Repair Manual SWE080L Staxio

Repair manual en
SWE080L
Valid from serial number: 6061850
Order number: 258947-040

Issued: 2009-10-05 TP
© BT
Document revisions:
Issue Order Changes

date number
2008-11-01 258947-040 Brand new version.
2009-04-17 258947-040 Update
2009-10-05 258947-040 Chapter 4.4 New table and amendments to text in the chapter
Chapter 5.3 Measure added in "Maintenance schedule mast"
Chapter 6, amendments to text and values
Chapter 7, amendments to text and values
Chapter "9.3 Tightening torque drive motor" added
Chapter 15 New descriptions related to the repair of the tiller arm
Chapter 17 New text related to hygiene when working on hydraulics
Chapter "17.8 Tightening torque hydraulic unit" added
Various minor corrections throughout entire document
This manual contains information on the following trucks:
T-code Model Serial number

844 SWE080L 6061850
© BT Repair manual SWE080L

Contents
Order no. Date Valid from serial no. T-code
258947-040 2009-10-05 6061850 844
1 – Contents
2 – General introduction .......................................................................... 2-1
2.1 How to use the manual ................................................................... 2-1
2.2 Warning symbols ............................................................................ 2-2
2.3 Pictogram ....................................................................................... 2-2
2.3.1 Screws/nuts ...................................................................... 2-2
3 – General safety rules ........................................................................... 3-1

3.1 Safety while working....................................................................... 3-1
3.2 Electrical system............................................................................. 3-2
3.3 Safe lifting....................................................................................... 3-3
4 – Installation .......................................................................................... 4-1

4.1 General........................................................................................... 4-1
4.2 Battery installation .......................................................................... 4-1
4.2.1 Battery installation safety ................................................. 4-1
4.2.2 Install battery .................................................................... 4-2
4.3 Programming PIN codes ................................................................ 4-3
4.3.1 Standards for PIN codes .................................................. 4-4
4.4 Setting the parameters ................................................................... 4-5
4.4.1 Adjusting the parameters for collision sensor (option) ..... 4-6
Collision sensor parameters 105, 106 och 111 ................ 4-6
Programming PIN for resetting the truck .......................... 4-7
4.4.2 Adjusting the parameters for the battery and battery charger
4-7
4.4.3 Parameter 107 - battery size ............................................ 4-9
Free ventilated batteries ................................................... 4-9
Verifying the parameter adjustment for free ventilated
batteries (Lead/acid batteries) ........................................ 4-10
Verifying the parameter adjustment for valve controlled
batteries (Hawker/Exide) ................................................ 4-10
4.5 Function and safety check ............................................................ 4-11
5 – Maintenance ....................................................................................... 5-1

5.1 General........................................................................................... 5-1
5.2 Service intervals ............................................................................. 5-1
5.3 Maintenance schedule.................................................................... 5-2
6 – Functions and parameters ................................................................ 6-1

6.1 General........................................................................................... 6-1
6.2 Function description ....................................................................... 6-1
Symbols on key pads and display .................................... 6-2
6.3 Principle functions .......................................................................... 6-3
6.4 Timer .............................................................................................. 6-8
© BT Repair manual SWE080L 1– 1

Contents
T code Valid from serial no. Date Order no.
844 6061850 2009-10-05 258947-040
6.5 Parameters .................................................................................... 6-9

6.5.1 General ............................................................................ 6-9
6.5.2 Show parameters ............................................................ 6-9
6.5.3 Enter the parameters ..................................................... 6-10
6.5.4 Operator parameters ..................................................... 6-11
Factory installed driver parameters ............................... 6-12
6.5.5 Service parameters ....................................................... 6-13
6.5.6 Factory parameters ....................................................... 6-16
7 – Troubleshooting ................................................................................ 7-1

