7SM12F 16D

Service Manual
en
7SM12F, 7SM16D
Valid from serial number: 922602-
Order number: 229102-040

Issued: 2006-03-13 ITS
©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Document revisions:
Issue date Order Changes

number
2005-04-05 226307 Completely new issue.
2005-11-18 229102 P2, P3, P4, 5000, TruckCom (8700, Flap “SEU” (Extra I/O mod-
ule))
2006-03-13 229102 P2, P3, 0350, 0450, 5000, 7000, 8340
This manual covers following truck models:
T-code Model Serial number

702 7SM12F 922602-
702 7SM16D 922602-
© TIEE SARL Service Manual 7SM12F, 7SM16D Approved by: L-G Andersson
Table of contents
Order number Date Valid from serial number T-code
229102-040 2006-03-13 922602- 702
1- Table of contents
1- Table of contents ................................................................................. 1-1
2- General product information – M2 ..................................................... 2-1

2.1 Intended application of the truck .................................................... 2-1
2.2 Prohibited application of the truck .................................................. 2-2
2.3 Truck data – 7SM16D .................................................................... 2-2
2.4 Truck data – 7SM12F..................................................................... 2-3
2.5 Truck dimensions – 7SM16D ......................................................... 2-4
2.6 Truck dimensions – 7SM12F ......................................................... 2-6
2.7 Identification plate .......................................................................... 2-8
2.8 Capacity plate ................................................................................ 2-9
2.9 Capacity plate for double pallet handling – 7SM16D...................... 2-9
2.10 Modification plate ......................................................................... 2-10
2.11 Main components......................................................................... 2-11
2.12 Warning and information plates and symbols – 7SM16D............. 2-14
2.13 Warning and information plates and symbols – 7SM12F ............. 2-16
3- Technical data – M4 ............................................................................ 3-1
4- Introduction Maintenance – P1 .......................................................... 4-1

4.1 Safety regulations with maintenance work ..................................... 4-1
4.2 Cleaning and washing.................................................................... 4-3
4.2.1 External cleaning ............................................................. 4-3
4.2.2 Cleaning the motor compartment .................................... 4-3
4.2.3 Electrical components ..................................................... 4-3
4.3 Safe lifting ...................................................................................... 4-4
5- Preventive maintenance – P2 ............................................................. 5-1

5.1 Maintenance schedule ................................................................... 5-1
5.2 Lubrication schedule ...................................................................... 5-6
6- Oil and grease specification – P3 ...................................................... 6-1
7- Tools – P4 ............................................................................................ 7-1

7.1 Super Seal connectors................................................................... 7-1
7.2 AMP connectors............................................................................. 7-2
7.2.1 AMP Connectors, 040 series ........................................... 7-3
7.3 Molex connectors........................................................................... 7-3
7.4 Grease guns .................................................................................. 7-4
7.5 Other tools ..................................................................................... 7-5
8- Support arms – 0350 ........................................................................... 8-1

8.1 Greasable support arms................................................................. 8-1
9- Engine suspension– 0450 .................................................................. 9-1

9.1 Component parts ........................................................................... 9-1
9.1.1 Component List ............................................................... 9-2
9.1.2 Adjusting play, turning tube mounting ............................. 9-3
© TIEE SARL Service Manual 7SM12F, 7SM16D 1- 1

Table of contents
T-code Valid from serial number Date Order number
702 922602- 2006-03-13 229102-040
10- Electric drive motor – 1760 ............................................................. 10-1

10.1 Component parts ......................................................................... 10-1
10.1.1 Dismantling of motor from truck ..................................... 10-2
10.1.2 Assembling .................................................................... 10-2
10.2 Service/Repairs ........................................................................... 10-3
10.2.1 Dismantling of motor ...................................................... 10-3
10.2.2 Assembling of motor ...................................................... 10-4
10.2.3 Cleaning ........................................................................ 10-4
11- Drive unit/gear – 2550 ..................................................................... 11-1

11.1 Component parts ......................................................................... 11-2
11.2 Leakage from top cover ............................................................... 11-3
11.3 Changing of the drive shaft’s sealing ring .................................... 11-4
11.3.1 Dismantling .................................................................... 11-4
11.3.2 Assembling .................................................................... 11-4
12- Electro magnetic brake – 3370 ....................................................... 12-1

12.1 Main components......................................................................... 12-1
12.1.1 Serial number 570989- .................................................. 12-1
12.2 Maintenance ................................................................................ 12-2
12.2.1 Exchange of brake disc ................................................. 12-2
13- Steering – 4000 ................................................................................ 13-1

13.1 Component parts, tiller arm.......................................................... 13-1
13.2 Adjustments ................................................................................. 13-2
13.2.1 Adjusting of brake microswitch ...................................... 13-2
13.3 Tiller arm handle .......................................................................... 13-3
13.3.1 Dismantling/Assembling ................................................ 13-5
14- Electrical systems – 5000 ............................................................... 14-1

14.1 General ........................................................................................ 14-1
14.1.1 Part numbers ................................................................. 14-1
14.2 Component identification ............................................................. 14-2
14.2.1 Component list ............................................................... 14-4
14.3 Electrical wiring diagram .............................................................. 14-6
14.3.1 Symbol list ..................................................................... 14-6
14.3.2 Overview ........................................................................ 14-7
14.3.3 Electrical wiring diagrams .............................................. 14-8
14.4 Functional description ................................................................ 14-14
14.4.1 Starting the truck ......................................................... 14-14
14.4.2 Driving ......................................................................... 14-14
14.4.3 Neutral speed reduction .............................................. 14-14
14.4.4 Neutral speed reduction on slopes .............................. 14-14
14.4.5 Braking ........................................................................ 14-14
14.4.6 Lifting the forks ............................................................ 14-15
14.4.7 Lifting the support arms ............................................... 14-15
14.4.8 Lowering the forks ....................................................... 14-15
14.4.9 Lowering the support arms .......................................... 14-15
14.4.10 Horn ............................................................................. 14-15
14.4.11 Hour meter ................................................................... 14-15
14.4.12 Transistor regulator ..................................................... 14-16
14.4.13 Spider expansion unit (SEU) (option) .......................... 14-16
14.4.14 TLS - Truck log system (optional) ................................ 14-19
14.4.15 ID unit (optional) .......................................................... 14-21
1- 2 Service Manual 7SM12F, 7SM16D © TIEE SARL

Table of contents
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14.5 Parameters ................................................................................ 14-24

14.5.1 General ........................................................................ 14-24
14.5.2 Viewing parameters - without the CAN service key ..... 14-24
14.5.3 Adjusting operator parameters - without the
CAN service key 14-25
14.5.4 Viewing & changing parameters - CAN service key
connected 14-26
14.5.5 Operator parameters ................................................... 14-28
14.5.6 Parameter description ................................................. 14-28
14.5.7 Service parameters ..................................................... 14-30
14.5.8 Parameter description ................................................. 14-31
14.5.9 Configurable “Option” Parameters ............................... 14-41
14.6 Diagnostic and troubleshooting.................................................. 14-54
14.6.1 General ........................................................................ 14-54
14.6.2 Error code history ........................................................ 14-55
14.6.3 Error codes .................................................................. 14-55
14.6.4 Transistor regulator errors ........................................... 14-68
14.6.5 Built-in Test Function ................................................... 14-70
14.7 Technical specifications – Curtis 1243 ....................................... 14-74
15- Hydraulic system – 6000 ................................................................. 15-1

15.1 General ........................................................................................ 15-1
15.2 Hydraulic diagram and components............................................. 15-1
15.2.1 Main components .......................................................... 15-2
15.2.2 Description ..................................................................... 15-2
16- Lifting mast – 7000 .......................................................................... 16-1

16.1 Adjusting the measurement between the guide and the mast...... 16-1
16.2 Grease the beam flanges and beam ribs ..................................... 16-2
16.3 Main lift chain system – ................................................................ 16-3
16.3.1 General .......................................................................... 16-3
16.3.2 Checking the chain setting ............................................ 16-3
16.3.3 Chain inspection ............................................................ 16-3
16.3.4 Noise ............................................................................. 16-3
16.3.5 Surface rust ................................................................... 16-3
16.3.6 Rusty links ..................................................................... 16-3
16.3.7 Stiff links ........................................................................ 16-4
16.3.8 Bolt rotation ................................................................... 16-4
16.3.9 Loose bolts .................................................................... 16-4
16.3.10 Outline wear .................................................................. 16-5
16.3.11 Stretching ...................................................................... 16-6
16.3.12 Damage ......................................................................... 16-6
16.3.13 Damaged discs .............................................................. 16-7
16.3.14 Damaged bolts .............................................................. 16-7
16.3.15 Dirty chain ...................................................................... 16-7
16.3.16 Cleaning ........................................................................ 16-7
16.3.17 Lubrication ..................................................................... 16-7

Table of contents
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17- Battery charger (built-in) – 8340 ..................................................... 17-1

17.1 General ........................................................................................ 17-1
17.2 Technical data – charger.............................................................. 17-2
17.3 Charging ...................................................................................... 17-2
17.4 Troubleshooting and service........................................................ 17-3
17.5 Setting the charger
(applies to machine numbers 723984-936512) 17-4
17.5.1 Current levels at different charger settings (applies to ma-
chine numbers 936513-) 17-5
18- TruckCom ........................................................................................ 18-1

18.1 General ........................................................................................ 18-1
18.2 Connection................................................................................... 18-1
18.3 Layout .......................................................................................... 18-2
18.3.1 Main program screen ..................................................... 18-2
18.3.2 Nodes ............................................................................ 18-2
18.3.3 Icons .............................................................................. 18-3
18.3.4 Tool buttons and menu bar ............................................ 18-3
18.3.5 Information window ........................................................ 18-4
18.3.6 Status bar ...................................................................... 18-4
18.4 Connection function .................................................................... 18-4
18.5 Disconnection function................................................................. 18-4
18.6 Downloading program function .................................................... 18-5
18.6.1 Normal downloading (truck with key) ............................. 18-5
18.6.2 Normal downloading (truck with keypad) ....................... 18-5
18.6.3 Emergency downloading (truck with keypad) ................ 18-6
18.6.4 Emergency downloading (truck with keypad) ................ 18-6
18.6.5 Downloading in old versions of logic card ..................... 18-6
18.7 Truck report function .................................................................... 18-7
18.8 Parameters function..................................................................... 18-8
18.9 Diagnostics function..................................................................... 18-8
18.9.1 Representation of signal colours ................................... 18-9
18.9.2 “Tiller arm” tab ............................................................... 18-9
18.9.3 “Drive Controller” tab (transistor regulator driving) ..... 18-10
18.9.4 “Pump controller” tab (transistor regulator pump) ....... 18-11
18.9.5 “EPS” (steering servo tab) ........................................... 18-12
18.9.6 SEU tab (Extra I/O module) ......................................... 18-13
18.10 Other menu functions................................................................. 18-13
18.10.1 Save to file ................................................................... 18-13
18.10.2 Download from file ....................................................... 18-13
18.10.3 Reset CAN adapter ..................................................... 18-14
18.10.4 Delete error code log ................................................... 18-14
18.10.5 Reset hour meter ......................................................... 18-14
18.10.6 Read error code log ..................................................... 18-14
18.10.7 Adjust date and time .................................................... 18-14
18.10.8 Adjusting the hour meter on older cards ...................... 18-14
18.10.9 Help ............................................................................. 18-14
18.10.10 Exit ............................................................................. 18-14
18.11 Specifications............................................................................. 18-15

Table of contents
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18.12 Installation.................................................................................. 18-15

18.12.1 Installation on a PC with Windows 95/98 .................... 18-15
18.12.2 Installation on a PC with Windows XP/2000 ................ 18-16
18.12.3 Installation on a PC with Windows NT ......................... 18-21
18.12.4 In case of communication problems with CAN ............ 18-21
18.12.5 To uninstall .................................................................. 18-21

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This page is intentionally left blank

General product information – M2
Intended application of the truck
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2- General product information – M2

The truck is a battery-powered support arm truck. In its standard design
the truck is equipped with a tiller arm for control while walking.
The tiller arm is specially designed to provide the best possible opera-
tor ergonomy, having all the controls and buttons within easy reach
without the operator needing to release the handle. The tiller arm is also
equipped with a display showing running time and battery status
among other things. The display is also used when the operator wishes
to change any of the operator parameters with which the truck can be
programmed.
7SM16D has a maximum lifting capacity of 1600 kg on the support
arms.
7SM16D has a maximum lifting capacity of 1200 kg on the forks.
7SM12F has a maximum lifting capacity of 1200 kg on the forks.
7SM12F has liftable support arms that facilitate the truck’s driving char-
acteristics on uneven surfaces and over thresholds. When the forks are
fully lowered on the support arms you can use the support arm lift to
raise a load of max. 1600 kg.
The truck has a 24 V electrical system and the speed is regulated by
means of a transistor controller to provide gentle control of acceleration
and speed while driving.
The forks are raised by means of a powerful hydraulic unit. The lift is
electrically controlled using the buttons on the tiller arm. Control of the
lowering speed and positioning of the forks when stacking is performed
using the truck's mechanical hydraulic valves.
The truck can be equipped with different accessories such as ride-on
platform, integrated charger, load support and a button for temporary
speed reduction. The truck can also be fitted with low temperature oil if
it is to be used in cool and humid conditions.
Note that some of the truck models described in the Operator’s Manual
may not be marketed in your country.
2.1 Intended application of the truck

The truck is solely designed and manufactured to handle goods. The
trucks should be fitted with the appropriate accessories relevant to the
application.

