Shall not occur under normal conditions./ Contact support
tion error organisation
E118 Command mode error Shall not occur under normal conditions./ Contact support
organisation
E119 Steer servo error during Home position (steering straight) not achieved within preset
homing operation (Time time.
out) Home reference sensor [S65] not adjusted correctly
Faulty reference sensor / Check reference sensor gap is
adjusted correctly, check wiring to sensor
E120 Steer servo- potentiome- Comparison of voltages between IN_0 & IN_1 is out of range. /
ter error Check potentiometer inputs
E121 Steer servo error -steer- Restart the truck
ing angle value check Check that sum of voltages between wire nos.
92-94 and 93-94 ≈ 5V
Re calibrate steering (See “ # 36 - Calibrate” on page 50)
E122 Steer servo -reference Defective steer servo [A5] / Check voltage between wire nos.
supply out of range 91-94 = 4,5 to 5,5 V
E123 Steer servo - Hall sensor Intermittent contacts inside steer servo
fault Defective steer servo [A5] / Check internal connections from
Hall sensors to main circuit board in steer servo [A5]
E124 Steer servo - overvolt- May occur when performing heavy reverse braking on newly
age [A5] charged battery (Voltage exceeded 39V) / Restart the truck
E125 Steer servo - internal Defective steer servo [A5,M6] /
short circuit [A5, M6] Check wiring for short-circuit
Restart the truck
E126 Steer servo - current off- Defective steer servo [A5,M6] / Restart the truck
set error [A5, M6]
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e
E127 Steer servo - tempera- Steer servo internal temperature outside range -40 to +85º C
ture error[A5, M6] Steering activity may be too intensive
Defective steer servo [A5,M6] / Restart the truck (See also
code C35)
E128 Not applicable in this -
truck
E129 Steer servo - supply und- Battery charge too low
ervoltage Intermittent connection in servo supply circuit [A5]
Steer servo fuse [F52] faulty or blown. / Check condition of
Fuse [F52]
Charge battery
E130 Steer servo - analogue Faulty steer angle potentiometer [R2]
steer signal input fault Intermittent connection in potentiometer circuit [R2,A5] / Check
wiring to potentiometer [R2]
Move tiller handle in all directions to ensure no wiring problems
exist.
steer signal input 0 fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 94-93,
check wiring to potentiometer [R2]
exist.
E132 Steer servo - current limit Output current to steer motor exceeding 80% of maximum for
reached longer than 5 seconds.
Steered portion of drive unit not moving freely./ Check for free
movement of drive wheel on floor. Check steering drive train is
free of dirt or other foreign objects.(See also code C82)
steer signal input 1 fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-92 ,
check wiring to potentiometer [R2]
exist.
E134 Steer servo - analogue Faulty steer angle potentiometer [R2] or wiring short circuit
steer signal input short between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to
circuit potentiometer [R2],
exist.
E135 Steer servo - offset value Voltage difference between [A5:INP.A_IN1 and INP.A_IN0] is
error too great
Requires re calibration / Re calibrate steering (parameter #36)
See “ # 36 - Calibrate” on page 50
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e
E136 Steer servo - steer angle Calibrated neutral position value is out of range.
potentiometer error Defective potentiometer [R2] / Ensure potentiometer is fitted
correctly.
Re calibrate steering (parameter #36). See “ # 36 - Calibrate”
on page 50
E137 Steer servo - checksum Faulty wiring / Check CAN bus signal cables and connec-
error on received data tions.[A5, A2]
Restart the truck
E138 CAN data not received Data from traction transistor regulator not received by [A2]
Faulty wiring / Check CAN bus signal cables and connec-
tions.[A1, A2]
Restart the truck
E139 Steer servo - data trans- Faulty wiring / Check CAN bus signal cables and connec-
mission to servo failed tions.[A5, A2]
Restart the truck
E140 Checksum error Faulty internal micro controller [A2], faulty software
E141 Software problem Faulty internal micro controller [A2], faulty software / New soft-
ware may need loading via CAN
E150 Data not received - Trac- Traction transistor regulator [A1] does not answer, bad connec-
tion transistor controller tions or faulty Traction transistor regulator [A1].
E151 Transmission to traction Broken CAN-wire.
transistor regulator failed Traction transistor regulator [A1] defective
E157 Bus off error CAN-bus problem, wiring harness or hardware problem.[A2] /
Check CAN wiring
E159 Over-run error CAN-bus problem, wiring harness or hardware problem.[A2] /
Check CAN wiring
E160 Error -safety switch Error in Hall sensor for safety switch against collision “belly
against collision button”/
Check switch is not activated.
E200 Drive motor field circuit Shunt field open [M1], harness broken, Traction transistor reg-
open ulator defective [A1]. / Check wiring and connections to shunt
field [M1]
E201 M minus error Problem with switch transistor in armature circuit inside Trac-
tion transistor regulator [A1]
Defective Traction transistor regulator [A1].
E202 Current sensor error - Armature current sensor fault in Traction transistor regulator
traction transistor regula- [A1].
tor [A1] Defective Traction transistor regulator [A1].
E214 CAN-timeout error - trac- Traction transistor regulator reports unexpected loss of data
tion transistor regulator flow from tiller head [A2]./ Check CAN bus signal cables and
[A1] connections
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10.6.4 Transistor regulator
STATUS
MODEL VOLTAGE
SERIAL CURRENT
General
Curtis 1243 is a regulator [A1] & [A3] for controlling shunt motors. Vary-
ing the voltage applied through the armature primarily controls the
speed. The voltage is varied through use of pulse-width modulation
(PWM). This involves varying the “on” time of the MOS-FET transistors
regulating the armature current.
Switching of the rotational direction is achieved by switching the pola-
rity on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
STATUS
MODEL VOLTAGE
tor bridge for the armature winding.
SERIAL CURRENT
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Transistor regulator errors