7.1 General .......................................................................................... 7-1
Software compatibility ...................................................... 7-1
7.1 Emergency travel mode ................................................................. 7-1
7.2 Troubleshooting methods .............................................................. 7-2
7.2.1 Troubleshooting general introduction .............................. 7-2
7.2.2 Completed troubleshooting .............................................. 7-3
7.3 Error code history........................................................................... 7-4
7.4 Error code system .......................................................................... 7-5
7.5 Error codes .................................................................................... 7-6
7.6 Troubleshooting diagram. ............................................................ 7-22
7.6.1 The truck cannot be driven ............................................ 7-23
7.6.2 The truck can only be driven at reduced speed ............. 7-24
7.6.3 The truck can be driven but behaves abnormally .......... 7-25
7.6.4 The truck can be driven but lacks certain functions ....... 7-25
Software compatibility .................................................... 7-25
Matrix for hardware compatibility ................................... 7-26
7.6.5 Faulty hydraulic functions .............................................. 7-26
7.7 Built-in test function...................................................................... 7-29
7.8 Status of digital inputs/outputs ..................................................... 7-30
7.8.1 Test function “9” – Transistor regulator ......................... 7-30
7.8.2 Test function “10” - Logic card ....................................... 7-33
7.8.3 Test function “12” – Expansion unit SEU (optional). ...... 7-34
7.9 Testing display function ............................................................... 7-35
8 – Chassis 0000 ...................................................................................... 8-1

8.1 General .......................................................................................... 8-1
8.2 Disassemble the drive unit from the fork frame .............................. 8-2
9 – Electrical drive motor 1700 ............................................................... 9-1

9.1 Components .................................................................................. 9-1
9.2 Disassemble engine and truck ....................................................... 9-2
9.3 Tightening torque Drive motor........................................................ 9-4
9.4 Fitting the tempreature sensor ....................................................... 9-4
9.5 Cleaning......................................................................................... 9-5
10 – Drive gear 2550 .............................................................................. 10-1

10.1 General ........................................................................................ 10-1
10.2 Components ................................................................................ 10-1
10.3 Removing the gear from the truck .. ............................................. 10-2
11 – Brake 3180 ..................................................................................... 11-1

11.1 Components ................................................................................ 11-1
11.2 Release of brakes ........................................................................ 11-2
1– 2 Repair manual SWE080L © BT

Contents
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12 – Drive wheel 3530 ............................................................................ 12-1

12.1 Changing drive wheel ................................................................... 12-1
13 – Castor wheel 3540 .......................................................................... 13-1

13.1 Components ................................................................................. 13-1
13.2 Castor wheel mounting................................................................. 13-2
13.3 Changing castor wheel ................................................................. 13-3
13.4 Changing castor wheel cradle ...................................................... 13-3
13.5 Changing springs.......................................................................... 13-3
13.5.1 Removing springs .......................................................... 13-3
13.5.2 Fitting the spring ............................................................. 13-3
14 – Support arm wheel 3550 ................................................................ 14-1
15 – Tiller arm 4000 ................................................................................ 15-1

15.1 Components in tiller arm............................................................... 15-1
15.2 Removing tiller arm....................................................................... 15-2
15.3 Changing gas spring..................................................................... 15-2
15.4 Changing the safety sensor .......................................................... 15-3
15.4.1 Dismantling .................................................................... 15-3
15.4.2 Assembly ........................................................................ 15-3
15.5 Components in tiller arm handle ................................................... 15-4
15.5.1 Removing the tiller arm handle ...................................... 15-5
15.5.2 Replacing the logic card ................................................. 15-5
15.5.3 Changing signal button/switch ....................................... 15-6
15.5.4 Changing raising/lowering button. .................................. 15-7
15.5.5 Changing push button .................................................... 15-7
15.5.6 Changing the position of the controls - support arm lift/fork lift
15-8
15.5.7 Changing a switch for safety reversing .......................... 15-9
16 – Electrical components ................................................................... 16-1

16.1 Changing wiring harness .............................................................. 16-1
16.1.1 Changing the transistor regulator's wiring harness. ....... 16-2
16.2 Replacing the transistor regulator................................................. 16-3
17 – Hydraulic system 6000 .................................................................. 17-1