Prohibited application of the truck
702 922602- 2005-11-18 229102-040
2.2 Prohibited application of the truck

The truck is designed for handling goods indoors. It is not permitted to
use the truck for other purposes including the following:
- In areas that contain dust or gases which can cause fires or ex-
plosions
- As a tow-truck for trailers
- To tow other trucks
- To transport/lift passengers
- To drive on gravel or grass
2.3 Truck data – 7SM16D

The table provides information regarding some technical data, which is
of value with daily use of the truck.
Truck type 7SM16D

Support arm lift, rated load, kg* 1600
Lift height, mm 1700 1900 2100
Fork lift, rated load, kg 1200 1200 1000
Travel speed without load (<750 kg), km/h 6
Travel speed with rated load (>750 kg <1200 kg), km/h 5
Travel speed with rated load (>1200 kg), km/h 4,4
Gradient with rated load, % 10
Weight without batteries, with platform, kg
240 Ah 675 685 695
320 Ah 685 695 705
Weight with batteries, with platform, kg
240 Ah 875 885 895
320 Ah 885 895 905
Turning radius (Wa), mm (fork length 1150 mm) 1786
Continuous noise level, according to CE pr EN 12053, dB A <70
Continuous noise level, according to ASME B56,11,5_1992, dB A 65
Permitted drive wheel, material Power friction
Siped Power friction
Non-mark Power friction
Tractothan
* Deviations may occur on trucks adapted to specific application; the

correct value can be found on the truck’s identification plate. In such
cases the truck is also fitted with a modification plate.
The truck’s lifting capacity, lift height and weight can be found on the
truck’s identification plate.

Truck data – 7SM12F
229102-040 2005-11-18 922602- 702
2.4 Truck data – 7SM12F

The table provides information regarding some technical data, which is
of value with daily use of the truck.
Truck type 7SM12F

Rated capacity, kg * 1200
Lifting capacity support arm lift with fully lowered 1600
forks, kg
Lift height, mm 2700 - 3700
Travel speed without load (<750 kg), km/h 6
Travel speed with rated load
(>750 kg <1200 kg), km/h 5
Travel speed with rated load (>1200 kg), km/h 4,4
Gradient with rated load, % 10
Weight without battery, kg 735-765
Weight with battery, kg (Ah) 935-965 (240)
Turning radius (Wa), mm (fork length 1150 mm) 1685
Continuous noise level, according to CE prEN
12053, dB A <70
Continuous noise level, according to ASME B56,
11, 5_1992, dB A 65
Permitted drive wheel, material Power friction
Power friction,
sajpat
Power friction,
nonmark
Tractothan
* Deviations may occur on trucks adapted to specific application; the

correct value can be found on the truck’s identification plate. In such
cases the truck is also fitted with a modification plate.
The truck’s lifting capacity, lift height and weight can be found on the
truck’s identification plate.

Truck dimensions – 7SM16D
702 922602- 2005-11-18 229102-040
2.5 Truck dimensions – 7SM16D

The illustration shows external dimensions for the truck in its standard
design.
B
D
E
F
G
I K
H L
N J

Truck dimensions – 7SM16D
229102-040 2005-11-18 922602- 702
Measure, for 240 Ah battery space Value (mm)

A - without platform 1365
A - with platform 1365
B 620
C 1330 - 2510
D 90
E 1000-1150
F - without platform (fork length = 1150 mm) 1963
G - with folded platform(fork length = 1150 mm) 2055
H 770
I - without platform 1786
J - with folded platform 1878
K 194
L 570
M - with lowered platform (fork length = 1150 mm) 2429
N - with lowered platform 2252

Truck dimensions – 7SM12F
702 922602- 2005-11-18 229102-040
2.6 Truck dimensions – 7SM12F

The illustration shows external dimensions for the truck in its standard
design.
B
D
E
F
G
I K
H L
N J

Truck dimensions – 7SM12F
229102-040 2005-11-18 922602- 702
Measure Value (mm)

A - without platform 1365
A - with platform 1365
B 620
C 1820 - 4120
D 90
E 1000-1150
F - without platform (fork length = 1150 mm) 1946
G - with folded platform (fork length = 1150 mm) 2038
H 800
I - without platform 1685
J - with folded platform 1777
K 294
L 570
M - with lowered platform (fork length = 1150 mm) 2412
N - with lowered platform 2151

Identification plate
702 922602- 2005-11-18 229102-040
2.7 Identification plate

The illustration shows the identification plate for the truck in CE-design.
Item Text Unit

A MODEL
B SERIAL NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V
The illustration shows the identification plate for the truck in ASME-
design.
A
Item Text Unit
B A MODEL
C B NO
D C RATED CAPACITY kg
E D WEIGHT WITHOUT BATTERY kg
E E BATTERY WEIGHT MAX kg
MIN kg
F
F BATTERY VOLTAGE V
G BATTERY TYPE ACCORD-
G ING TO ASME-NORM UL583

Capacity plate
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2.8 Capacity plate

The illustration shows the capacity plate used on the truck.
Item Text Unit

H SERIAL NO
I LIFT HEIGHT mm
J ACTUAL CAPACITY kg
K LOAD CENTRE mm
L THE TRUCK MUST ALWAYS BE DRIVEN WITH
LOWERED FORKS EXCEPT WHEN PLACING
OR REMOVING LOAD
L5 ACTUAL CAPACITY ON THE SUPPORT ARMS kg
2.9 Capacity plate for double pallet

handling – 7SM16D
The picture shows the capacity plate that applies with double pallet
handling.
Permitted max. Permitted max. Permitted min.

load on forks load on support load on support
arms arms
M1 - M9 L1 - L9 V1 - V9

Modification plate
702 922602- 2005-11-18 229102-040
2.10 Modification plate

The illustration shows the modification plate which is found on the truck
if it is supplied as non-standard or if it has been modified after leaving
the manufacturer. The plate includes information according to the table
below.
Item Text
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

Main components
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2.11 Main components

1. Tiller arm:
The truck is manoeuvred by the driver while walking. 204 degree
steering area.
The brakes are applied in the tiller arm’s upper and lower positions.
2. Identification plate:
With model designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, battery volt-
age and manufacturer.
3. Covers:
Removable which provides good accessibility when servicing.
4. Emergency switch off
5. Hydraulic control:
For controlling lifting and lowering functions.
6. Hydraulic unit:
Pump motor, pump and oil tank are integrated in a compact unit.
7. Hydraulic valves:
The valves are located to provide easy access.
8. Drive unit with brake:
Suspended drive unit with spring-loaded mechanical brake, travel
motor, gears and drive wheel combined into a compact unit. Steer-
ing bearings between motor and gears.
9. Serial number:
The serial number plate fitted to the chassis.
10. Electric panel:
Removable, which provides good access when servicing. 24 volt
electrical supply. The speed is variably controlled by means of a
transistor.
11. Support castor wheels:
Two support castor wheels to ensure stability
12. Battery:
24V with different Ah values. The battery is automatically locked in
the battery compartment.
13. Emergency disconnector and battery connector:
The battery is charged via the permanently fitted charging connec-
tor.
14. Mast:
Fitted with a finger guard to cover the driver's normal reach.

Main components
702 922602- 2005-11-18 229102-040
7SM16D
14
5
12
13
7
11 8
10 9

Main components
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7SM12F
14
5
12
13
7
11 8
10 9

Warning and information plates and symbols – 7SM16D
702 922602- 2005-11-18 229102-040
2.12 Warning and information plates

and symbols – 7SM16D
The figure shows the position and significance of the plates and sym-
bols located on the truck.
1. Hydraulic lever: Lifting/lowering of the forks

2. Hydraulic lever: Lifting/lowering of the support arms
3. Travel direction
4. Signal/Horn
5. Capacity plate
6. Identification plate, A: CE, B: ASME, depending on market
7. Hydraulic control: Lower
8. Serial number
9. Hydraulic oil filling
10. A) Do not walk under an elevated load
B) Do not stand on the forks
11. Lifting points
12. Modification plate
13. Capacity plate for double pallet handling

Warning and information plates and symbols – 7SM16D
229102-040 2005-11-18 922602- 702
6A 6B
1 2
1 2
10A
10B
13 11
12
M-PLATE A
TYPE B
S/NO C D
CODE NO DATE
E F G
11
7 9
8

Warning and information plates and symbols – 7SM12F
702 922602- 2005-11-18 229102-040
2.13 Warning and information plates

and symbols – 7SM12F
The figure shows the position and significance of the plates and sym-
bols located on the truck.
1. Hydraulic lever: Lifting/lowering of the forks

2. Hydraulic lever: Lifting/lowering of the support arms
3. Travel direction
4. Signal/Horn
5. Capacity plate
6. Identification plate, A: CE, B: ASME, depending on market
7. Hydraulic control: Lower
8. Serial number
9. Hydraulic oil filling
10. A) Do not walk under an elevated load
B) Do not stand on the forks
11. Lifting points
12. Modification plate
13. Maximum height for rated capacity

229102-040 2005-11-18 922602- 702
6A 6B
1 2
1 2
10A
11
10B
13
12
M-PLATE A
TYPE B
S/NO C D
CODE NO DATE
E F G
7 9
8

702 922602- 2005-11-18 229102-040

Technical data – M4
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3- Technical data – M4
Model 7SM12F 7SM16D

Drive motor
Type TSL140S-DS30 TSL140S-DS30
Output, kW 1.2 1.2
Duty cycle S2, 60 min S2, 60 min
Minimum carbon brush length, mm 13 13
Nominal commutator diameter, mm 50 50
Minimum commutator diameter, mm 47 47
Resistance, shunt field winding, Ω at 25 C° 0.49 0.49
Resistance armature winding, Ω at 24 °C 0.0156 0.0156
Insulation resistance between the windings and >=1 Mohm >=1 Mohm
motor casing
Weight, kg 14 14
Broms
Type BFK457-08 BFK457-08
Braking force, Nm 12 12
Output, W 25 25
Resistance coil, Ω 23 23
Nominal play in actuated position, mm 0.2-0.4 0.2-0.4
Minimum thickness brake disc, mm 5.5 5.5
Thickness of a new brake disc, mm 7.0 7.0
Transmission/drive gear
Type 2-stage angle trans- 2-stage angle trans-
mission mission
Gear ratio 19,14:1 19,14:1
Oil volume, litre 1.0 1.0
Oil type Hypoid oil Hypoid oil
at normal temperature SAE 80W/90 SAE 80W/90
at temperature < -15oC SAE 75W SAE 75W

702 922602- 2006-03-13 229102-040
Model 7SM12F 7SM16D

Wheels
Drive wheel, mm Dia 215x70 Dia 215x70
Axle pressure without load, kg 345 345
Axle pressure at rated load, kg 345 345
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm
Support arm wheel, mm Dia 80x75 Dia 80x75
Axle pressure without load, kg (Ah) 2 x 270 (240) 2 x 220 (240)
Axle pressure at rated load, kg (Ah) 2 x 1310/1640 (240) 2 x 1195/1515 (240)
Support castor wheels, mm Dia 125 x 50 Dia 125 x 50
Axle pressure without load (Ah) 2 x 355 (240) 2 x 328 (240)
Axle pressure at rated load, kg 2 x 520/590 (240) 2 x 553/633 (240)
Hydraulic system
Output, kW 2.2 2.2
Duty cycle,% 5 5
Minimum carbon brush length, mm 12 12
Minimum commutator thickness/diameter, mm 4.75 4.75
Pressure at rated load, bar 191 191
Overflow pressure, bar 220 220
Pump flow, litre/minute 5.0 5.0
Tank volume, litre 4.5 4.5
Oil type: Hydraulic oil Hydraulic oil
at normal temperature ISO-L-HM32 ISO-L-HM32
at temperature < -15oC ISO-L-HV32 ISO-L-HV32
Fuses
Drive motor circuits, A 125 125
Pump motor circuits, A 125 125
Control circuits, A 7,5 7,5

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Model 7SM12F 7SM16D

Battery compartment, Batteries
Dimensions LxWxH, mm 180 Ah 196 x 643 x 452 196 x 643 x 452
240 Ah 196 x 643 x 572 196 x 643 x 572
320 Ah 244 x 643 x 572 244 x 643 x 572
Capacity, Ah 180 -320 180 -320
Weigh, kg 150 -250 150 -250
Driving speed
Without load, 0 - 750 kg, km/h 6,0 6,0
With rated load, 750 - 1200 kg, km/h 5.3 5.3
With rated load, 1200 - 1600 kg, km/h 4.4 4.4
support arms
Lift/lowering speed
Lift without load, m/s 0.19 0.19
Lift with rated load, m/s 0.10 0.11
Lowering without load, m/s 0.15 0.15
Lowering with rated load, m/s 0.19 0.19
Power consumption
Driving without load, A 23 23
Driving with rated load, A 36 36
Lift without load, A 54 54
Lift with rated load, A 148 148
Incline climbing ability
With rated load 10 % 10 %
Measurement, L2
Medium 796 813
Long 848 865
Turning radius WA 1685 1786
Weight
Truck without battery, Medium 735 655

702 922602- 2006-03-13 229102-040

Introduction Maintenance – P1
Safety regulations with maintenance work
229102-040 2006-03-13 922602- 702
4- Introduction Maintenance – P1
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with TOYOTAS’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
Day time: 08.00-17.00 (20 hr./week)
2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work
are carried out.
4.1 Safety regulations with

maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system

Safety regulations with maintenance work
702 922602- 2006-03-13 229102-040
• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local directives
• Do not release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal
• Disconnect the battery when welding on the truck
NOTE!
The battery can be damaged.
When welding using an electric power source the welding current can
enter the battery.
The battery should therefore be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

Cleaning and washing
229102-040 2006-03-13 922602- 702
4.2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the battery con-
nector.
4.2.1 External cleaning

• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion
• Rinse off loose grime using tepid water
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the chapter
Maintenance and lubrication chart.
4.2.2 Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing
NOTE!
The electrical system can be damaged.
Electrical components must not be cleaned with a high pressure
washing unit.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water
4.2.3 Electrical components

• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors, connec-
tions, solenoid valves, etc. using a damp cloth and a cleaning agent
NOTE!
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