The table below depicts the error codes that may be shown by the
STATUS LED or read using the hand-held terminal.
Table 32: Transistor regulator error code

STATUS LED Hand-held Explanation Possible cause
terminal dis-
play
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator
LED on - Defective regulator Defective regulator
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in
SHUNT FAULT shunt defective motor controller.
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in
B- armature circuit inside motor control-
ler
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current for Attempt to drive more current than
SHORT contactor feeding specified from outputs.
or shorted field Problem to regulate field current.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shunt field open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <17 volts
VOLTAGE 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor
regulator
4. Operation under extreme condi-
tions
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Resetting errors
To reset an error turn [S17] to off and then on again.
Error Reset when

OVERVOLTAGE Battery voltage falls below 33 V
THERMAL CUTBACK The temperature is within allowed range
THROTTLE FAULT 1, 2 Error has been fixed
LOW BATTERY VOLTAGE When battery voltage exceeds 16 V
Safety
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
WARNING!
Remove all watches, jewellery and always use insulated tools only.
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10.6.5 Built-in Test Function

The truck’s control system provides a number of useful built-in test
functions
• Connect CAN-key in [X41] and press [A17].
• Battery status is shown.
• Press Horn [S18] repeatedly to choose Built-in Test mode.

NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!
Table 33: Built-in test modes

Flashing symbol Displayed data Unit
Speed reference value sent to trac- -
tion transistor controller.
Lift / lower command value sent to

pump transistor controller.
Main control card signals [A2) -

See Table 36:
Inputs / outputs traction transistor -

regulator & pump transistor regula-
tor. See Table 34: & Table 35:
Battery voltage V
Armature current to traction motor A

[M1]
Field current to traction motor [M1] A
Armature PWM to traction motor %

[M1]
Armature current to pump motor A

[M3]
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Table 33: Built-in test modes

Flashing symbol Displayed data Unit
Field current to pump motor [M3] A
Armature PWM to pump motor [M3] %
Signal from pressure sensor [B4] bar

(Hydraulic pressure in lift circuit)
Signal from pressure sensor [B5] bar

(Hydraulic pressure in powertrak
circuit)
Maximum lift pressure setting. bar
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Digital inputs/outputs test mode

In the digital inputs/outputs mode, the operation of both inputs and out-
puts can be checked by checking the individual segments of the main
display as given in the following tables.
Table 34: Transistor regulator inputs

Function Segment
Tiller arm in drive pos.[S10], input
A1:INP.TILLER ARM IN DRIVE POS:
Platform not folded up switch [S59], input

A1:PLATFORM NOT FOLDED UP
Man on platform switch [S19], input

A1:INP.MAN ON PLATFORM
Gates up switch [S53], input A1:GATES UP
Gates down switch [S56], input

A1:GATES DOWN
Support arms at top switch [S31], input

A3:INP.SUPPORT ARM AT TOP
Support arms at bottom switch [S90], input

A3:INP.SUPPORT ARM AT BOTTOM
Forks < 1800mm [S33/2] magnetic switch , input

A3:LIFT LIMIT <1,8M
Powertrak lift limit [S33/1] magnetic switch, input

A1:LIFT LIMIT POWERTRAK 1,<1,8M
Powertrak fill up valve watchdog (Senses

whether Y59 is drawing current correctly -
should normally show the inverse of output sig-
nal)
Powertrak drain valve watchdog (Senses
whether Y58 is drawing current correctly -
should normally show the inverse of output sig-
nal)
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Table 35: Transistor regulator outputs

Function Segment
Signal horn [H1], output A1.SIGNAL HORN
Brake solenoid [Y1], output

A1.BRAKE RELEASE
Main contactor [K10], output OUT.MAIN.CON-

TACTOR
Powertrak fill up valve [Y59], output

A1:OUT.POWERTRAK FILL UP VALVE
Powertrak drain valve [Y58], output

A1:OUT.POWERTRAK DRAIN VALVE
Fork / support arm valve [Y52], output

A3.OUT.FORK SUP.ARM VALVE
Support arm lower valve [Y41], output

A3.SUPPORT ARM LOWERING VALVE
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Table 36: Main control card signals [A2]

Function Segment
Support arms down [A2:S20]
Support arms up [A2:S19]
Signal horn [S18]
Option switch -lefthand left
Option switch -lefthand middle
Option switch -lefthand inner
Option switch -righthand inner
Option switch -righthand middle
Option switch -righthand outer
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10.6.6 Display test mode

The digital display [A6] itself can be tested to verify all the segments of
the display function correctly.
To select Display test mode carry out the following procedure:


• Hold [S18] depressed until “d” is displayed, then release [S18]. Fig.
Fig. 12
12
All number segments on the display and symbol lamps should flash
sequentially. Fig. 13
Fig. 13
Technical specifications – Curtis 1243
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10.7 Technical specifications – Curtis

1243
Table 37: Technical specification -Curtis 1243

Item Traction Lift Unit Explanation
Rated operating voltage 24 24 Volts
Overvoltage limit 33 33 Volts
Undervoltage limit 16 16 Volts Minimum operating volt-
age
Electrical insulation towards cold 500 500 V AC Minimum
body
PWM frequency 16 16 kHz
Max. current of armature wind- 200 300 Amps for 2 minutes
ing *
100 100 Amps for 1 hour
Max. current of field winding 25 35 Amps for 2 minutes
20 20 for 1 hour
Contactor voltage 24 24 Volts Same as battery voltage
Contactor current 2 2 Amps Max (current limit at 2.5
amps)
KSI input voltage, Min. 16.8 16.8 Volts
KSI input current 50 50 mA
Logic input voltage >7.5; High >7.5; High Volts
<1; Low <1; Low
Logic input current 15 15 mA
Operating temperature -40 to +50 -40 to +50 °C
Overtemperature, reduction 85 85 °C
Undertemperature, reduction -25 -25 °C
* During specific test conditions.