17.1 General......................................................................................... 17-1
17.2 Hygiene when working on hydraulics ........................................... 17-2
17.2.1 Washing ......................................................................... 17-2
17.2.2 Packaging ...................................................................... 17-2
17.2.3 Handling ......................................................................... 17-2
17.2.4 Storage ........................................................................... 17-3
17.2.5 Carrying out work ........................................................... 17-3
17.3 Hydraulic unit 6100....................................................................... 17-4
17.3.1 Emptying the hydraulic tank ........................................... 17-5
17.3.2 Hydraulic system, bleeding ............................................ 17-5
Cylinders with bleeding valve ......................................... 17-5
Cylinders without bleeding valve .................................... 17-5
17.4 Hydraulic connections 6230 ......................................................... 17-6
17.4.1 Quick change connector ................................................ 17-6
Assembling the quick change connector ........................ 17-6
Dismantling the quick change connector ....................... 17-7

Contents
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17.5 Hydraulic calibration..................................................................... 17-8

17.6 Adjustment of the pressure limit valve.......................................... 17-9
17.7 Disassembling the hydraulic unit................................................ 17-11
17.8 Hydraulic unit tightening torques................................................ 17-13
18 – Lift mast – 7000 .............................................................................. 18-1

18.1 Main mast 7100 ........................................................................... 18-1
18.1.1 Components .................................................................. 18-1
18.1.2 Maintenance .................................................................. 18-2
Mounting ........................................................................ 18-2
The angle of the mast must be checked as per table .... 18-2
18.2 Fork carriage 7420 ....................................................................... 18-3
18.2.1 Maintenance .................................................................. 18-3
....................................................................................... 18-3
18.3 Main lift chain system 7120 .......................................................... 18-4
18.3.1 Checking the chain setting ............................................ 18-4
18.3.2 Inspecting the chain ....................................................... 18-4
Noise ............................................................................. 18-4
Surface rust ................................................................... 18-4
Rusty links ..................................................................... 18-4
Stiff links ........................................................................ 18-4
Bolt rotation ................................................................... 18-5
Loose bolts .................................................................... 18-5
Plate wear ...................................................................... 18-5
Elongation ...................................................................... 18-6
Damage ......................................................................... 18-7
Damaged plates ............................................................ 18-7
Damaged bolts .............................................................. 18-7
Dirty chain ...................................................................... 18-7
18.3.3 Cleaning ........................................................................ 18-7
18.3.4 Lubrication ..................................................................... 18-8
18.4 Changing the fork-lift trolley using an overhead crane or another truck
18-9
18.5 Changing the cylinder ................................................................ 18-10
18.6 Changing the stand .................................................................... 18-11
19 – Accessories ................................................................................... 19-1

19.1 Spider expansion unit .................................................................. 19-1
19.2 TLS - Truck log system ................................................................ 19-2
19.3 ID unit........................................................................................... 19-2
19.4 Toyota Wireless Information System T.W.I.S. ............................. 19-2
19.5 Automatic height preselector ....................................................... 19-2
19.6 Built-in battery charger ................................................................. 19-3
19.6.1 Technical data ............................................................... 19-3
19.6.2 Battery charging ............................................................ 19-4
Main charge ................................................................... 19-4
Uneven charging ........................................................... 19-4
Charging complete ........................................................ 19-4
20 – Appendices .................................................................................... 20-1

20.1 General ........................................................................................ 20-1
21 – Technical data ............................................................................... 21-1

21.1 SWE080L..................................................................................... 21-1
Contents
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22 – General tightening torque ............................................................. 22-1

22.1 General......................................................................................... 22-1
22.2 Galvanised non-oiled bolts ........................................................... 22-1
22.3 Untreated, oiled bolts.................................................................... 22-1
23 – Tools ............................................................................................... 23-1

23.1 MQS contacts ............................................................................... 23-1
23.2 AMP contacts ............................................................................... 23-3
23.2.1 AMP contacts Multilock series 040 ................................ 23-4
23.3 Molex contacts.............................................................................. 23-4
23.4 Grease guns ................................................................................. 23-5
23.5 Other tools .................................................................................... 23-6
24 – Oil and grease specification ......................................................... 24-1
25 – Electrical components and wiring diagram ................................. 25-1