Safe lifting
702 922602- 2006-03-13 229102-040
4.3 Safe lifting

All lifting must be carried out on a flat, non-slip and firm surface. Avoid
new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving during
the lift. If the lift applies to the brake wheel, chock the other wheels
so that the truck stands still
• Select a lifting point so that the lift is as easy as possible (one corner
at a time). If the truck has marked lifting points on the under side of
the chassis these can be used to obtain a well balanced lift
• Ensure that the surface under the jack is clean and free from oil and
grease
• Ensure that your hands and the jack’s lever are free from oil and
grease
• Use the lever that belongs to the jack. A lever that is too short re-
quires more force than is necessary. If the lever is too long there is a
risk of the jack being overloaded
• Support the truck:
- as close as possible to the part of the chassis that is to be lifted.
This reduces the risk of the truck tipping over
- so that the truck cannot roll
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

Preventive maintenance – P2
Maintenance schedule
229102-040 2006-03-13 922602- 702
5- Preventive maintenance – P2
5.1 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 application 5 20 500 1000 3000
Interval in days/weeks/months - may vary due 1d 1w 6m 12m 36m
to application
0000. Chassis
0000.1 Check all links and locking pins I
0000.2 Check wear on cover/battery locking I
0000.3 Check of cracking and damage I
0000.4 Check the drive housing’s mounting on the chassis T
0000.5 Check finger guard I
0000.6 Check signs and stickers I
0350 Support arm
0350.1 Force grease into the lubricant nipples I/L6
0380. Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
1700. Drive motor
1700.1 Check clearance in connections I/T1 I/T
1700.2 Check the carbon brushes in the drive motor M
1700.3 Clean the drive motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing I
2550 Drive gear
2550.1 Check for leakage I3 I
2550.2 Check the oil level. Measured using the screwed in I
dipstick
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steering bear- I
ing
2550.5 Change the oil in the drive gear L4 L

702 922602- 2006-03-13 229102-040

to application
3100. Brake
3100.1 Clean and check functionality C
3100.2 Check the brake disc M
3100.3 Check the clearance in disengaged position M
0,2-0,5 mm
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tightening I/T
torque on bolts
(New wheel: Drive tread thickness = 30mm) (Tighten-
ing torque = 65Nm)
3500.3 Check that the castor wheel turns and rotates freely I
3500.4 Check for wear on the castor wheel I
(New wheel: Drive tread thickness = 10mm)
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I
5000 Electrical functions
5000.1 Check the function of the brake microswitch I I
5000.2 Check the function of the collision safety switch I
5000.3 Check the function of the horn I I
5000.4 Check for wear to cables in the tiller arm I
5000.5 Check the function of the driver’s control I I
5000.6 Check the error code log and operating times I I

229102-040 2006-03-13 922602- 702

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 charger 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 Cleaning and checking of mounting in chassis C/T1 C/T
5400.2 Re-tighten cable connections T1
5400.3 Check the contactor points on K10 and K30 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
5700 Electronic circuit board
5700.1 Check connectors and cables TI
5700.2 Check all segments on display I
6000 Hydraulic system
6000.1 Check hoses and connections for leakage 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
6100.5 Change the oil and clean the filter L5 L

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to application
6600. Lift cylinder
6600.1 Check for leakage I
6600.2 Check the mountings I
7100 Lifting Mast
7100.1 Check for damage and crack formation I
7100.2 Re-tighten tha mast mounting bolts T
(Tightening torque =197N m)
7100.3 Check the play of the inner section rollers I
7100.4 Check the lateral play of the inner section I
7100.5 Check for wear on the lifting chains and chain rollers I
7100.6 Check the adjustment of the lifting chains I
1 = The connections are re-tightened for the first time after 500 h, and
then every 1000 h/12 months.
2 = The attachment bolts are re-tightened after 500 h/6 month to
45 Nm.
3 = Check for leakage in conjunction with the first oil change.
4 = The oil is changed for the first time after 500 h/6 month, and then
every 3000 h/36 months.
5 = The oil is changed and the filter cleaned for the first time after 500 h/
6 month, and then every 1000 h/12 months.
6 = If the truck goes into a refrigerated environment or other harsh envi-
ronment, the point is addressed at more frequent intervals.
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.

229102-040 2006-03-13 922602- 702
6600
4110
7100
0380
5000
5700
0000
5110 3100
6000
5400
2550
3500 1700

Lubrication schedule
702 922602- 2006-03-13 229102-040
5.2 Lubrication schedule
Pos no Service point Interval/Running hours Lubricant

500h 1000h 3000h
1 Wheel bearings L A
2 Mast beam L F
2 Inside surfaces of S I
beam ribs
2 Inside surfaces of S A
beam flanges
3 Lifting chains L D
4 Hydraulic system C O B
5 Steering Bearings L G
6 Drive gear C O C
7 Push rods and links S H
L = Lubrication C = Check O = Oil change

229102-040 2006-03-13 922602- 702
6 5

702 922602- 2006-03-13 229102-040

Oil and grease specification – P3
229102-040 2006-03-13 922602- 702
6- Oil and grease specification – P3
Table 1: Oil and grease specification

Lubricant Specification Application area
> - 15°C < - 15°C
A Grease 223690 223690 Bearings and bush-
Q8 Rembrandt EP2 Q8 Rembrandt EP2 ings
Inside surfaces of
beam flanges
B Hydraulic oil ISO-L-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 BT 055-70111 BT 055-74320 Mast
G Grease Staburags Staburags Pilot bearing
NBU 8EP NBU 8EP
H Fett S213366 S213366 Support arms, lubri-
cant nipples of push
rods and links
I Fett Gleitmo 805 Gleitmo 805 Inside surfaces of
beam ribs
Ambient temperature Viscosity Recommended products ( Similar products

class from 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

Oil and grease specification – P3
702 922602- 2006-03-13 229102-040
6 5

Tools – P4
Super Seal connectors
229102-040 2006-03-13 922602- 702
7- Tools – P4
7.1 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 – P4
AMP connectors
702 922602- 2006-03-13 229102-040
7.2 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 – P4
Molex connectors
229102-040 2006-03-13 922602- 702
7.2.1 AMP Connectors, 040 series

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

16
9
8
1
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins

Tools – P4
Grease guns
702 922602- 2006-03-13 229102-040
7.4 Grease guns

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

pipe and nozzle.
755142 Two-hand grease gun with angled discharge 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 discharge pipe.
Length 125 mm.
755140 Nozzle for neck nipples. Fits grease guns with
hose and discharge pipe.

Tools – P4
Other tools
229102-040 2006-03-13 922602- 702
7.5 Other tools

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

2=163792 gramme changes
08-13022 Driving gear puller

Tools – P4
Other tools
702 922602- 2006-03-13 229102-040

Support arms – 0350
Greasable support arms
229102-040 2006-03-13 922602- 702
8- Support arms – 0350
8.1 Greasable support arms

Greasable support arms are an option on 7SM12F and standard on
7SM16D.
Grease the lubricant nipples marked with arrows using S213366
according to the lubrication chart.
x2

Support arms – 0350
Greasable support arms
702 922602- 2006-03-13 229102-040

Engine suspension– 0450
Component parts
229102-040 2006-03-13 922602- 702
9- Engine suspension– 0450
9.1 Component parts
21
20
4 5
6
19
7 8
18 11
9
14 13 12 10
15
17
16

Component parts
702 922602- 2006-03-13 229102-040
9.1.1 Component List
Pos. Description Notes

1 Screw 2x M6S 8x30
2 Plate
3 Circlip
4 Console
5 Washer 8x
6 Screw 2x M6S 12x45
7 Lock bracket
8 Screw MC6S 8x12
9 Axle
11 Grease nipple 2x
12 Pivot pipe
13 Grease nipple 4x
14 Bushing 4x
15 Engine bracket
17 Axle 2x
18 Washer (0.5 mm) Number
as required
18 Washer (1 mm) Number as
required
19 Bushing 4x
20 Link 2x
21 Grease nipple 2x

Component parts
229102-040 2006-03-13 922602- 702
9.1.2 Adjusting play, turning tube mounting

When replacing the turning tube, or in case play has occurred between
the turning tube mountings, shim the mountings of the turning tube as
much as possible. The play should be 0
Shim the following four locations to achieve a play of 0.

Component parts
702 922602- 2006-03-13 229102-040

Electric drive motor – 1760
Component parts
229102-040 2006-03-13 922602- 702
10- Electric drive motor – 1760
10.1 Component parts

16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
Pos Description Note

1 Screw M6x25
2 Bearing shield
3 Locking ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20
8 Carbon brush
9 Rotor
10 Key
11 Plug
12 Stator
13 Cable

Component parts
702 922602- 2006-03-13 229102-040

14 Cable
15 Bearing shield
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Locking ring
21 Locking ring
10.1.1 Dismantling of motor from truck

• Switch off the truck and pull out the battery plug.
• Remove the covers for the motor compartment.
• Release the cables for the motor and tiller arm.
• Unscrew the four nuts for the attachment of the motor to the drive
gear.
• Loosen the cables for the key switch and emergency switch. Pull out
all the cables from the cover’s cable duct.
• Loosen the cover over the motor compartment and the tiller arm’s
mounting from the motor. Remove the cover over the motor com-
partment together with the tiller arm.
• Carefully lift the motor straight up, without damaging the sealing sur-
faces to the drive gear and place the motor on a clean surface.
• Protect the drive gear from impurities by covering over its opening in
an appropriate manner, e.g. with a piece of plastic.
The requisite service and repair of the motor can now be carried out.
10.1.2 Assembling
• Assembling is carried out in the reverse order.
• Carefully lift down the motor in the drive gear to avoid damaging the
seals and gear wheels.
• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm.
• Fit and adjust the brakes as per the instructions. Screw tight the cov-
er and tiller arm, and connect the cables that were previously re-
moved. Check that the polarity is correct.
• The function of the brakes should be checked before the truck is
moved.

Service/Repairs
229102-040 2006-03-13 922602- 702
10.2 Service/Repairs
10.2.1 Dismantling of motor

16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
• Release the brake disc’s companion flange by first removing the

locking ring together with the washer in the end of the rotor shaft.
The companion flange can now be lifted off. It may be necessary to
unclamp it with an appropriate tool.
• Remove the four plugs that cover the carbon brushes, move the
springs on the carbon brushes to one side and pull out the carbon
brushes.
• Dismantle the commutator end’s bearing shield (2) together with the
carbon brush bridge (5) and carbon brushes (8) by unscrewing the
eight screws (1). Now put down the motor with a firm resting point
against the edge of the bearing shield, and carefully tap on the rotor
shaft’s end with a rubber mallet.
• Dismantle the drive end’s bearing shield (15) together with the rotor
(9). Make sure not to damage the motor windings when the rotor is
removed from the motor housing.
• After dismantling the motor’s bearing shields and removing the rotor
from the motor housing, the gear wheel in the rotor’s drive end is re-
moved. This is done by unscrewing the nuts on the gear wheel and
then pulling the gear wheel off with a puller. Note that the gear wheel
is locked with Loctite to the rotor shaft.

Service/Repairs
702 922602- 2006-03-13 229102-040
• Now release the inner locking ring together with the underlying
washer. Pull out the rotor shaft from the bearing (18).
• Release the outer locking ring together with its washer, and remove
the bearing from the bearing shield.
• Remove the bearing shield’s seal (17) and carefully clean the bear-
ing shield.
• Fit a new seal in the bearing shield.
10.2.2 Assembling of motor

Assemble the motor in the reverse order.
• Carefully check that the rotor can move freely in the direction of rota-
tion and that the carbon brushes are flush with the commutator.
• Check the motor’s insulation resistance (between respective wind-
ing and the motor housing). For a new motor this should lie between
2 - 3 Mohm. When a used motor has been exposed to impurities an
insulation resistance down to approx. 1 Mohm is acceptable.
• Fit a new O-ring in the drive shaft end’s bearing shield and a new
seal on the collar of the bearing shield.
10.2.3 Cleaning
An extremely critical factor to ensure correct functioning of the motor is
that it is kept as clean as possible. The motor and the motor compart-
ment must be regularly checked for dust, oil, and other impurities.
A vacuum cleaner with an appropriate nozzle can be used to clean the
motor if the motor windings and inner compartment are dry Com-
pressed air can be used in combination with a vacuum cleaner. In which
case the compressed air must be clean and dry.
A cloth of non-fluffing material should be used if the windings have a
coating. The cloth can also be moistened with a grease-dissolving,
organic and volatile detergent that does not damage the windings. Use
detergent sparingly to avoid it penetrating into the parts of the motor.
Residual detergent should be removed with an appropriate solvent, if it
leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to use a
solvent that is sprayed onto the parts. It is important that the detergent
is applied in a way to prevent dirt from penetrating into the parts of the
motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is done
then the rotor must always be dried with the application of heat. There
must be adequate ventilation during the drying process, and the drying
should continue until a number of measurements of the insulation
resistance provide equivalent and approved results.