WARNING!
The regulators ([A1] & [A3]) cannot be swapped.
Technical specifications – Curtis 1243
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Hydraulic system – 6000
Hydraulic diagram
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11- Hydraulic system – 6000
11.1 Hydraulic diagram
11.1.1 With height-adjustable support arms
B4 B5
FORKS
Y59
CV3 OR1 OR2
LS
POWER
TRAK
SUPPORT
ARMS SB2
Y41 Y58
SB1 Y10
CV2
CV1
OR3 Y52
RV
P M3
Hydraulic diagram
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11.1.2 Without height-adjustable support

arms
B4 B5
Y59
FORKS OR1 OR2
POWER
TRAK
SB1 Y10 Y58
RV
P M3
Main Components
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Y59 M3, P 11.2 Main Components

Table 38: Main Components
Pos. Designation
Y58 1 Air bleed valve, oil filling
B4
B4 Pressure sensor, fork lift/support arm lift
Y52
B5 B5 Pressure sensor, PowerTrak
LS Load selector valve (only trucks with height-adjustable
LS support arms)
SB2 M3 Pump motor
P Pump
RV Overflow valve, max. 200 bar
SB1 Constant flow valve
RV SB2 Lowering brake valve (only trucks with height-adjustable
Y41
1 support arms)
Y10 Y10 Proportional valve, lowering forks
SB1
Y41 Lowering valve, lowering support arms (only trucks with
height-adjustable support arms)
Y52 Selector valve, fork/support arms (only trucks with
height-adjustable support arms)
Y58 PowerTrak valve, draining PowerTrak cylinder
Y59 PowerTrak valve, filling PowerTrak cylinder
Description
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11.3 Description
11.3.1 Lifting system

The pump motor (M) features speed control for continuous adjustment
of the fork lifting speed. Two non-return valves (CV1,CV2), one for fork
lifting and one for support arm lifting, are installed to prevent leakage
through the pump. The routing valve (Y52) controls selection of support
arm lifting or fork lifting. An overflow valve (RV) prevents overpressure
in the system. The pressure sensor (B4) detects the cylinder pressure,
providing data about the load on the forks, and it is also used to monitor
possible overloading. This allows limitation of the speed when carrying
loads heavier than 800 kg and also serves as a warning in case the
max. load is exceeded. The proportional valve (Y10) enables stepless
adjustment of the speed when lowering the forks. The maximum fork
lowering speed is adjusted by a flow limiting valve (SB1). The lowering
valve (Y41) controls lowering of the support arms. The maximum sup-
port arm lowering speed is adjusted by a flow limiting valve (SB2).
When lifting the forks, if internal leakage via the support arm lifting valve
(Y52) should occur this is drained by using the check valve (OR3) and
fluid is returned to the reservoir. This prevents unintended support arm
movement.
There is no return filter in the hydraulic system.
11.3.2 The PowerTrak system

The truck is equipped with the PowerTrak system, which adapts the
drive wheel pressure in accordance with the load on the forks and the
drive wheel wear. This results in less wear on the drive wheel and pro-
motes safer load handling.
The PowerTrak cylinder operates when the forks have been lifted to
maximum 1800 mm, however system operation varies depending on
the mast type. The pressure sensor (B5) detects the pressure and is
used to control and monitor the PowerTrak system. This prevents
excessive drive wheel pressure when handling loads at lifting heights
>1800 mm. The PowerTrak system uses two valves (Y58,Y59), one for
filling and another for draining. When the machine receives no power,
both valves are shut off in order to maintain the pressure in the Power-
Trak cylinder. Replenishment and draining are done by switching on the
power to either valve. A load sensing valve (LS) controls the amount of
pressure applied on the PowerTrak cylinder. The check valve (OR2)
operates to dampen cylinder movement.
Description
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11.3.3 Working pressure

The working pressure shows the classified weight: 110 bar.
11.3.4 Overflow valve

The overflow valve opens at the following pressure: 200 bar.
11.3.5 Pressure sensor

The pressure sensor is used to adjust the speed and is affected by the
load.
Load < 800 kg. Travel speed = 8.0 km/h
Load >800 kg. Travel speed = 7.0 km/h (Declines linearly to 7.0 km/h at
maximum load)
Description
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Lift mast – 7000
Mast incline
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12- Lift mast – 7000
12.1 Mast incline

NOTE
Only applies to trucks with height-adjustable support arms.
• The mast’s backward incline is adjusted using shims (1). The adja-
cent angle on the frame must be 0.3+/-0.2° (5.2+/-3.5 mm/m).
• The mast’s side incline is adjusted using shims (2). The adjacent an-
gle on the mast must be a maximum of 0.1° (1.7 mm/m).
Lift mast – 7000
Main lift chain system
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12.2 Main lift chain system
12.2.1 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out in
the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and 7800
as applicable.
12.2.2 Chain inspection

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.
Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.
Surface rust
Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced
Rusty links
Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.
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.
Lift mast – 7000
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Bolt rotation
Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
The chain should be replaced
.
Loose bolts
If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.
Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
Lift mast – 7000
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in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.
Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.
Table 39: Stretching

Type of Nominal Minimum Pitch P Nominal chain Maximum permitted
chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (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 are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.
Lift mast – 7000
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Damage
The chain should be replaced if damaged in any way.
Damaged discs
If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
Damaged bolts
It can be difficult to discover whether a bolt has broken. It can appear as
bolt rotation and/or that the outer disc is loose.
Dirty chain
If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.
12.2.3 Cleaning
If a chain is very dirty it is recommended that it is replaced.
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 agent as these can contain abrasives.
Lift mast – 7000
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12.2.4 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
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 driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket 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:
Lift mast – 7000
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Table 40: Recommended Product

Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrica-
tion
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubri-
cation
< + 5°C
Anticorit LBO 160 TT, Fuchs DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.
Lift mast – 7000
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TruckCom
General
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13- TruckCom
User Manual for trucks using the “PowerDrive” platform. This Manual is
valid for version 3.5 of TruckCom p/n 182147-008.
13.1 General
TruckCom is a communication program which communicates with
trucks equipped with CAN (Controller Area Network) communication.
It enables the following tasks to be performed:
• downloading truck control software.
• viewing and adjusting operator / truck parameters and hour meters.
Additionally, the truck’s parameter set (including hour meter values)
can be saved to file and reloaded later.
• viewing diagnostic data for various digital inputs / outputs and ana-
logue data including voltages, currents and certain temperatures.
The program is a Windows program running under Windows® 95/98,
Windows® XP/2000 and Windows® NT.
13.2 Connection
A CAN interface of the CPC-PP type is needed to connect it to the
truck, with attendant cable. Connect the interface via the printer port on
a PC. Connect the cable between the interface and the truck's CAN ter-
minal.
The CAN interface is supplied with power from the truck electronics and
is protected from any high voltages in the truck if a fault should occur.
TruckCom
Layout
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13.3 Layout
13.3.1 Main program screen

Information
Menu bar window
Tool
buttons
Nodes
Icons
Tool button bar
Fig. 14 Main TruckCom program screen

The Main window opens when the program is started. This shows the
menu bar, tool buttons, workspace, log window and status window.
13.3.2 Nodes
Devices which are connected to and communicate via the CAN inter-
face are called nodes. The nodes detected on the bus are shown in the
node window. The current node status and input component/informa-
tion is shown with different icons.
Fig. 15 A typical node window display
TruckCom
Layout
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13.3.3 Icons
Icon Description
Node OK is shown when contact is made with a node
and no errors have been reported.
Node not connected is shown when there is no contact

with a node in the network.
Node not OK is shown when an error has been reported

by a node. Click on node to obtain more information.
Program version is shown when information is available

on which software is installed. Click to obtain more infor-
mation.
Information is shown when a node has information on,
for example, error codes.
Truck report
GB“13.7 Truck report function” on page 7
Parameters is shown when a node has information on a

parameter.
Diagnostics
Exit
13.3.4 Tool buttons and menu bar

The tool button bar allows direct access to the program’s most common
functions. The menu bar allows access to all the program functions.
Explanations of each menu bar item are given in the relevant section.
Search for Disconnect Truck

units from PC Download report
Parameters Diagnostics Information Exit

Fig. 16 Tool button bar
TruckCom
Connection function
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13.3.5 Information window

The right section of the main window contains a status window where
different messages are shown.To see previous messages, use the
scroll arrows in the right margin.
13.3.6 Status bar

There is a status bar at the bottom of the main window, which shows
variable status when the program is run.
1 2 3 4 5
HELPTEXT REC MACHINE
The following are shown from the left:

Help text "pop-up" via the mouse cursor, connected/not connected to
network, truck type connected, initiation result of CAN interface and the
present time.
13.4 Connection function

To connect the PC the network, select the Scan units function. This can
be done with the menu <Nodes | Scan units> or with the tool button
[Scan nodes].
This should also be done when the truck is supplied with voltage and in
normal drive mode.The program will now run a check and installation of
the CAN interface. A diagnosis will also be carried out to check which
units are connected in the system. The result of this diagnosis is shown
in the Node window.
13.5 Disconnection function

Select the Disconnect function to disconnect from the network. This
can be done with the menu <Nodes | Set PC off-Line> or with the tool
button [Set PC off-Line].
The CAN interface is then reset and the CAN cable can be disconnect-
ed if so required. This enables connection to another truck without hav-
ing to close the program.
TruckCom
Downloading program function
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13.6 Downloading program function

To download a new program to one of the nodes, select the Download
software function. This can be done with the menu <Tools | Download
software... > or with the tool button [Download].
Type
123456
13.6.1 Normal downloading (truck with key)

Select Open.. to open the file to be downloaded into a node. The file
name, file type and version number are shown in the window for file
information. If it is file for a controller, indicate which type of controller is
to receive the file. Start downloading by selecting Start... and by restart-
ing the truck by turning the key off and on twice.
Restart must be made within 20 seconds from when the Start button
has been activated.
Close the download window when the download is ready, and then dis-
connect the PC from the network. A new connection can now be made
to verify the new program.
13.6.2 Normal downloading (truck with

keypad)
Select Open to open the file to be downloaded into a node. The file
name, file type and version number are shown in the file information
dialogue box. If it is file for a controller, indicate which type of controller
is to receive the file. Start downloading by depressing and then releas-
ing the red key on the keypad.
The truck must be restarted within 20 seconds from when the Start key
has been activated.
TruckCom
Downloading program function
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When downloading has been completed, close the download dialogue

box and then disconnect the PC from the network. It is now possible to
reconnect to verify the new application.
13.6.3 Emergency downloading (truck with

keypad)
• Disconnect the battery connector.
• Select OK in the dialogue box.
• Keep the red key on the keypad depressed while reconnecting the
battery connector.
• Release the red key to commence downloading.
13.6.4 Emergency downloading (truck with

keypad)
E141 will be shown in the truck’s display when starting, if for any reason
there is no program in the electronics card (interrupted downloading).
Communication with the truck via the PC will then be minimised. Use
“E141” to download the program in the card.
On some trucks, a counter, which continuously counts up, is displayed.
NOTE!
Once programmed, the logic cards in some trucks can only be up-
graded with the same basic firmware. In other words, it is not possible
to replace the basic firmware (other machine type).
13.6.5 Downloading in old versions of logic

card
To download to older versions of electronic cards which do not support
restart with key, the button Old card... should be used instead of Start...
Downloading is carried out in the same way, except that restart is done
by using the battery lug instead of the key.
TruckCom
Truck report function
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13.7 Truck report function