25.1 Electrical components .................................................................. 25-1
25.2 Wiring diagram ............................................................................. 25-6
25.2.1 Index of symbols ............................................................ 25-6
25.2.2 Overview diagram .......................................................... 25-7
25.2.3 Wiring diagram ............................................................... 25-8
26 – Hydraulics chart ............................................................................. 26-1
27 – Instructions for disposal ............................................................... 27-1

27.1 General......................................................................................... 27-1
27.2 Marking of plastics........................................................................ 27-1
27.2.1 General marking of products and packaging ................. 27-1
27.2.2 Marking to BT Standard ................................................. 27-2
Abbreviations ................................................................. 27-2
Example of marking ....................................................... 27-2
27.3 Pressure vessels .......................................................................... 27-3
27.3.1 Gas damper ................................................................... 27-3
27.4 Sorting categories......................................................................... 27-4

Contents
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This page is deliberately left empty

General introduction
How to use the manual
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2 – General introduction
2.1 How to use the manual

The service manual is divided into chapters containing the following
information:
• Functions and parameters – This chapter contains a basic
description of the main functions of the truck and the control system
parameters
• Installation and initial operation – This chapter describes the work
that needs to be done before the truck is used for the first time
• Maintenance – This chapter contains a general periodic
maintenance schedule and a detailed description of the
maintenance to be carried out
• Troubleshooting – This chapter describes the error codes that
appear in the display when the truck completely or partly stops
working. The chapter also describes reasons why errors occur and
suggested remedies.
• Step by step – This chapter describes the various parts of the truck,
for example the hydraulic system, including what the parts look like
and the service activities that need to be carried out. The various
descriptions are organised according to BT's C-code system.
• Appendices – The appendices contain:
- instructions for disposal
- information about electrical components and wiring diagrams
- hydraulics diagrams
- list of required tools
- information about general tightening torques
- oil and grease specifications
- technical data.

General introduction
Warning symbols
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2.2 Warning symbols

The following warning symbols are used in the service manual:
DANGER!
DANGER! means there is a risk of potentially fatal accidents or
serious injury, as well as material loss or damage. Always
accompanied by the warning symbol.
WARNING!
WARNING! means there is a risk of damage to components that are
sensitive to electrostatic discharge.
Follow applicable ESD protection regulations.
NOTE!
The word NOTE means there is a risk of material loss or damage if the
instructions are not followed. Also used to draw attention to a non-
standard torque.
2.3 Pictogram
2.3.1 Screws/nuts
Wherever possible, pictograms have been used to describe certain
working operations.
Pictograms are primarily used for operations that require loosening or
tightening of screws:
×n
s mm
The pictograms contain information about the screw head type and
have arrows that show if the screw should be loosened or tightened.
Text beneath the pictogram provides additional information about
's': tool dimension, 'n': number of screws and, where necessary, 'T':
recommended tightening torque.

General safety rules
Safety while working
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3 – General safety rules

Only persons trained in servicing and repairing this type of truck are
qualified to carry out servicing and repair work.
3.1 Safety while working

To ensure that you work safely and to prevent accidents while working
on a truck, remember the following:
• keep the area where servicing activities are performed clean. Oil or
water will make the floor slippery.
• use the correct working position. Service activities often involve
kneeling or bending forward. Try sitting on a toolbox, for example, to
relieve the strain on your knees and back.
• loose articles and jewellery may become trapped in the moving parts
of the truck. Never wear loose articles or jewellery while working on
the truck.
• use well maintained tools that are intended for the work being
carried out.
• store and transport old oil according to applicable local regulations.
• do not flush solvents or similar that have been used for cleaning
down drains that are not intended for this purpose. Follow the local
disposal regulations.
• heated paint gives off harmful gases. Therefore remove the paint at
least 100 mm around the welding/grinding area using sanding
equipment or paint remover when welding or grinding a painted
area.

Electrical system
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3.2 Electrical system

When working on the electrical system of the truck, remember the
following:
• a short circuit may occur if metal objects come into contact with live
electrical connections. This can result in burns. Remove watches,
rings and other metal jewellery before starting work.
• always use insulated tools while working on the electrical system.
• always switch off the truck's power supply before opening the hoods
to the drive assembly and the electrical system.
• disconnect the battery when using electric welding equipment. The
welding current can enter and damage the battery.
• always remove the battery plug when carrying out maintenance on
the truck, unless the instructions in this repair manual state
otherwise.
• blow electric motors clean using compressed air.
• clean electrical panels, PCBs, contactors, contacts, magnetic
valves, etc., with a moist cloth and a cleaning agent.
Note!
Risk of short circuit that may damage electrical components.
Do not break the warranty seal on the PCBs.