Drive unit/gear – 2550
229102-040 2006-03-13 922602- 702
11- Drive unit/gear – 2550
3
4
5
6
01
7
8
24
9
25 27
10 26
11
28
13
12 14
32
31
30
15 29
19
18
17
16
20
23
21 22

Component parts
702 922602- 2006-03-13 229102-040
11.1 Component parts

01 Drive gear complete
2 Air valve
3 Cover
4 Dip stick
5 Washer
6 Gasket
7 Nut Tightening torque 70 Nm
Locked with punch mark
8 Washer
9 Gear wheel Primary gear
10 Conical roller bear-
ing
11 Shims
12 Screw Top cover and gear housing
Tightening torque 26.6 Nm
Lock with Loctite 242
13 Shims
ing
15 Pinion/ Crown gear Cog clearance 0.09-0.15 mm
Pretension bearing with 2-5/100
Stamped size on pinion adjusted
with shims
17 Shims
ing
19 Shims
20 Screw Bottom cover and gear housing
21 Screw Bottom cover and gear housing
22 Cover
23 Gasket
24 Gear wheel Motor gear

Leakage from top cover
229102-040 2006-03-13 922602- 702

25 Washer
27 Screw Motor and gear housing
28 Nut Tightening torque 26.6 Nm
ing
30 Shims
31 Seal
32 Drive shaft
11.2 Leakage from top cover

Dismantling
• Lift up the truck, and block up to ensure that it is stable.
• Unscrew the drive wheel.
• Unscrew the M8 nuts (28), that hold the gear and motor, with a box
wrench. Support the gear so that it does not drop.
• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex
socket wrench.
• Change the gasket (6).
Assembling is carried out in the reverse order
• Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm
Lock with Loctite 242.
• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

Changing of the drive shaft’s sealing ring
702 922602- 2006-03-13 229102-040
11.3 Changing of the drive shaft’s

sealing ring
The drive shaft’s sealing ring can be changed with the gear mounted in
the truck.
Follow the instructions below if oil is leaking from the drive shaft.
11.3.1 Dismantling
• Unscrew the drive wheel (1).
• Remove the lower cover and drain off the oil (22).
• Release the drive shaft nut. Remove the nut and washer (16,17).
• Carefully tap out the drive shaft with a brass drift and hammer (32).
• Pull off the bearing from the drive shaft with tool 08-13022 (29).
• Check that the bearing washers are not damaged. If they have been
damaged by the puller tool, measure the total thickness of the shim
washers and change them before assembling (30).
• Remove the sealing ring from the drive shaft (31).
11.3.2 Assembling
Assembling of the gear after changing the drive shaft’s sealing ring is
carried out in the reverse order to dismantling.
Pay special attention to the following during assembling:
• Fill the sealing ring with grease after fitting it on the drive shaft.
• Make sure that only undamaged shim washers with the same total
thickness as the originals are put on the drive shaft.
• Press the bearing on the drive shaft and make sure not to damage
the bearing’s shim washers.
• When fitting the drive shaft with bearing, shim washers and seal,
make sure that the shaft keys correspond with the crown gear’s keys
and that the bearing and seal are correctly positioned in the gear
housing before the shaft is pressed in completely.
• Put the distance ring on the drive shaft end, and put on the shaft nut.
Always use a new nut. Tighten the shaft nut to a torque of 300 Nm
and lock it with a punch mark in the middle. The drive shaft nut
should be lubricated before it is put on the shaft.
• Change the gasket before fitting the bottom cover. Make sure that it
is not damaged. Fit the cover and tighten the bolts to a torque of 26.6
Nm. The bolts should be lubricated before they are fitted. Fill up with
oil in accordance with the instructions for replenishing the oil.
Fit the drive gear and tighten the bolts to a torque of 65 Nm.

Electro magnetic brake – 3370
Main components
229102-040 2006-03-13 922602- 702
12- Electro magnetic brake – 3370
12.1 Main components
12.1.1 Serial number 570989-

1 9
2
8
3
4
7
5 6
Pos No Description
1 Magnetic coil
2 Cap screws
3 Electrical wire
4 Pressure plate
5 Pressure springs
6 Flange
7 Mounting bolts
8 Brake disc
9 Hub

Electro magnetic brake – 3370
Maintenance
702 922602- 2006-03-13 229102-040
12.2 Maintenance
Basically the brake is maintenance free in normal work environments.
However it is recommended according to the preventive maintenance
schedule to check the brake disc for wear.
12.2.1 Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been
reduced to 5,5 mm.
• Disconnect the electrical wires of the brake.
• Undo and remove the three fastening bolts.
• Loosen the brake disc from the hub and check for wear and tear. Re-
place the brake disc if the surface is unevenly worn.
• Reassemble the brake.
• Reconnect the electrical wiring.

Steering – 4000
Component parts, tiller arm
229102-040 2006-03-13 922602- 702
13- Steering – 4000
13.1 Component parts, tiller arm

1
8
9
10 11
12
14 13
16
15
18 17
19
20
21
22
23

1 Screw 4
2 Washer
3 Handle
4 Screw 4
5 Washer 2
6 Cable holder

Steering – 4000
Adjustments
702 922602- 2006-03-13 229102-040

7 Nut
8 Gas damper
9 Bracket
10 Stop screw
11 Screw 4
12 Ball joint
13 Screw
14 Distance
15 Bush 2
16 Damper 2
17 Axle
18 Cam
19 Distance
20 Screw
21 Distance
22 Distance
23 Switch S 10
13.2 Adjustments
13.2.1 Adjusting of brake microswitch

Switch (23) is always adjusted to its lowest position.
• Unscrew the screws (13, 20) that hold the switch and the distance.
• Press down the switch and tighten the screws.
• Check that the switch is actuated by the cam (18) in the arm’s top
and bottom position.

Steering – 4000
Tiller arm handle
229102-040 2006-03-13 922602- 702
13.3 Tiller arm handle

28
29
27 26
24 14
25 14
23 22
17
21 18
20 16
19 15
14
30 14
31 13
12
10 11
32 9
8
35 33
34
5 6 7
4
1 2
3

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic circuit board
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
15 Spring
16 Pushbutton Not used
17 Arm
18 Holder

Steering – 4000
Tiller arm handle
702 922602- 2006-03-13 229102-040

19 Spring
20 Control switch
21 Axle
22 Sliding bearing
23 Control stop
24 Arm
25 Spring holder
26 Spring
27 Spring holder
28 Sliding bearing
29 Control switch
30 Button for safe reversing
31 Arm
32 Spring
33 Lower cover
34 Screw M4x40
35 Screw 2xM5x45 - 2xM5x60

Steering – 4000
Tiller arm handle
229102-040 2006-03-13 922602- 702
13.3.1 Dismantling/Assembling
• Dismantle cover (2), (keyboard option).
• Remove the screws (35), hold top cover firm (7).
• Disconnect the cable connected to the electronic circuit board (4).
• Remove the screws (34).
• Carefully lift off the lower cover (33), and place a finger between the
lower cover (33) and button (30) to hold the button (30) in place.
Assembling is carried out in the reverse order.
NOTE!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure to take the necessary precautions before working with the
electronics.
Changing of signal button/switch (9, 10)

• Dismantle the button as per the diagram.
• Disconnect the connection for the switch on the electronic circuit

board (4).
• Press out the switch from its mounting.

Steering – 4000
Tiller arm handle
702 922602- 2006-03-13 229102-040
Changing of lift/lowering button (13)

• Remove the button by placing a screwdriver in the hole (A) as per
the diagram below.
A A
• Unscrew the holder (18) so that the arm (12) comes loose.
Changing of pushbutton (16)

• Press the button by hand sideways.
• Place a screwdriver as per the diagram and carefully pry the button
loose.
• Unscrew the button’s holder and arm.


Electrical systems – 5000
General
229102-040 2006-03-13 922602- 702
14- Electrical systems – 5000

This chapter concerns the software182643-004 and later versions.
14.1 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.
14.1.1 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.

Component identification
702 922602- 2006-03-13 229102-040
14.2 Component identification

S10
S21 S17
X41
F50
F51
K10
F1
A1
Y1
F3
M1
R1
K30 H1
M3
P2
Y34
Y52
P1
Y41
S42

229102-040 2006-03-13 922602- 702
A2:S22 A2:S21 A2:S1-9 A2:S10-18 A2
1
10
18
A2:S17 A2:S20 A2:S19

A6
S113 S116
S112 S115
S111 S114
S18:1 S18:2
A2:S20
A2:S19
L1
A2:S22
A2:S21
A2:S17
A17

702 922602- 2006-03-13 229102-040
14.2.1 Component list
Symbol Description Function Notes

A1 Transistor regulator
A2 Electronic card
A6 Display
A17 Keypad PIN-number login Option
F1 Fuse Drive motor circuit 125 A

F3 Fuse Pump motor circuit 125 A
F 50 Fuse Operating circuit A5 7,5 A
F 51 Fuse Operating circuit A1 7,5 A
F 52 Fuse Optional equipment Option
G1 Battery 24 V
H1 Horn
K10 Contactor Main contactor

K30 Contactor Pump motor
A2:S1-S9 Speed control Forwards/Reverse

A2:S10-S18
M1 Motor Drive motor

M3 Motor Pump motor
P1 Pressure switch Pressure switch support arm 70 bar

lift
P2 Pressure switch Pressure switch fork lift 120 bar
R1 PTC-resistor Power supply 15 Ohm
S111 Switch Option

S112 Switch Option
S113 Switch Turtle button
S114 Switch Option

229102-040 2006-03-13 922602- 702
Symbol Description Function Notes

S115 Switch Option
S116 Switch Option
S10 Switch Travel brake Brake lever
S17 Switch Key
S18 Switch Horn button
A2:S17 Switch Safety reversing
A2:S19 Switch Fork lifting
A2:S20 Switch Fork lowering
S21 Switch Emergency switch off
A2:S21 Switch Support arm, lifting
A2:S22 Switch Support arm, lowering
S32 Switch Lift height limiting, 1.6 m
S33 Switch Lift height limiting
S42 Switch Manual fork lowering
S90 Switch Lift height limiting
Y1 Brake
Y34 Magnetic valve Forks
Y41 Magnetic valve Fork lowering
Y52 Magnetic valve Support arm lifting
X1 Connector Battery
X41 Connection point CAN-communication

Electrical wiring diagram
702 922602- 2006-03-13 229102-040
14.3 Electrical wiring diagram
14.3.1 Symbol list
Table 2: Symbol list

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

A1 A2
M
E1 S E2
Contactor Coil for hydraulic magnetic valve
Pressure switch, NC Connector
Momentary switch, NO
NO = Normally Open, NC = Normally closed

a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases)
b. DC = Direct Current
c. SEM = Separately Excited Motor

229102-040 2006-03-13 922602- 702
14.3.2 Overview
2 1
3 F1 R1
M1
24 (+) POWER 24VDC 6 A2 A1 X1
M
40 (16) SUPPLY 24VDC ARMATURE (M)
(-) POWER 0VDC 4 S
+
E2 E1 G1
FIELD (S2)
-
P1 5 X1
63 FIELD (S1)
(10) SUPPORT ARM LOAD CHARGER
40
p 64 K10 S170
MAIN CONTACTOR (4)
P2 F51
49
(15) FORK LOAD
A1 ONLY TRUCK WITH
21
MAX LOAD 1200KG S21
p
F3
S10 M3
57 S33 S90 A1
M
A2
(12) TILLER ARM
45
66 PUMP CONTACTOR (6)
K30
(13) LIFT LIMIT 1,6M H1
S32
39
ONLY TRUCK SIGNAL HORN (7)
WITH MAX Y1
LOAD 1200KG 31
BRAKE RELEASE (5)
Y41
38
S42 65 LOWER VALVE (9)
34
(11) MAN. LOWERING
58
FORK VALVE (2)
Y52
53
SUPPORT ARM VALVE (3)
CAN HIGH/LOW
(1/8)
24 24
X41 F50 1
20
40 120 CHARGER
119 RED
BLACK (+) OUT. POS.
(-) OUT. NEG. A30
X9 S17 (X3:3/7) CAN HIGH/LOW
22
ONLY 40 (X3:2) +24VDC A2:S17
KEYBOARD (X3:6) 0VDC Hall F
(X2:1/2) TURTLE A2:S19 EXT. EQUIP.

Hall
(X1:1) HORN 2
S113 (X4:1) HORN 1 A2:S20
S18:2 A2 Hall
S18:1
(X4:2) A2:S1-S9 A2:S10-S18
Hall Hall
(X1:2)
(X2:1/3)
KEYBOARD DISPLAY
(X11) (X12) (X1)
A17 A6

702
14- 8
T-code
TRANSISTOR REGULATOR
A1
X1 G1 24V X1
1 + - 40
Sh. 6 - INP. POWER SUPPLY 0V DC
R1 F1
2 3
+ INP. POWER SUPPLY +24V DC
130A PUMP MOTOR DRIVE MOTOR

PTC 15~E
F50 F3 M3 M1
20 2 1 9 1 2 10 A1 A2 A1 A2 6
Sh. 3 M M M OUT ARMATURE
7,5A 130A
F51 S
21 E1 E2 4
Sh. 2 S2 OUT. FIELD
7,5A
922602-
FEXTERNAL EQUIPMENT
5
S1 OUT. FIELD
Service Manual
X10 Y1 X10
1 2 31
5 OUT. BRAKE
24
Sh. 2
S10
Valid from serial number
X10 X10
Bn Bl 57
12 INP. TILLER ARM IN DRIVE POS.
Bu
K10
A1 A2 64
4 OUT. MAIN CONTCTOR
X10
40
7SM12F, 7SM16D
Sh. 3
13 14
Date
SWE120L
K30 X12 X13 S33 X13 S90 X12
A1 A2 146 13 14 145 21 22 45
6 OUT. PUMP CONTACTOR
2006-03-13
0:2
14.3.3 Electrical wiring diagrams
Y41
1 2 38
9 OUT. LOWER VALVE
H1
39
7 OUT. SIGNAL HORN
- +
229102-040
Order number
218893
1/6, Prod C
© TIEE SARL
© TIEE SARL
229102-040
Order number
Date
TRANSISTOR REGULATOR
A1
EMERGENCY SWITCH OFF
S21
2006-03-13
21 1 2 24
Sh. 1 16 INP. SUPPLY +24V DC
24
Sh. 1 6
P1
63
10 INP. SUPPORT ARM LOAD
922602-
Service Manual
p
P2
49
15 INP. FORK LOAD
SWE120L p
X200 S32 X200
37 13 14 50 66
13 INP. LIFT LIMIT 1.6 M
S42
2 3 65
11 INP. MAN. LOWERING
Y34
7SM12F, 7SM16D
58
2 OUT. FORK VALVE
Y52
53
3 OUT. SUPPORT ARM VALVE
702
119 119
T-code
Sh. 3 8 CAN HIGH
120 120
Sh. 3 8 CAN LOW
218893
2/6, Prod C
14- 9
702
14- 10
T-code
ONLY KEY BOARD ELECTRONIC CARD TILLER ARM