It is possible to generate a report to a file or disk with the truck’s config-
uration and status. Select menu <Tools | Generate truck report...> or
with the tool button Truck report. Save the report in Report.file.
NAME
Example of information generated in the truck report:

[GENERAL] [ERROR LOG]
REPORT DATE-TIME=2004-01-19 11:11:58 01=104 00007.5
CPC-PP SERIAL No=8002041 02=104 00007.5
MACHINE NUMBER=555555 03=104 00007.5
CUSTOMER=CUSTOMER 1 04=104 00007.5
TECHNICIAN=NONAME 05=104 00007.5
COMPANY=Other -
NOTES=Test report -
-
[CAN NODES] 09=104 00005.0
MAIN CARD=0
CURTIS DRIVE CONTROLLER=16
[MAIN CARD CONFIGURATION]
SOFTWARE=181179-001 [DRIVER PARAMETERS]
HARDWARE=167833-004 1=100
SERIAL NO=53676 2=100
3=75
[DRIVE CONTROLLER CONFIGURATION] -
SOFTWARE=5 -
DRIVE CURRENT LIMIT (A)=300 -
FIELD MAXIMUM (A)=34 100=0
SERIAL NO=52857
MFG Date:=26/05/03
HOUR METERS]
A IGNITION TIME=81
B TOTAL MOVEMENT=7 [TRUCK PARAMETERS]
C DRIVE MOTOR TIME=7 11=0
D PUMP MOTOR TIME=0 12=0
S SERVICE TIME=7 13=0
The contents of certain rows can vary according to truck type.
TruckCom
Parameters function
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13.8 Parameters function

To change the truck parameters, select the Parameter function. This
can be done with the menu <Tools | Change parameters > or with the
tool button Parameters.
NOTE!
The truck must in Normal mode (i.e. not Parameter mode) when con-
necting TruckCom. Otherwise TruckCom will report “Unable to deter-
mine truck brand”
The parameter numbers follow the description in the respective truck
Service Manuals, section 5000.
The parameter window shows the information and the current settings
for all parameters. The parameters are divided into 4 tabs.
• [Driver] - Driver; driver parameters and PIN code storing
• [Truck] - Truck; service parameters
• [Time] - Time; time-related service parameters
• [Option parameters] - Option parameters. (no. 15 to 19)
WARNING!
Do not attempt to make any adjustments to the option parameters un-
less you have sufficient knowledge of the truck’s options/ modified
functions. Specially modified trucks may require that you have ac-
cess to special service information.
Improper adjustment of the option service parameters may result in a
malfunction.
13.9 Diagnostics function

To access diagnostics, select the Diagnostic function. This can be done
with the menu <Tools | Diagnostic...> or with the tool button Diagnostic.
NOTE!
If the value “---” is shown in a field, or a “read status LED” is red, the
communication has been interrupted for some reason and error data
cannot be shown.
NOTE!
The tab information displayed in the diagnostics mode depends on
the type of truck connected.
TruckCom
Diagnostics function
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
13.9.1 Representation of signal colours

The screen dumps shown in the following section have been modified
to improve legibility in black & white print.
WHITE
GREEN
RED
13.9.2 “Tiller arm” tab
Clicking on the tiller arm tab will display a dialogue showing the follow-
ing:
• Speed lever -The status of the speed control and travel direction se-
lector. The status of each individual hall element is displayed.
• Buttons -The status of the control buttons is displayed. “Sxx” refers
to the switch designations as given in the circuit diagram.
• Option - Status of option buttons
• Battery - The measured battery voltage
• R14 - Shows the measured signal voltage from the lift/lower control
• R15 - Not used at present
TruckCom
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
13.9.3 “Drive Controller” tab

(transistor regulator driving)
Clicking on the Drive Controller tab will display a dialogue showing the
following:
• Status of digital inputs and outputs of the transistor regulator. pin re-
fers to the motor controller pin designations as given in the circuit di-
agram.
• Field PWM - The effective power output supplied to the field circuit
as a percentage.
• Armature PWM - The effective power output supplied to the arma-
ture circuit as a percentage
• Field current - The current flowing in the field circuit in Amperes.
• Armature current - The current flowing in the Armature circuit in Am-
peres
• Raw throttle data - The received speed control signal as a percent-
age.
• Temperature - The temperature of the output stage of the transistor
controller in degrees Celsius
• Inp pin 10 - The input voltage from the mode/pressure sensor.
“digital O” indicates the digital status of the input.
• Inp pin 11 -The input voltage from the man-on platform sensor.
TruckCom
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
13.9.4 “Pump controller” tab

(transistor regulator pump)
If the truck is equipped with a lift/lower transistor regulator, the Pump

controller tab displays the following:
• Status of digital inputs and outputs of the transistor regulator. pin re-
fers to the motor controller pin designations as given in the circuit di-
agram.
• Field PWM, Armature PWM, Field current, Armature current, Tem-
perature - See explanation in 13.9.3
• Raw throttle data - The received lift/lower signal as a percentage.
• Out pin9 - The output signal to the proportional lowering valve as a
percentage.
• Inp pin 10 - The input voltage from the pressure sensor.
• Inp pin 11 - The input voltage from the pressure sensor.
TruckCom
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
13.9.5 “EPS” (steering servo tab)
Clicking on the “EPS” tab will display a dialogue showing the following:
“Status”
• “Operational” - Indicates the status of the servo’s control system
• “EPS enabled” - Indicates the status of the servo’s power stage out-
put.
• “Reference switch reached” - indicates status of drive wheel in cen-
tre reference switch.
• “Reference position found” - indicates whether a successful steering
in centre has been performed.
• “EPS in power save mode” - Shows whether the steering servo is in
the standby mode (following a certain amount of inactivity).
“Actual values” (Measured values)
• “Temperature EPS” - The temperature of the steering servo output
stage in degrees Celsius.
• “DC bus voltage” - Supply voltage to steering servo
• “Wheel position” - Shows the estimated steering angle of the drive
wheel.
• “Voltage analog input 1, pin5”- The measured DC input signal (0)
from the steering potentiometer.
• “Voltage analog input 2, pin13”- The measured DC input signal (1)
from the steering potentiometer.
• “Current” - The measured current supplied to the steer servo motor
in Ampere
• “Actual velocity” -The measured rotational speed of the steer servo
motor shaft in r.p.m.
TruckCom
Other menu functions
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13.9.6 SEU tab (Extra I/O module)
When the truck is equiped with a Spider Extension Unit (former Extra I/
O module) the SEU tab shows following:
• “INP X” - Shows the logical status for the digital inputs.
• “OUT X” - Shows the logical status for the digital outputs.
• “Analog input X” - Shows the voltage level on the analog inputs.
See chapter 5000 for more information about the SEU and how the
inputs and outputs are connected.
13.10 Other menu functions
13.10.1 Save to file