A2
KEY
S17 X5 X5
20 22
Sh. 1 X3 2 INP. +24V DC
X5 X5
119 119
Sh. 2 X3 3 CAN HIGH
X5 X5
120 120
922602-
Sh. 2 X3 7 CAN LOW

X5 X5
40 40
Sh. 1 6 X3 6 INP. OV DC
Service Manual
X9
20 1 A2:S17
BELLY BUTTON
40 2
X41 A2:S1-S9 A2:S10-S18

20 119 3 SPEED REF. VALUE
40 120 4
A2:S21
CAN, CONNECTION
7SM12F, 7SM16D
119 SUPPORT ARM LIFT
Date
120 A2:S22
SUPPORT ARM LOWER
CAN, SERVICE CONNECTOR
2006-03-13
A2:S19
FORK LIFT
A2:S20
FORK LOWER
229102-040
Order number
218893
3/6, Prod C
© TIEE SARL
DISPLAY ELECTRONIC CARD
A6 A2
X1 1 X12 1 +5V DC
© TIEE SARL
229102-040
Order number
X1 2 X12 2 SI
DISPLAY
A6
X1 3 X12 3 SCK
8 8 8 8
Date
X1 4 X12 4 ENABLE
2006-03-13
X1 5 X12 5 LCLK
X1 6 X12 6 0V DC
922602-
Service Manual
S18:1
1 2
X4 1 INP. HORN 1
X4 2 OUT. OV DC HORN 1
S18:2
1 2
X1 1
7SM12F, 7SM16D
INP. HORN 2
X1 2 OUT. 0V DC HORN 2
702
S113
T-code
1 2
X2:1/2 TURTLE
OPTION
X2:1/3 TURTLE
218893
4/6, Prod C
14- 11
702 922602- 2006-03-13 229102-040
5/6, Prod C
218893
ELECTRONIC CARD
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

© TIEE SARL
229102-040
OPTION
Order number
ONBOARD CHARGER
Date
2006-03-13
START INTERLOCK ELECTRONIC CARD

ONBOARD CHARGER A5
S170 K10
24 23 A1 A2 64
Sh. 2 4 OUT. MAIN CONTACTOR
922602-
Service Manual
ONBOARD CHARGER, PLUG. A/B
ONBOARD CHARGER
A30
1 (RED) (RED)
Sh. 1 + OUT. POSITIVE CHARGER VOLTAGE
40 (BLACK) (BLACK)
Sh. 3 - OUT. NEGATIVE CHARGER VOLTAGE
7SM12F, 7SM16D
PLUG. A
MAINS, VAC
PLUG. B
702
MAINS, VAC
T-code
MAINS, EARTH
218893
6/6, Prod C
14- 13
Functional description
702 922602- 2006-03-13 229102-040
14.4 Functional description
14.4.1 Starting the truck

• To enable the truck to be started, the battery plug must be connect-
ed, the emergency switch (S21) closed and the start key (S17) in the
ON position.
A1 14.4.2 Driving
B-
S1 • S10 closed .
T1
Ish S2 • The speed control activated in any direction.
- M-
A2
+
Shunt
A
Ia A1
T2
14.4.3 Neutral speed reduction
K10 B+ • The speed control to neutral position, motor starts to work as gener-
ator. Brake energy comes back to battery.
• The brake will be activated when the truck comes to a stand still
even if the tiller is in drive position.
• Energy back to the battery.
• The transistors (T2) for the generated brake current are not live.
A1
B-
S1
T1
Ish S2
- M-
A2
+
Shunt
A
Ia A1
T2
K10 B+
14.4.4 Neutral speed reduction on slopes

If the driver release the speed control on a slope and the truck doesn’t
come to a stop within a certain time the electrical brake will be applied
by the system.
14.4.5 Braking
The brake is always applied when the truck is started with the
tiller in it’s upper or lower position (S10 open). The brake is released in
the same moment as the conditions for driving are fulfilled and the truck
starts to move.
Conditions to brake the truck:
• S10 open.

229102-040 2006-03-13 922602- 702
14.4.6 Lifting the forks

• A2:S19 activated.
• Battery status OK (if battery capacity >20% left).
14.4.7 Lifting the support arms

• A2:S21 activated
• Battery status OK (if battery capacity >20% left).
14.4.8 Lowering the forks

14.4.9 Lowering the support arms

14.4.10 Horn
• S18 activated.
14.4.11 Hour meter

• Press S18 and turn S17 to “on” at the same time.
• Press S18 until you read H= hour meters.
• You have now choosen H=hourmeters the symbol “B” will be high-
lighted.
• You can now choose type of hourmeter by pressing the speed con-
trolt.
A= Key time.
A b= Drive motor time.

c= Pump motor time.
d= Activity time.
s= Time to service.
E D C B

702 922602- 2006-03-13 229102-040
14.4.12 Transistor regulator
STATUS
MODEL VOLTAGE
SERIAL CURRENT
Curtis 1243 is a regulator [A1] for controlling separately excited motors

(SEM). Varying the voltage applied through the armature primarily con-
trols the speed. The voltage is varied through use of pulse-width modu-
lation (PWM). This involves varying the “on” time of the MOS-FET tran-
sistors 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-
tor bridge for the armature winding.
14.4.13 Spider expansion unit (SEU) (option)

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. Up to two SEU units can be
fitted in the truck to handle more complex options. 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, including certain standard options. In this case, correct
operation of the modification/option is achieved by adjustment of serv-
ice 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 already fitted with an SEU as standard can also have addi-
tional modifications using “configurable options”. These additional
modifications are controlled by the setting of service parameters 16 to
19.
Refer to section Configurable “Option” Parameters on page 41 for more
detailed information.
229102-040 2006-03-13 922602- 702
A2
Electronic
card
TLS
A36 Extra / Customised
SEU function(s)
CAN bus
X41
CAN service
connector
A1
Traction
controller
Fig. 2 Connection architecture for SEU
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-
tipin connector which handles all inputs, outputs, CAN and supply sig-
nals.

702 922602- 2006-03-13 229102-040
Table 3: SEU 42-p connector

Pin Connection Pin Connection Pin Connection
14 AGND 28 AGND 42 CAN_L
13 +5V EXT 27 CAN_H 41 AGND
12 ANALOG IN 4 (5V) 26 ANALOG IN 5 (30V) 40 ANALOG IN 6 (30V)
11 ANALOG IN 1 (5V) 25 ANALOG IN 2 (30V) 39 ANALOG IN 3 (30V)
10 RS-232 +12V 24 RS-232 TxD 38
9 RS-232 GND 23 RS-232 RxD 37
8 22 36
7 DIGITAL IN 7 (H)a 21 DIGITAL IN 8 (H) 35
6 DIGITAL IN 4 (L)b 20 DIGITAL IN 5 (H) 34 DIGITAL IN 6 (H)
5 DIGITAL IN 1 (L) 19 DIGITAL IN 2 (L) 33 DIGITAL IN 3 (L)
4 18 BOX ADDRESS 1 32 BOX ADDRESS 2
3 DIGITAL OUT 4 17 GND 31 GND
(PWM OUT 2)
2 DIGITAL OUT 3 16 DIGITAL OUT 1 30 DIGITAL OUT 2
(PWM OUT 1)
1 B+ (+24V) 15 GND 29 GND (0V)
a.H = high-current (7 mA)
b.L = low-current (1 mA)

229102-040 2006-03-13 922602- 702
14.4.14 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.

702 922602- 2006-03-13 229102-040
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 4: Settings TLS

Function Description Default setting
PIN code PIN code for different driver 00001 (profile 1)
profiles. 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.

229102-040 2006-03-13 922602- 702
14.4.15 ID unit (optional)

General
The ID unit is used to start the truck. A smart card or an ID key (see
image below) is used instead of a PIN code. It is standard for 2 ID keys
to be enclosed with the unit. These have standard settings for use with
all types of truck and departments.
Login is performed by pressing the green button and then holding the
smart card/ID key close to the ID unit. If the information on the card is
confirmed, the truck starts with the correct driver profile and the green
LED lights up. If the information on the card is not confirmed, a red LED
lights up for 0.7-0.8 seconds. If no information is detected within 5 sec-
onds, the procedure must be repeated.
Logging off is performed by pressing the red button. The red LED then
lights up for 0.7-0.8 seconds.
A2
Electronic card
Installation
NOTE:
During commissioning of the truck (or the ID unit), the ID unit should
be programmed with a specific department and truck type. To avoid
unauthorised use, rider-controlled trucks and ‘walkie’ trucks, at the
very least, must be programmed as different types of truck.
• Connect the service key.
• Set the ID unit to parameter 39. See “14.5.7 Service parameters” on
page 30. (If values 9-12 are not available, the software must be up-
graded with the aid of TruckCom.)
• Remove the service key.
• Disconnect the battery contact.
• Replace the keypad with the ID unit. Take care during connection
and disconnection.
• Connect the battery contact.
• Start the truck by pressing the green button and then, within 5 sec-
onds, holding a smart card or ID key close to the scanner on the ID
unit. (If the service key is connected, you need only press the green

702 922602- 2006-03-13 229102-040
button.) The green LED lights up if login was approved, and the red
LED lights up if an invalid smart card/ID key has been used. (Smart
cards/ID keys are preprogrammed with a standardised start code.)
• Switch off the truck by pressing the red button. The red LED lights
up.
Settings
Up to 16 types of truck and 14 departments can be used with the sys-
tem. A smart card/ID key can be programmed for several departments
and types of truck, depending on what the driver is authorised to use.
A smart card/ID key can also be used to program the ID unit if the type
of card is changed (see table below). The truck then detects the depart-
ment and type of truck selected on the smart card/ID key. When the ID
unit is programmed, a red LED lights up for 0.7-0.8 seconds.
Table 5: Settings ID unit

Truck Description Default
Department Up to 14 departments in any combination (1-14) All
Type of truck Up to 16 types of truck in any combination (1-16) All
Smart card/ID key Description Default
Department Up to 14 departments in any combination (1-14) 14
Type of truck Up to 16 types of truck in any combination (1-16) 16
Type of card Driver card (1) or programming card (3) 1
Driver profile Profile for different driver parameters (0-9) 0
Driver ID - -
A programming unit from Davis Derby (see image below) is required in

order to be able to program a smart card/ID key. The unit is connected
to a normal PC.

229102-040 2006-03-13 922602- 702
• Connect the programming unit to the PC’s Com port using the ac-
companying cable.
• Turn on the PC and open the programming software.
• Connect the programming unit to the mains power.
See separate manual (232629) for more information on programming.

Parameters
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14.5 Parameters
14.5.1 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
14.5.2 Viewing parameters - without the CAN

service key
Proceed as follows to display parameters when a CAN service key is
not connected:

PIN code and then press on the keypad.

• Hold S18 depressed until “P” is displayed (Fig. 3), then release S18.
Parameters symbol lights.

Fig. 3
The different parameters are now displayed by repeatedly operating
speed control L1. Operator 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 1,3,5,7,9 & 11. See “ Login method and driver pa-
rameter access” on page 38.
2.Service parameters can be viewed without a CAN key being
plugged in but they cannot be adjusted.

Parameters
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14.5.3 Adjusting operator parameters -

without the CAN service key
NOTE!
Operator parameters can only be set without a CAN key if parameter
#39 is set to value 1, 3, 5, 7, 9 or 11. See Login method and driver pa-
rameter access on page 38.
To change the value of a particular operator 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 Operator parameters
active. Any changes made will only be in effect when that particular
“operator” is logged in.
• Select the required parameter.
• 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 Parameter description on page 28.

Parameters
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14.5.4 Viewing & changing parameters - CAN

service 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 (Fig. 4), then release S18.
Fig. 4
When pressing the speed control L1 forwards repeatedly, the first oper-
ator profile will be displayed. Continue to press L1 in the forward direc-
tion and the next operator profile will be displayed (operator no. 2), etc.
until the last operator (operator no. 10). See Fig. 5.
Operator parameter no.
Once the 10 operator profile have been displayed, the truck service
Profile no.
parameters will be displayed as L1 is repeatedly pressed in the forward
Fig. 5 direction.

Parameters
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Changing a parameter
• Select the required parameter.
• Set the parameter value by repeatedly operating speed control L1

up or down.
Parameters symbol lights (stops flashing).

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
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
For detailed descriptions and effects of these parameters see the sec-
tion Service parameters on page 30.
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.
1.Certain parameters numbers displayed are not active in this truck

model.

Parameters
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14.5.5 Operator parameters
Parameter Description Unit Min. Max. Step Std. Description

01 Speed, Turtle % 40 100 5 60 Speed, Turtle button
button 40: slow speed
100: maximum speed.
02 Max. speed % 40 100 5 100 Max. speed
40: slow speed
100: maximum speed
03 Acceleration 10 100 5 70 10: slow acceleration
100: maximum accelera-
tion
04 Braking in 5 100 5 50 Specifies motor braking
neutral mode once the lever is put into
neutral.
5: weak braking power
100: maximum breaking
power
05 Logout 1min 0 20 1 20 The time it takes for the
truck to switch off when
the keypad is used. The
time counts down from
the moment the last
power-consuming unit is
used. Value = 0 gives 4
hours.
In steps of 1
14.5.6 Parameter description

Parameter 1
The speed of use of the turtle button can be adjusted.
Parameter 2
The maximum speed can be adjusted.
Parameter 3
The lower the parameter value, the longer it takes for the truck to
achieve maximum speed.
Parameter 4
Specifies the motor braking power when the lever (L1) is put into neu-
tral. The lower the parameter value, the longer the braking time.