The truck parameters can be saved in the PC for downloading at a later
date.Select <File | Save to file | Parameters>. All parameters in the
nodes which are connected to the bus will be scanned in and saved in
a file.If only the hour meters are needed, select <File | Save to file |
Hour meters>.
13.10.2 Download from file

A set of parameters can be downloaded from the PC to the truck. Select
<File | Load from file | Parameters >. The parameters in the file will be
copied to the nodes connected to the bus. If only the hour meter set-
tings are needed, select <File | Load from file | Hour meters >.
TruckCom
Other menu functions
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
13.10.3 Reset CAN adapter

If problems should occur when resetting the CAN adapter connected to
the PC, this can normally be done manually by making sure that the
adapter is supplied with voltage and then selecting <Nodes | Reset
CPC-PP>.
13.10.4 Delete error code log

To delete the truck’s error code log, start the truck in parameter mode
and then select <Tools | Erase error log>.
13.10.5 Reset hour meter

To reset the truck’s hour meter, start the truck in drive mode and then
select <Tools | Reset hour meters >.
13.10.6 Read error code log

To show the truck’s error code log, select <Tools | Read error log >.
13.10.7 Adjust date and time

To quickly adjust the truck’s data and time, select < Tools | Adjust date
& time >. The time given in the PC will now be downloaded into the
truck.
NOTE!
This does not apply to trucks without a real-time clock.
13.10.8 Adjusting the hour meter on older

cards
To adjust the hour meter on trucks with older cards, select
<Tools | Adjust Hour meters>. The time given in the PC will now be
downloaded into the truck.
13.10.9 Help
About the TruckCom application
To see program information, select <Help | About TruckCom...> or use
the tool button [Information].
13.10.10 Exit
To exit the program, select <File | Exit > or use the tool button [Exit].
TruckCom
Specifications
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13.11 Specifications
Table 41: CAN interface specification

Description Value
Power consumption 40-120 mA
Supply voltage 11-28 V
Transfer rate 125 kbit/s
Storage temperature -20-80 °C
Operating temperature 0-60 °C
13.12 Installation
NOTE!
The program must be installed from the hard disk.
NOTE!
The software application in the computer can be damaged, which is
why the PC installation should be performed by someone with the re-
quired knowledge. TOYOTA does not accept any responsibility for
any errors that occur during the installation.
NOTE!
All references to PC operating system actions, menus and commands
are based on the English language version of Windows®.
13.12.1 Installation on a PC with Windows®

95/98
If a previous version of the TruckCom application has been installed on
the PC, it will be necessary to edit the System.ini file.
Start the Msconfig.exe application by selecting the Start button, select-
ing Run and then typing msconfig.
• Click on System.ini and open the folder (386Enh).
• Unmark the option at Device=C:\Windows\Cpcppvd.vxd.
• Save the change and close the application.
Now continue with installationThe software application is supplied on a
CD or via a network. Start installation by running X:\SETUP.EXE, where
X:\ is the drive on which the installation application can be found.Then
follow the on-screen instructions.
TruckCom
Installation
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
13.12.2 Installation on a PC with Windows XP/

2000
To make the application work, it is necessary to enter a value in the
Windows® Registry and then make a few alterations in the Windows®
Control panel.
Due to the built-in Windows® security, this must be done manually.
The instructions below provide step-by-step guidance to enable these
changes and make the interface operate under Windows XP and Win-
dows 2000.The changes can be made either before or after TruckCom
is installed.
• Open the Registry Editor. To do this, select the Start button, then
Run, type regedit and hit Enter.
• Mark the Enum folder which can be found under

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the
Registry Editor.
• Select the Edit option, then Find and type PortName to search for
the correct folder.
TruckCom
Installation
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
NOTE! The location of the folder differs between different computers

(some may be \Enum\Root\.., while others could be \Enum\ACPI\ etc.).
Thus be sure to search for the correct folder.
When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in

the PortName data field and that the folder name is Device Parameters.
• Right-click with the mouse in the right box to enter a new value of the
DWORD type and with the name
EnableConnectInterruptIoctl.
TruckCom
Installation
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
• Change the value in data field 1 by right-clicking on the name and

selecting Modify.
EnableConnectInterruptIoctl
The Device Parameters folder should look like the one in the picture.
The Registry change is now complete. Close the Registry Editor.
Changes in Windows® Control Panel

• Select the Start button.
• Choose Settings, then Control Panel and double-click on System.
• Select Hardware.
• Click on Device Manager and open Ports (Com & LPT).
TruckCom
Installation
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
TruckCom
Installation
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
• Double-click on the LPT port to be changed, and select the Port Set-
tings tab.
• Check the "Use any Interrupt assigned to the port" option and click
on OK.
The software application is supplied on a CD or via a network. Start

installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found. Then follow the on-screen
instructions.
TruckCom
Installation
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
13.12.3 Installation on a PC with Windows NT