Parameters
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Parameter 5
The time it takes for the truck to switch off when the keypad is used.
The time counts down from the moment the last power-consuming unit
is used.
Value = 0 gives 4 hours.

Parameters
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14.5.7 Service parameters

Parameter Description Unit Min Max Step Std Description
10 PIN-code 0 9999 1 1 Facility for specifying up to 10
PIN codes (10 different driv-
ers).
14 Crawling -10 10 1 -5 The amount of power the mon-
speed itor should emit when you
reach the first speed sensor
can be specified here.
-10: low speed for the first
speed sensor.
10: high speed for the first
speed sensor
15 Non-config- See “ Parameter 15 - Non-configurable options” on page 31.
urable option
0 to 9
16 Configurable These parameters provide correct operation of trucks which have
option #1 been modified with an approved special request modification. If no
17 Configurable such modifications are present on the truck, these parameters shall
option #2 all be set to “0”
See “14.5.9 Configurable “Option” Parameters” on page 41.
18 Configurable
option #3
19 Configurable
option #4
20 Hour meter 1 5 1 2 Select hour meter.
option
21 Battery size 1 20 1 95 Selection of battery size.
22 Inductive 0 1 1 1 0: Mechanical switch
sensor 1: Inductive sensor
25 Service inter- 1h 0 2000 50 100 Option for setting service timer
val
28 Lift button 1 3 1 1 Button selection
selection
39 Password 1 12 1 1 States which level of authoriza-
tion the driver has for the
parameters.
Odd values specify open driver
parameters, even values spec-
ify that driver parameters must
be opened using the CAN key

Parameters
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14.5.8 Parameter description

Parameter 10
NOTE!
The functionality of parameter #10 is set aside if the value of parame-
ter #39 is set to 5,6,7 or 8. The PIN codes are managed using the so-
called expanded keypad. See section Expanded keypad - General on
page 38 for more detailed information.
Ten drivers can have their own PIN code to gain access to the truck.
Each driver can set all driver parameters individually.
On delivery the PIN code is set to 1 and this only applies for driver no. 1.
Code 0 is not accepted as a solitary code.
When you wish to start the truck enter your code and press the green
button numbered 1.
When you want to switch off the truck, press the red button numbered
0.
When the CAN key is connected, you can start the truck by simply
pressing the green button numbered 1. Switch off by pressing the red
button numbered 0.
Parameter 14
Specifies the speed you will have when you reach the first speed sen-
sor.
Parameter 15 - Non-configurable options

Up to 10 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
32 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.
After 1 second the value of the sub-parameter will be displayed.

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

L1 up or down. See Table 6: for details.
• Press horn button S18 once to confirm the new setting.
The parameters symbol lights (stops flashing).

The non-configurable option will now be activated.
• Ensure the option operates correctly before returning the truck for
normal use.
P
Table 6: Parameter #15 Non-configurable

options
Option name Value NOTE!
Sub-parameter No.
Default setting
Function OFF
Function ON
0 Click-2-creep 1 0 0
1 Turtle 1 0 0
Parameter 16 - Configurable option #1

See “14.5.9 Configurable “Option” Parameters” on page 41,




Parameters
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Parameter 20
You decide yourself what the hour meter will show.
1A = Key time
2b = Movement time
3c = Drive motor time
4d =Pump motor time
5s = Time for service
Parameter 21
You must specify the type of battery the truck is equipped with.
In order to set the meter for the battery’s level of discharge, the follow-
ing should be taken into account:
• Acid concentration when the battery is fully charged, to check the
grade of the battery. Must be between 1.27-1.29.
• When the lifting capacity is disconnected (the battery is 80 % dis-
charged), the value must be close to, but not below, 1.14.
The acid concentration can vary depending on the battery make.

Parameters
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Recommendation on parameter setting for freely

ventilated batteries
Parameter 21 Battery size 7SM12F,

7SM16D
1
Less discharge 2
3
4
5 260 Ah - 320 Ah
Standard value
6 190 Ah - 250 Ah
7 120 Ah - 180 Ah
8
9
10
11
Greater discharge 12
13
14
15
16
17
18
19
20
WARNING !
The service life of the battery will be reduced if the value of parameter
21 is set at too high a value. The standard setting of parameter 21 is
set for normal truck handling. Other applications may require a differ-
ent setting of parameter 21. Check that the parameter setting is the
correct one using the instructions below.

Parameters
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Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Remove the battery from the truck and allow to rest for at least two
hours. NB! No charging or discharging during this period.
• Measure the acid weight of the battery at room temperature. If the
acid weight is less than 1.15 g/cm3, the parameter value must be
reduced. If the value significantly exceeds 1.15 g/cm3, the risk of
damage to the battery is reduced. At the same time, the operating
time of the truck is reduced. If a longer operating time is required, the
parameter value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.

Parameters
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Recommendation on parameter setting for valve-

controlled batteries (VRLA)
Parameter 21 Battery size 7SM12F,

7SM16D
1
2 260 Ah - 320 Ah
Less discharge
3 190 Ah - 250 Ah
4 120 Ah - 180 Ah
5
6
7
8
9
10
11
12
13
14
15
Greater discharge
16
17
18
19
20
WARNING !
The service life of the battery will be reduced if the value of parameter
21 is set at too high a value. The standard setting of parameter 21 is
set for normal truck handling. Other applications may require a differ-
ent setting of parameter 21. Check that the parameter setting is the
correct one using the instructions below.

Parameters
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Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Disconnect the battery from the truck and allow the battery to rest for
at least two hours. NB! No charging or discharging during this peri-
od.
• Measure the battery voltage at room temperature. If the voltage is
less than Uend, see the table below, the parameter value must be re-
duced. If the value significantly exceeds Uend, the risk of damage to
the battery is reduced. At the same time, the operating time of the
truck is reduced. If a longer operating time is required, the parameter
value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.
Battery type Battery voltage at rest, Uend

Hawker Evolution 24,24 V
Parameter 22
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1
Parameter 25
Using this parameter you can specify a limit for when the next service is
to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for
a service, warning 29 (C29) is shown in the display.
Parameter 28
Using this parameter you can select which button is to be used for lift/
lower.
0 = No lift / lower button activated.
1 = Bottom lift / lower button activated (default).
2 = Top lift / lower button activated.
3 = Both lift / lower buttons are activated.

Parameters
702 922602- 2006-03-13 229102-040
Parameter 39
Login method and driver 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.
• 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.
Expanded keypad - General

The truck can contain a maximum of 10 individual driver profiles. The
expanded keypad function thus allows you to assign a maximum of 10
PIN codes for each of the driver profiles. This allows you to manage a
maximum of 100 unique PIN codes.
If the expanded keypad function is activated, the standard manage-
ment of PIN codes normally accessible via parameter #10 is set aside.
Expanded keypad - Programming

A number of PIN codes can be made accessible by activating the so-
called block. Block no. 0 is activated as standard. This means that 3 dif-
ferent driver profiles are available from the start. Activation of other

Parameters
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blocks means that all PIN codes for the block are accessible (See Table
8:). If all 10 blocks are activated, there will be 10 PIN codes available for
the driver profile.
The truck program stores a standard list of PIN codes as per Table 8:
These PIN codes can be changed to any value, but you should avoid
the same PIN code in different driver profiles.
To start programming the expanded keypad:
• Connect an appropriate CAN service key to X41
• Enter code 341671 and press on the keypad.

• Select the programming command from Table 7:
Table 7: Programming command - expanded keypad

Progamming Function Notes
Reset to factory settings Block 1 - 9 is deacti-
Press “1” + vated. Original PIN
codes reset as per
Table 8:
PIN codes in the block can be B= Block no. 0 - 9
Press “2” + B + used
PIN codes in the block cannot B= Block no. 0 - 9
Press “3” + B + be used
Programming a new PIN code B= Block no. 0 - 9
Press “4” + B + F + NNNN + F= Driver profile no.
0-9
NNNN = PIN code

The expanded keypad programming is now complete
Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN
codes to be valid.
Carry out a practical test by logging in using some of the new PIN
codes. It is important to establish that the correct driver profile has been
activated when a certain PIN code has been entered, especially if a
specific driver profile has been set for a specific application/goods han-
dling.
Table 8: shows the PIN codes available as standard in the program.
These can be activated for use or changed according to the driver’s
wishes.
One or more of these blocks can be activated.
A driver profile is activated, on normal login, by all PIN codes whose
block no. is activated.

Parameters
702 922602- 2006-03-13 229102-040
The truck program does not approve login using the PIN code “0000”.
Service personnel should keep notes on activated blocks, changed PIN
codes and specially-set driver profiles.
NOTE!
Resetting the expanded keypad does NOT affect the driver profile set-
tings.
Table 8: Standard PIN code assignment with the expanded

keypad
Driver 0 1 2 3 4 5 6 7 8 9
profile
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
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14.5.9 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 thorough
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 behaviour of the Spider expansion unit
(SEU) which must be fitted in the truck. See “14.4.13 Spider expansion
unit (SEU) (option)” on page 16. This method of implementation allows
the standard software program to be used without the need for a spe-
cialised software. Normally, these parameters are configured by the
manufacturer 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 set-
tings can then be transferred to the new card thus ensuring the special
option functions correctly.
Summary of base options

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 customization. See table
below.
Table 9: Summary of base options

Base Function Refer to...
option
1 Pressing an option button controls a digital o/p. table 10 on page 44
2 Activating a digital input will reduce maximum drive speed. table 11 on page 45
3 Specific truck movement(s) activates a digital o/p. table 12 on page 46
4 Activating a digital input causes main contactor to close. table 13 on page 49
5 Activating digital inputs will operate lift /lower. table 14 on page 50
6 Lift height can be restricted by activating a digital input + ability to table 15 on page 52
override by pressing an option button.
11 Automatic control of fork lifting/lowering. table 16 on page 53

Parameters
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Convention for 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 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. 6 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 9:.
• 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 9:.
Adjust arguments #2, #3 and #4 using the same method as above.

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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Detailed option parameter tables
Table 10: Base option 1 - Option button controls SEU output

Argument #0 Option designator
Values Meaning
Initial display 1 Sets relevant parameter to handle base option 1

(value shown after 2 s delay)
Argument #1 Selection of SEU unit 1 or 2
Values Meaning
0 option is handled by SEU unit 1(A36)
Initial display
(value shown after 2 s delay) 1 option is handled by SEU unit 2 (second SEU unit)
Argument #2 Selection of SEU digital output
Values Meaning Pin no.
0 activate SEU digital o/p 1 (1,6A) 16
Initial display
(value shown after 2 s delay) 1 activate SEU digital o/p 2 (1,6A) 30
Argument #3 Selection of option button
Values Meaning
1 activated by option button 1
Initial display
(value shown after 2 s delay) 2 activated by option button 2
Argument #4 Type of switching
Values Meaning
0 activated when button is depressed
Initial display
(value shown after 2 s delay) 1 option is toggled when button is pressed

Parameters
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Table 11: Base option 2 - Reduced drive speed by SEU i/p

Initial display Values Meaning
2 Sets relevant option parameter to handle base option 2

1 option is handled by SEU unit 2 (second SEU unit)
Argument #2 Selection of SEU digital input
Initial display Values Meaning Pin no.
0 activate SEU digital i/p 1 (1mA) 5
(value shown after 2 s delay) 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 2 s delay) 2 Affects both speed ranges

Parameters
702 922602- 2006-03-13 229102-040
Table 12: Base option 3 - Truck movement activates SEU o/p

Initial display (value displayed after Values Meaning
2 s) 3 Sets relevant option parameter to handle base
option 3

2 s) 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 (value displayed after Values Meaning Pin no.
2 s) 0 activate SEU digital o/p 1 (1.6 A) 16
1 activate SEU digital o/p 2 (1.6 A) 30
...table continued on next page

Parameters
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...continued from previous page
Argument #3 Selection of activating movement
Initial display (value displayed Values Drive Drive Lift Lower Any
for- back- forks forks other
ward ward movement
after 2 s) 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
702 922602- 2006-03-13 229102-040

Argument #4 Output switching mode
2 s) 0 Output continuously on
1 Output switches at 1 Hz
2 Output switches at 2 Hz

Parameters
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Table 13: Base option 4 - Activate main contactor by SEU i/p


Argument #2 Selection of SEU digital input
0 activated by SEU digital i/p 1 (1 mA) 5
(value shown after 2 s delay) 2 activated by SEU digital i/p 3 (1 mA) 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 14: Base option 5 - Activate lift/lower by SEU i/p

5 Sets relevant option parameter to handle base
option 5
(value shown after 2 s

delay)
0 option is handled by SEU unit 1 (A36)
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 14: Base option 5 - Activate lift/lower by SEU i/p

Argument #3 Enable / Disable 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 15: Base option 6 - Lift height restriction by SEU i/p &
override

Argument #2 Selection of SEU digital input for restriction switch
0 activate SEU digital i/p 1 (1 mA) 5
(value shown after 2 s delay) 2 activate SEU digital i/p 3 (1 mA) 33
Argument #3 Selection of option button to override
(value shown after 2 s delay) 3 activated by option button 3
Argument #4 Not used

Parameters
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Table 16: Base option 11 - Automatic lift/lower function


Argument #2 Selection of option buttons
0 No option buttons used
1 Option button 1 & 2 used (left side of handle)
(value shown after 2 s delay) 2 Option button 2 & 3 used (left side of handle)
3 Option button 3 & 4 used (one on each side of handle)
4 Option button 4 & 5 used (right side of handle)
5 Option button 5 & 6 used (right side of handle)
6 Option button 1, 6, 2 & 5 used (Duplicate switches on
both sides of handle)
7 Option button 2, 5, 3 & 4 used (Duplicate switches on
both sides of handle)

Diagnostic and troubleshooting
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Table 16: Base option 11 - Automatic lift/lower function

Argument #3 Selection of input & output signals
0 Photocell -SEU digital i/p 1 (1 mA) 5
Lower limit -SEU digital i/p 2 (1 mA) 19
upper limit -SEU digital i/p 3 (1 mA) 33
(value shown after 2 s delay) External lift button -SEU digital i/p 4 (1 mA) 6
External lower button -SEU digital i/p 5 (7 mA) 20
Auto lamp o/p - SEU digital o/p 1 (1,6 A) 16
External lift button -SEU digital i/p 5 (1 mA) 20
Argument #4 Activation of external lift & lower buttons
0 Disabled
1 Enabled
14.6 Diagnostic and troubleshooting
means constantly on means flashing
14.6.1 General
The trucks’s electronic control system incorporates built-in fault code
Fig. 7 display and logging. This capability works as a powerful complement in

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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. 7).
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 C50 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 C19 to C43 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.
14.6.2 Error 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 (Fig. 8), then release S18.
Fig. 8 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.
14.6.3 Error codes

• Press and hold S18 while turning S17 to “ON” position.
• Press and hold S18 until E = error codes is displayed.