The software application is supplied on a CD or via a network. Start
installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found. Then follow the on-screen
instructions.
13.12.4 In case of communication problems

with CAN
Make sure the computer settings for the printer port in the BIOS Setup
are as follows:
Port address: 0378
IRQ: 7
Mode: Output only
For detailed information on how to change the Setup settings, refer to
the User's Guide supplied with the computer.
13.12.5 To uninstall
To uninstall TruckCom under Windows®:
• Select the Start button, Settings, Control Panel, Add/Remove Pro-
grams.
• Then select the TruckCom Program and click Change/Remove.
TruckCom
Installation
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
Destruction instructions
General
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
14- Destruction instructions
14.1 General
These instructions have been drawn up as a part of TOYOTA's environ-
ment management program. An important motive is, by taking nature
into consideration, to economise with resources. In other words, you
should try to recycle material as far as possible, thus minimising the dis-
charge of environmentally hazardous substances.
These disassembly instructions are based on an F code (truck family)
and are further divided into C codes (parts and functions on the truck).
These C-codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive gear
• 3000 Brake/belt/wheel systems
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function - lift mast
• 8000 Auxiliary/installation equipment
• 9000 Accessories/optional equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means that some of the
instructions refer to the marking to determine the collection container to
use.
14.2 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally hazardous substances and metals that it
includes.
Abbreviations
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.3 Abbreviations
The following abbreviations for Service Manuals and plastic materials
are used in the dismantling instructions. Abbreviations used are:
ABS = Acrylonitrile-butadiene-styrene
PA = Polyamide
PMMA = Plexiglass
PP = Polypropylene
SM = Service Manual
14.4 Sorting
The sorting method for component parts is based on how the parts can
be recycled and whether they must be taken care of in a special way.
• Plastics must first and foremost be sorted into recyclable and non-
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastics. Instructions
either denote in which container the plastic should be placed or
there is a reference to the material marking on the plastic compo-
nent. In those cases where the collection container for the plastic
part is indicated, the plastic type abbreviation code is also indicated.
Sorting is not necessary for non-recyclable plastics. These are
placed in a container intended for combustible material.
• Place small plastic and rubber parts in a container intended for com-
bustible material.
• Iron and steel scrap is sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
e.g. plastics, should be sorted separately.
• Oil is collected in the intended container.
• Oil filters are collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses, should be sort-
ed separately.
• Batteries should be returned to the manufacturer, either directly to
the manufacturer or through TOYOTA.
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts such as screws, bolts, nuts, washers, etc. are not in-
cluded in the dismantling instructions. These should be placed in a
container intended for iron and steel scrap.
Chassis (0300)
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14.5 Chassis (0300)
14.5.1 Dismantling
• Disassemble the chassis from the truck (1).
14.5.2 Material handling

All parts should be treated as iron and steel scrap.
Hoods, covers (0340)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.6 Hoods, covers (0340)

1
14.6.1 Dismantling
• Remove the panel (1, 2).
• Remove the hood (3).
• Remove the plastic handle (4).

The hood should be treated as iron and steel scrap.
Place the plastic handle and the panel in a container intended for ABS.
Fork structure (low-lifter) (0380)
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14.7 Fork structure (low-lifter) (0380)

1
For wheels see 3500
14.7.1 Dismantling
• Remove the fork structure (1).

Place the fork structure in a container intended for iron and steel scrap.
Travel platform including mount (0560)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.8 Travel platform including mount

(0560)
1
4
3 2
14.8.1 Dismantling
• Remove the platform (1).
• Remove the mat (2).
• Remove the gas damper and destroy it by cutting it into two (3).
• Remove the switch (4).

Place the platform and the gas damper in a container intended for iron
and steel scrap.
Place the mat in a container intended for combustible material.
Place the switch in a container intended for electronic scrap.
Overhead guard (option) (0810)
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14.9 Overhead guard (option) (0810)

1
14.9.1 Dismantling
• Remove the overhead guard (1).

Place the overhead guard in a container intended for iron and steel
scrap.
Operator protective device (0840)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.10 Operator protective device (0840)
14.10.1 Dismantling
• Remove the operator protective device (1).
• Remove the plastic handles (2).

Place the operator protective device in a container intended for iron and
steel scrap.
Place the plastic handles in a container intended for cables.
Electric pump motor (1710)
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
14.11 Electric pump motor (1710)
14.11.1 Dismantling
• Remove the hydraulic unit.
• Remove the hydraulic lines.
• Remove the pump motor including the pump (1).

All oil should be handled as hazardous waste.
Place the hydraulic oil lines in a container intended for oil-contaminated
material.
Place the motor together with the pump in a container intended for haz-
ardous waste.
Electric travel drive motor (1760)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.12 Electric travel drive motor (1760)
14.12.1 Dismantling
• Remove the cables.
• Remove the travel drive motor including the electric parking brake
from the gear (1).

Cables are placed in a container intended for cables. Place the motor
and the electric parking brake in a container intended for hazardous
waste.
Drive unit/gear (2550)
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14.13 Drive unit/gear (2550)
14.13.1 Dismantling
• Drain the oil from the gearbox.
• Remove the gearbox from the drive motor (se SM).
• Remove the drive wheel.

The oil should be handled as hazardous waste.
The gearbox is placed in a container intended for iron and steel scrap.
Wheels (3500)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.14 Wheels (3500)
Chassis 850
2
1
14.14.1 Dismantling
• Remove the drive wheel (1), swivel wheel (2) and fork wheels (3).

Place the vulcanised wheels in a container intended for vulcanised
wheels.
Steering arm (4110)
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14.15 Steering arm (4110)

2
1
3
14.15.1 Dismantling
• Remove the display (1).
• Remove the logic card (2).
• Remove the potentiometer (3).
• Remove the keypad (4).
• Remove the cable.