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• When E is selected, the “E” symbol will light up as an indication of

what is shown in the display.
• The 50 most recent error codes are stored. The latest error is dis-
played first. The display shows the error code first, followed by the
time when the error occurred.
• The error codes are divided into two groups, C = caution and E = er-
ror.
• C codes are not stored. They are only cautions and remain lit in the
display as long as the fault remains.
• If there is only one error registered in the memory, the other empty
entry lines appear as follows: Error: E - - - and time: - - - - .
Code C3
Description TLS: Shock sensors registered values outside
the limits
Possible error A shock sensor has reported values that exceed
cause the truck’s tolerance values.
Driving may be too hard
Check that the shock sensor’s limit values are
correctly set.
Check that the shock sensor is correctly posi-
tioned./The brake engages and stops the truck.
The TLS reset command activates the truck
Code C4
Description TLS: Use of the truck has been blocked
Possible error Truck use can be “blocked” by a TLS command. /
cause The truck cannot be used until a new TLS com-
mand cancels the blocking of the truck

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Code C19
Description Parameter caution. Displayed for 5 seconds.
Possible error The parameters have probably been changed.
cause When changing/updating the program the param-
eters have automatically been changed to default
values (only applies to old program versions).
In later program versions the parameters are only
changed if they are outside the values permitted
by the new program.
Action 1. This means that the special parameters
must be reset manually.
Code C20
Description Speed control caution.
Possible error Problem with the speed control sensors.
cause The toggle switch may have been activated when
starting or there may be a fault on one of the sen-
sors on the electronic card. (tiller arm head)
Action 1. Restart with the speed control in neutral
position.
2. Replace the electronic card.

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Code C28
Description Emergency switch caution
Possible error The emergency switch has been activated.
cause No current to the travel regulator, input. A1/16.
Action 1. Check fuse F51.
2. Check the emergency switch.
3. Check the cables from the battery and the
battery contacts.
4. If PTC resistor R1 is very hot, remove the
battery contact and allow the resistor to
cool.
Restart.
Code C29
Description Service warning
Possible error Time for service.
cause The service counter has not been reset since the
last service.
Code C41
Description Warning of low battery voltage
Possible error Battery voltage < 17 volt.
cause The battery parameters are not correctly set.
Time to charge up the battery.

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Code C41
Action 1. Check parameter 21, battery size and type.
2. Check the battery contact and the pole
connections on the battery
3. Check the key switch, S17, poor contact
causes unpermitted voltage drop.
The electrical system measures the voltage inside
the travel regulator.
Code C42
Description Warning of high battery voltage
Possible error Battery voltage > 33 volt.
cause Energy return feed to battery during motor braking
with a fully-charged battery.
Action 1. The fault disappears after a few lifts, once
the battery has been run down slightly.
2. Check the cabling, the battery contact and
the contact points on main contactor K10.

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Code C43
Description The travel regulator shuts off due to excess or
subnormal temperature.
Possible error Too intensive operation or ambient temperature
cause too cold.
Error in the travel regulator.
Temperature levels below -25oC or above +85oC
reduce running speed.
Action 1. Check that the M12 fan is functioning. (Ap-
plies to P 24)
2. Check that the travel regulator is installed
with good contact with the chassis.
Code C90 (Option)

Description Extra I/0 (0) CAN communication error
Possible error Data from extra I/0 box /(0) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.
Code C91 (Option)

Description Extra I/0 (1) CAN communication error
Possible error Data from extra I/0 box /(1) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.
Code C92 (Option)

Description Configuration error Extra I/0 (0)
Possible error Incorrect setting of options in the extra I/0 box (0)
cause Check the outputs’ allocation on the I/0 expansion
box (0)
Code C93 (Option)

Description Configuration error Extra I/0 (1)
Possible error Incorrect setting of options in the extra I/0 box (1)
cause Check the outputs’ allocation on the I/0 expansion
box (1)

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Code E101
Description Travel regulator does not correspond with the type
of truck
Possible error Incorrect travel regulator or electronic card has
cause been installed. The truck has a built-in control
function that checks to ensure the wrong combina-
tion of travel regulator and electronic card has not
been installed.
Action Check travel regulator and electronic card.
Code E104
Description Switch-transistor to brake is short-circuited
Possible error Error in the travel regulator, output. A1/3.
cause Incorrect value on parameter 22
Action Check cabling and contacts. Measure Ohms on
the magnet coil (Y1) for the brake. Value 13-15
ohm.
Check parameter 22

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Code E106
Description Digital outputs short-circuited or exceeding field
current limit.
Possible error Problem regulating the field current.
cause Internal monitoring error.
Action 1. Check the output for main contactor K10
(A1/4), check cabling and contacts and
measure ohms for the coil. Value 25-30
ohm. Check the output for the brake coil
K10 (A1/3), check cabling and contacts and
measure ohms for the coil. Value 13-15
ohm.
2. Check the output for horn (A1/7), check ca-
bling and contacts.
3. Check the drive motor’s shunt winding and
cabling and contacts. Unfortunately it is not
possible to measure ohms for the field
winding using a standard universal instru-
ment, since the winding has a value as low
as 0.3 ohm.

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Code E107
Description Contactor K10 does not close.
Possible error Problem with main contactor points or coil.
cause Contactor’s operating cabling off/not connected.
Interruption in the travel regulator’s output, A1/4.
Action 1. Check if the contactor is activated.
2. If the contactor is working, check the con-
tact points and accompanying cabling.
3. If the contactor is not working, check the
coil and accompanying cabling. Measure
Ohms for the coil. Value 25-30 ohm.
4. Check the travel regulator’s output, A1/4.

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Code E108
Description Contactor K10 does not open.
Possible error Main contactor points welded.
cause Short circuit in the travel regulator’s output A1/4.
Action 1. Check that the contactor’s contact points
are not welded together.
2. Check that the R1 resistor is not short-
circuited.
3. If the contact points are OK, but the contac-
tor engaged, check cable 64 and the travel
regulator’s output A1/4.
Code E110
Description System error.
Possible error Temporary error/error in the travel regulator.
cause
Action 1. Restart the machine.
2. Replace travel regulator.
Code E140
Description Error in control total.
Possible error Fault on the internal micro-monitoring (tiller arm
cause head), incorrect software or circuit board.

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Code E141
Description Software problem.
Possible error Fault on the internal monitoring (tiller arm head),
cause incorrect software or circuit board.
Action 1. Restart the machine.
2. Download the program again.
3. Replace the electronic card
w
Code E150
Description Fault in the data communication.
Possible error Break on the CAN cable.
cause
Action 1. Check the 119 and 120 cables and their
contacts.
Code E151
Description Tx error in data communication.
Possible error Travel regulator not responding.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
Code E157
Description Bus shut off.
Possible error CAN bus problem.
cause

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Code E159
Description Transgression error.
Possible error CAN bus problem.
cause
Code E160
Description Error in safety reversing function
Possible error Error in important sensor part.
cause
Action 1. Replace the electronic card
Code E200
Description Open field.
Possible error Shunt field’s circuit open.
cause
Action 1. Check the field winding connections E1
and E2. Unfortunately it is not possible to
measure ohms for the field winding using a
standard universal instrument, since the
winding has a value as low as 0.3 ohm.
2. Check cables 4 and 5 and outputs S1 and
S2
3. Replace travel regulator

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Code E201
Description M minus error.
Possible error Problem with switch transistor in the armature cir-
cause cuit inside the travel regulator.
Action 1. Check cable and connections between A1/
M on the travel regulator and connection
A2 on drive motor.
Code E202
Description Fault on sensor in travel regulator
Possible error Fault on armature current sensor in travel regula-
cause tor
Action Replace travel regulator
Code E214
Description CAN timeout in power amplifier.
Possible error The motor monitor is reporting an unexpected
cause data loss from the electronic card in the tiller arm
head.
Action 1. Check cables 119 and 120 between elec-
tronic card and travel regulator.
2. Replace electronic card

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14.6.4 Transistor regulator errors

All errors generated by or within the transistor regulator [A1] are com-
municated to the main control card [A2]. The fault conditions are then
displayed as error or caution codes according to the Error codes on
page 55. However, there is a status LED on the transistor regulator
which displays the current status of the regulator.
STATUS
MODEL VOLTAGE
The table below depicts the error codes that may be shown by the
SERIAL CURRENT
STATUS LED or read using the hand-held terminal.
Table 17: Transistor regulator error code

STATUS Curtis hand- Explanation Possible cause
LED held terminal
display
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 motor
SHUNT FAULT shunt defective. 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 arma-
B- ture circuit inside motor controller.
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 volt- 1. Battery voltage < 17 volts.
VOLTAGE age. 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. > 85 oC or < -25 oC.
CUTBACK perature reduction. 2. Truck overloaded.
3. Wrong installation of transistor regu-
lator.
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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14.6.5 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 18: Built-in test modes

Mode Flashing symbol Displayed data
1 Speed reference value sent to Curtis.
2 Digital inputs/outputs can be tested. See “ Digital

inputs/outputs test mode” on page 71.
3 Battery voltage (V).
4 Armature current (A).
5 Field current (A).
6 PWM Armature in %.
7 Status Curtis.

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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.
Inputs check
Table 19: Inputs check

Element Segment Function
[S31] Segment on when support arms
not at top.
[S10] Segment on when tiller arm is in

drive position.
[A2:S19] Segment on when forks lift button

is depressed.
[A2:S20] Segment on when forks lower but-

ton is depressed.
[A2:S21] Segment on when support arms lift

button is depressed.
[A2:S22] Segment on when support arm

lower button is depressed.
[S18] Segment on when signal horn but-

ton(s) pressed.

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Outputs check
Table 20: Outputs check

[Y1] Segment on when Brake solenoid
output activated.
Comple- Segment on when Brake solenoid

ment [Y1] NOT activated.
[K10] Segment on main contactor output

is activated.
[K30] Segment on when pump contactor

output is activated.
[Y34] Segment on when fork cylinder

selection valve output is activated.
[Y52] Segment on when support arm

selection valve output is activated.
[Y41] Segment on when lower valve out-

put is activated.

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Option buttons check
Table 21: Option buttons check

[S116] Segment on when option button
6 is pressed.

5 is pressed.

4 is pressed.

3 is pressed.

2 is pressed.

1 is pressed.
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:


Fig. 9
• Hold S18 depressed until “d” is displayed (Fig. 9), then release S18.
All number segments on the display and symbol lamps should flash
sequentially (Fig. 10).
Fig. 10

Technical specifications – Curtis 1243
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14.7 Technical specifications – Curtis

1243
Value Unit Explanation

Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature winding * 150 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 20 Amps for 2 minutes
20 for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 2 Amps Max (current limit at 2.5 amps)
KSI input voltage, Min. 16.8 Volts
KSI input current 50 mA
Logic input voltage >7.5; High Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C
* During specific test conditions.

Hydraulic system – 6000
General
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15- Hydraulic system – 6000
15.1 General
To avoid functional problems with the lowering valve, such as uninten-
tional lowering of forks, the valve must be cleaned and the function
checked before replacing the valve.
15.2 Hydraulic diagram and

components
n
2 1
4 G H
J K
3 B C
A
E
D
P
F
F

Hydraulic diagram and components
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15.2.1 Main components

Pos No Description Remark
1 Lift Cylinders Fork lift
2 Lift Cylinders Support arm lift
3 Hydraulic Unit A = Non return valve
B = Lowering valve, manual
C = Lowering valve, el
D = Overflow valve
E = Flow control valve
F = Filter
M = Pump motor
P = Pump
4 Pressure switches/lift G = Support arm lift
functions Load >750 kg
Speed = 5,3 km/h
Load > 1200 kg
Speed = 4,4 km/h
H = Fork lift
Load > 750 kg
Speed = 5,3 km/h
J = Valve, support arm lift
K = Valve, fork lift
15.2.2 Description
Lift
When the pump motor starts, the oil flows through the non return valve
to the lift cylinders.
Lowering
When the lowering valve is actuated by the lowering lever on the chas-
sis, or the lowering button on the tiller arm, the valve opens to allow the
oil in the pressure lines to return to the oil tank. The lowering speed can
be regulated by the movement of the lowering lever on the chassis.
Lowering using the button on the tiller arm gives a constant lower
speed.
Operating pressure
The operating pressures at rated load are:
• 7SM12F: 191 bar
• 7SM16D: 191 bar

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Relief valve
The relief valve opens at the following pressures:
• 7SM12F: 220 bar
• 7SM16D: 220 bar
Pressure switch
The pressure switch is used to regulate the speed and is influenced by
the load. It only has an off/on operation.
Load < 750 kg. Speed = 6,0 km/h
Load > 750 kg. Speed = 5,3 km/h
Load > 1200 kg – support arms. Speed = 4,4 km/h.