Place the display, logic card, potentiometer and keypad in a container
intended for electronic scrap.
Place the cable in a container intended for cables.
Steering arm (4110)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.16 Steering arm (4110)

1
14.16.1 Dismantling
• Remove the gas damper and destroy it by cutting it into two (1).
• Remove the switch (2).

Place metal parts and the gas damper in a container intended for metal
scrap.
Place the switch in a container intended for electronic scrap.
General electric equipment (5100)
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14.17 General electric equipment (5100)
14.17.1 Dismantling
• Remove the battery.

Cables are placed in a container intended for cables.
The battery (classified as hazardous waste within the EU) should be
returned to the battery manufacturer or the manufacturer's representa-
tive (see the rating plate on the battery). The battery can also be hand-
ed in to a TOYOTA representative, who bears responsibility for return-
ing the battery to the manufacturer).
Cabling (5590)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.18 Cabling (5590)
14.18.1 Dismantling

Cables are placed in a container intended for cables.
Steering and protective electronics (5700)
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
14.19 Steering and protective

electronics (5700)
14.19.1 Dismantling
• Remove the electronic units (1).

Place the electronic units in a container intended for electronic scrap.
Lift/lowering sensor (5820) and safety sensor (5830)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.20 Lift/lowering sensor (5820) and

safety sensor (5830)
14.20.1 Dismantling
• Remove the height sensor (1).
• Remove the load sensor and the height reference sensor (2).

Place the sensors in a container intended for electronic scrap.
Hydraulic unit (6100)
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14.21 Hydraulic unit (6100)

1
14.21.1 Dismantling
• Drain the oil from the hydraulic system.
• Remove the hydraulic oil lines (see 6230).
• Remove the oil reservoir (2).
• Drain the oil from the reservoir.
• Remove the hydraulic unit (1) (motor + pump) (see 1710).

All oil should be handled as hazardous waste.
Place the hydraulic oil lines in a container intended for oil-contaminated
material.
Place the tank in a container intended for PP.
Place the motor together with the pump in a container intended for haz-
ardous waste.
Main mast (7100)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.22 Main mast (7100)
A
A-A
14.22.1 Dismantling
• See the SM for the disassembly procedure of the main mast.
• Remove the plastic components from the main mast.

The mast should be treated as iron and steel scrap.
Place the plastic components in a container intended for combustible
material.
Chassis-mounted hydraulic oil lines (6230) (and main lift cylinder (6610))
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
14.23 Chassis-mounted hydraulic oil

lines (6230) (and main lift cylinder
(6610))
14.23.1 Dismantling
• Remove the cylinder.
• Drain the cylinders of all oil.
• Destroy the cylinder by cutting it into two (1).
• Remove the hydraulic oil lines (see 2).
• Remove the hydraulic hoses (3).

The oil should be handled as hazardous waste.
Place the cylinder and hydraulic oil lines in a container intended for iron
and steel scrap.
Place the hydraulic hoses in a container intended for oil-contaminated
material.
Battery charger connector (9380)
789, 790, 791, 817, 818 924454- 2007-03-23 230087-040
14.24 Battery charger connector (9380)

2
1
14.24.1 Dismantling
• The battery charger connector (1) is included with the battery.
• Remove the battery charger connector (2).

Place the battery charger connector (2) in a container intended for elec-
tronic scrap.
Battery charger connector (9380)
230087-040 2007-03-23 924454- 789, 790, 791, 817, 818
©TOYOTA Industrial Equipment
Europe SARL Ancenis, France

Service Manual Spe160l 7SLL12.5 - 20F Sn.924454aa

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Service Manual

7SLL12.5, 7SLL16, 7SLL20, 7SLL13.5S,

Order number: 230087-040

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

3- Maintenance ........................................................................................ 3-1

4- Tools ..................................................................................................... 4-1

5- Chassis – 0000 ..................................................................................... 5-1

6- Electric drive motor – 1760 ................................................................. 6-1

7- Drive unit/gear – 2550 ......................................................................... 7-1

8- Electromagnetic brake – 3370 ............................................................ 8-1

9- Electrical steering system – 4300 ...................................................... 9-1

10- Electrical systems – 5000 ............................................................... 10-1

10.5 Parameters ................................................................................ 10-38

11- Hydraulic system – 6000 ................................................................. 11-1

12- Lift mast – 7000 ............................................................................... 12-1

13- TruckCom ........................................................................................ 13-1

14- Destruction instructions ................................................................. 14-1

14.21 Hydraulic unit (6100) .................................................................. 14-19

This page is intentionally left blank

Table 1: Technical data

Table 1: Technical data

Table 1: Technical data

Table 1: Technical data

Table 1: Technical data

Table 1: Technical data

2.1 General tightening torques

2.1.1 Galvanised, non-oiled bolts

2.1.2 Untreated, oiled bolts

This page is intentionally left blank

3.1 Safety rules during maintenance

• Prior to commencing any work on the hydraulic system of the truck,

3.2 Cleaning and washing

3.2.1 External cleaning

3.2.2 Cleaning the motor compartment

3.2.3 Electric components

3.3 Safe lifting

3.4 Lifting the truck

3.5 Maintenance schedule

Table 2: Maintenance schedule

Table 2: Maintenance schedule

Table 2: Maintenance schedule

Table 2: Maintenance schedule

Table 2: Maintenance schedule

3.6 Lubrication chart

Table 3: Lubrication chart

3.7 Oil and grease specification

Table 4: Oil and grease specification

Ambient temperature Viscosity Recommended products (Similar products from

4.1 Super Seal connectors

Figure Number Application

159229 Tools for loosening locks (1)

159230 Tool for fitting secondary locks

159231 Tool for fitting secondary locks

159228 Tools for removing pins/sleeves (3)

4.2 AMP connectors

Figure Number Application