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Lifting mast – 7000
Adjusting the measurement between the guide and the mast
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16- Lifting mast – 7000
16.1 Adjusting the measurement

between the guide and the mast
The measurement between the guide and the mast (A) must be max.
13 mm. When replacing the mast, be sure to set the distance correctly
and check whether adjustment of the measurement is required.
Use the screw (B) to adjust play between the guide and mast and thus
correcting the distance (A). Following adjustment, be sure to grease the
beam ribs with Gleitmo 805.
B
A
B

Grease the beam flanges and beam ribs
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16.2 Grease the beam flanges and beam

ribs
Grease the inside surfaces of the beam flanges with Q8 Rembrandt
EP2 (see the lubrication chart).
Grease the inside surfaces of the beam ribs with Gleitmo 805 (see the
lubrication chart).

Main lift chain system –
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16.3 Main lift chain system –
16.3.1 General
Applies to all machines with a mast.
16.3.2 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.
16.3.3 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.
16.3.4 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.
16.3.5 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
16.3.6 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.

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16.3.7 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.
16.3.8 Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
.
16.3.9 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.

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16.3.10 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
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”.

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16.3.11 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.
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%.
16.3.12 Damage
The chain should be replaced if damaged in any way.

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16.3.13 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
16.3.14 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.
16.3.15 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”.
16.3.16 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.
16.3.17 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.

702 922602- 2006-03-13 229102-040
• 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:
Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubri-
cation
< - 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.

Battery charger (built-in) – 8340
General
229102-040 2006-03-13 922602- 702
A B 17- Battery charger (built-in) – 8340
17.1 General
The SMCI 300 is a 24 V battery charger with firmware designed to
charge freely ventilated or valve-regulated plumbic acid batteries (Evo-
lution type). Chargers on trucks with machine numbers 723984-936512
are designed for battery sizes ranging from approx. 100 Ah up to 320
Ah. Chargers on trucks with machine numbers from 936513- are
designed for freely ventilated batteries with sizes ranging from approx.
100 Ah to 350 Ah and for valve-regulated batteries in sizes 134 Ah, 174
Ah and 201 Ah.
C The charger relies on state-of-the-art switching technology and should

be connected to an earthed 220-240 V single phase wall socket (B).
The built-in microcomputer controls the charging process according to
the pre-programmed charging curve. During charging, the charging
process is displayed using a status indicator on the charger panel (A).
The micro-controller also supervises charging with regard to the charg-
ing time and temperature. This enables interruption of charging, for
example if a fault is detected in a battery cell or in case of insufficient
cooling of the charger.
The battery size and battery type can be selected with the switch locat-
ed on the ventilation panel (C). Set the switch using a flat screwdriver.

Technical data – charger
702 922602- 2006-03-13 229102-040
17.2 Technical data – charger
Dimensions 250x115x67 mm
Weight 1.6 kg
Ambient temperature -25° C to +40° C
Line voltage 90-255 V AC 45-400 Hz
Note! The charging current is
reduced in case of a line voltage
below 200 V
Rated voltage 24 V DC
Rated current 30 A
Max. output power 800 W
Efficiency > 86%
Battery types Freely ventilated lead batteries with
water filling, Valve-regulated (VR)
lead batteries
Protection class IP 20
Other Temperature regulated cooling fan
Protected against incorrect polari-
sation.
In order for chargers on trucks with

machine numbers from 936513- to
switch on, the battery voltage must
be between 19.8 and 34.7 V
17.3 Charging
WARNING!
Please note that when charging valve-regulated batteries (Evolution
A B type), the SMCI300 has been designed to charge batteries that are
used in normal room temperature, i.e. +15°C to +30°C. For other tem-
peratures, the charger must be loaded with different firmware, availa-
ble from the charger dealer.
Machine numbers 723984-936512

Connect the charger to the mains (B). A few seconds after charging
starts, the orange status indicator on the parking device (A) lights up.
This indicator remains lit until the battery has been fully charged, at
which time it changes colour to green.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
C
Troubleshooting and service
229102-040 2006-03-13 922602- 702
discharged freely ventilated 320 Ah battery may need up to 14 hours of

recharging, while a VR battery may require even longer time.
Once charging has been completed, after a certain time depending e.g.
on the battery type, the SMCI 300 switches to trickle charging. The
green indication remains lit to indicate the battery has been completely
charged.
Following completed charging, return the power plug to the parking
device (B).
Machine numbers 936513-

Connect the charger to the mains (B). Before charging starts, the bat-
tery type will be indicated for three seconds. Continuous green indica-
tion is used for valve-regulated batteries (Evolution type) and continu-
ous orange indication for freely ventilated batteries.
After this, the charger setting is indicated through a number of blinks
corresponding to the selected setting (see table on page 5)
Charging begins once the charger setting has been indicated. Charging
in progress is displayed by the orange status indicator lighting up next
to the parking device. This indicator remains lit until the battery has
been fully charged, at which time it changes colour to green.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
discharged freely ventilated 320 Ah battery may need up to 14 hours of
recharging, while a VR battery may require even longer time. A 201 Ah
Evolution battery, for example, may require up to 14 hours or recharg-
ing.
Once charging has been completed, after a certain time depending e.g.
on the battery type, the SMCI300 switches to trickle charging. The
green indication remains lit to indicate the battery has been completely
charged.
Following completed charging, return the power plug to the parking
device.
17.4 Troubleshooting and service

First check whether the charger indicates an error. A red blinking indi-
cator means that the charger has not detected any connected battery
or that a battery has not been set with the selection switch. Check the
switch position, cables, terminals and other battery connections. Meas-
ure the battery voltage.
If the charger still does not operate, contact the supplier for service.

Setting the charger (applies to machine numbers 723984-936512)
702 922602- 2006-03-13 229102-040
17.5 Setting the charger (applies to

machine numbers 723984-936512)
Freely ventilated batteries
Switch Battery size I2 current Max. current,

Output trickle charging
current
0 No charging (red LED lit) - - -
1 100-119 Ah 22 A 5.5 A 0.6 A
2 120-144 Ah 26 A 6.6 A 0.7 A
3 145-174 Ah 30 A 8.0 A 0.8 A
4 175-209 Ah 30 A 9.6 A 1.0 A
5 210-249 Ah 30 A 11.5 A 1.2 A
6 250-299 Ah 30 A 13.7 A 1.4 A
7 300-350 Ah 30 A 16.2 A 1.6 A
Valve-regulated batteries
Switch Battery size Output I2 current Max. current,

current trickle charging
8 No charging - - -
9 300-350 Ah 30 A 3.8 A 1.6 A
A 250-299 Ah 30 A 3.4 A 1.4 A
B 210-249 Ah 30 A 2.8 A 1.2 A
C 175-209 Ah 28 A 2.4 A 1.0 A
D 145-174 Ah 22 AA 1.9 A 0.8 A
E 120-144 Ah 18 A 1.5 A 0.6 A
F 100-119 Ah 15 A 1.3 A 0.6 A

229102-040 2006-03-13 922602- 702
17.5.1 Current levels at different charger

settings (applies to machine numbers
936513-)
Freely ventilated batteries
Switch Battery voltage Battery Battery Indica- Max. charg-

posi- type size tion ing current
tion = I1
0 No charging - - Continuous -
red
1 24 V Freely venti- 100-119Ah 1 blink, 22 A
lated Orange
2 24 V Freely venti- 120-144 Ah 2 blinks, 26 A
lated Orange
lated Orange
lated Orange
lated Orange
lated Orange
lated Orange
8 No charging - - Continuous -
red

702 922602- 2006-03-13 229102-040
Valve-regulated batteries (Evolution type)
Switch Battery voltage Battery Battery Indica- Max. charg-

posi- type size tion ing current
tion = I1
9 24 V Valve-regu- 134 Ah 1 blink, 23 A
lated green
A 24 V Valve-regu- 174 Ah 2 blinks, 30 A
lated green
B 24 V Valve-regu- 201 Ah 3 blinks, 30 A
lated green
C No charging - - Continuous -
red
D No charging - - Continuous -
red
E No charging - - Continuous -
red
F No charging - - Continuous -
red

TruckCom
General
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18- TruckCom
User Manual for trucks using the “PowerDrive” platform. This Manual is
valid for version 3.5 of TruckCom p/n 182147-008.
18.1 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 Microsoft® Win-
dows® 95/98, Microsoft® Windows® XP/2000 and Microsoft® Win-
dows® NT.
18.2 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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18.3 Layout
18.3.1 Main program screen

Information
Menu bar window
Tool
buttons
Nodes
Icons
Tool button bar
Fig. 11 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.
18.3.2 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. 12 A typical node window display

TruckCom
Layout
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18.3.3 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“18.7 Truck report function” on page 7
Parameters is shown when a node has information on a

parameter.
Diagnostics
Exit
18.3.4 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. 13 Tool button bar

TruckCom
Connection function
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18.3.5 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.
18.3.6 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.
18.4 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.
18.5 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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18.6 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
18.6.1 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.
18.6.2 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.

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Downloading program function
702 922602- 2006-03-13 229102-040
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.
18.6.3 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.
18.6.4 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).
18.6.5 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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18.7 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
702 922602- 2006-03-13 229102-040
18.8 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.
18.9 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
229102-040 2006-03-13 922602- 702
18.9.1 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
18.9.2 “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
702 922602- 2006-03-13 229102-040
18.9.3 “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
229102-040 2006-03-13 922602- 702
18.9.4 “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 18.9.3
• 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
702 922602- 2006-03-13 229102-040
18.9.5 “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
229102-040 2006-03-13 922602- 702
18.9.6 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.
18.10 Other menu functions
18.10.1 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>.
18.10.2 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
702 922602- 2006-03-13 229102-040
18.10.3 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>.
18.10.4 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>.
18.10.5 Reset hour meter

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

To show the truck’s error code log, select <Tools | Read error log >.
18.10.7 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.
18.10.8 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.
18.10.9 Help
About the TruckCom application
To see program information, select <Help | About TruckCom...> or use
the tool button [Information].
18.10.10 Exit
To exit the program, select <File | Exit > or use the tool button [Exit].

TruckCom
Specifications
229102-040 2006-03-13 922602- 702
18.11 Specifications
Table 22: 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
18.12 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.
18.12.1 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
702 922602- 2006-03-13 229102-040
18.12.2 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
229102-040 2006-03-13 922602- 702
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
702 922602- 2006-03-13 229102-040
• 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
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TruckCom
Installation
702 922602- 2006-03-13 229102-040
• 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
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18.12.3 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.
18.12.4 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.
18.12.5 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.

©TOYOTA Industrial Equipment
Europe SARL Ancenis, France

7SM12F 16D

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Service Manual

Order number: 229102-040

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

2- General product information – M2 ..................................................... 2-1

3- Technical data – M4 ............................................................................ 3-1

4- Introduction Maintenance – P1 .......................................................... 4-1

5- Preventive maintenance – P2 ............................................................. 5-1

6- Oil and grease specification – P3 ...................................................... 6-1

7- Tools – P4 ............................................................................................ 7-1

8- Support arms – 0350 ........................................................................... 8-1

9- Engine suspension– 0450 .................................................................. 9-1

© TIEE SARL Service Manual 7SM12F, 7SM16D 1- 1

10- Electric drive motor – 1760 ............................................................. 10-1

11- Drive unit/gear – 2550 ..................................................................... 11-1

12- Electro magnetic brake – 3370 ....................................................... 12-1

13- Steering – 4000 ................................................................................ 13-1

14- Electrical systems – 5000 ............................................................... 14-1

1- 2 Service Manual 7SM12F, 7SM16D © TIEE SARL

14.5 Parameters ................................................................................ 14-24

15- Hydraulic system – 6000 ................................................................. 15-1

16- Lifting mast – 7000 .......................................................................... 16-1

© TIEE SARL Service Manual 7SM12F, 7SM16D 1- 3

17- Battery charger (built-in) – 8340 ..................................................... 17-1

18- TruckCom ........................................................................................ 18-1

1- 4 Service Manual 7SM12F, 7SM16D © TIEE SARL

18.12 Installation.................................................................................. 18-15

© TIEE SARL Service Manual 7SM12F, 7SM16D 1- 5

This page is intentionally left blank

1- 6 Service Manual 7SM12F, 7SM16D © TIEE SARL

2- General product information – M2

2.1 Intended application of the truck

© TIEE SARL Service Manual 7SM12F, 7SM16D 2- 1

2.2 Prohibited application of the truck

2.3 Truck data – 7SM16D

Truck type 7SM16D

* Deviations may occur on trucks adapted to specific application; the

2- 2 Service Manual 7SM12F, 7SM16D © TIEE SARL

2.4 Truck data – 7SM12F

Truck type 7SM12F

* Deviations may occur on trucks adapted to specific application; the

© TIEE SARL Service Manual 7SM12F, 7SM16D 2- 3

2.5 Truck dimensions – 7SM16D

2- 4 Service Manual 7SM12F, 7SM16D © TIEE SARL

Measure, for 240 Ah battery space Value (mm)

© TIEE SARL Service Manual 7SM12F, 7SM16D 2- 5

2.6 Truck dimensions – 7SM12F

2- 6 Service Manual 7SM12F, 7SM16D © TIEE SARL

Measure Value (mm)

© TIEE SARL Service Manual 7SM12F, 7SM16D 2- 7

2.7 Identification plate

Item Text Unit

2- 8 Service Manual 7SM12F, 7SM16D © TIEE SARL

2.8 Capacity plate

Item Text Unit

2.9 Capacity plate for double pallet

Permitted max. Permitted max. Permitted min.

© TIEE SARL Service Manual 7SM12F, 7SM16D 2- 9

2.10 Modification plate

2- 10 Service Manual 7SM12F, 7SM16D © TIEE SARL

2.11 Main components