Safe lifting
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3.3 Safe lifting
All lifting must be carried out on a flat, nonslip and stable surface. Avoid
freshly laid tarmac or tarmac at high daytime temperatures.
• When lifting the drive wheel, chock the other wheels so that the truck
stands still.
• Select the lifting points so that the lift is as easy as possible (one
corner at a time). If the truck has marked lifting points on the lower
part of the chassis, these should be used for a well-balanced lift.
• Ensure the area where you place the jack is clean and free of oil and
grease.
• Ensure there is no grease or oil on your hands or the jack lever.
• Use the lever supplied with the jack. If the lever is too short, it will
require more effort than is necessary. If the lever is too long there is
a risk that the jack will be overloaded.
• Place supports:
- as close to the raised part of the chassis as possible to reduce the
falling height if the truck tips over
- so that the truck cannot roll.
• Never place a support under the jack to increase the lifting height.
• Never work under a lifted truck without appropriate supports.
DANGER!
Risk of crushing – a poorly chocked truck may fall.
Never work under a truck that is not blocked with supports or secured
by a lifting device.

Safe lifting
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Installation
General
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4 – Installation
4.1 General
The chapter describes the work that has to be done before the truck is
put into operation.
4.2 Battery installation

4.2.1 Battery installation safety
Remember the following safety regulations before you begin working
with the battery:
• Gel batteries are only intended for use at room temperature with a
temperature interval of +15 to +30, otherwise there is a great risk
that the battery will be damaged and its lifetime reduced.
• Always use protective equipment to protect the eyes, face and skin
when you are inspecting, handling or filling batteries.
DANGER!
Battery acid causes burns. If your skin or clothing comes into contact
with battery acid, rinse the area immediately with cold water. If your
face or eyes come into contact with battery acid, rinse the area with
cold water and seek immediate medical attention.
• Ensure that there is a shower and an eye bath nearby in case an
accident occurs.
• A battery emits explosive gases. Never use naked flames or
anything else that could cause sparks close to a battery.
• Do not put tools or other metal objects on the battery. This can lead
to a short circuit or explosion.

Installation
Battery installation
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4.2.2 Install battery

The battery that is to be installed in the truck must be of the right size. A
battery that is too small in terms of size and weight can seriously affect
the truck's braking ability and stability when lifting. See the truck's data
plate for correct information about the battery.
1. Lift the battery into place using an approved lifting device and a
suitable battery yoke or lifting straps.
DANGER!
The battery may fall when the lifting device is loosened if it has not
been secured with an axle stand or other similar suspension gear of
the right height. Check the height of your suspension gear before
loosening the lifting yoke.
2. Check the electrolyte level in the battery. This should normally be
10-15 mm above the cell plates.
3. Connect the battery cables/battery sleeve.
DANGER!
Always check that you have the right polarity when connecting the
battery cables. Compare the markings on the cables with the
markings on the battery terminals. A wrongly connected battery may
cause a short circuit.
4. Close the battery lid.
5. Put the battery connector back.
6. Check or enter the parameters for the battery and battery charger.
See the section Adjusting battery and battery charger parameters
in this chapter.
7. Function test the truck before using it.

Installation
Programming PIN codes
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4.3 Programming PIN codes

The majority of PIN codes can be made available by activating the so-
called block. Block 0 (zero) is activated as standard, which means that
3 driver profiles can be used from the start. Activating the second block
makes all PIN codes for that block accessible. If all 10 blocks are
activated, 10 PIN codes become available for the driver profile.
The truck programme stores a standard set PIN code according to the
table "Standard assignment of PIN codes". These PIN codes may be
changed to a chosen value, but PIN codes that exist for other driver
profiles should be avoided.
There are two alternative methods for programming PIN codes. The
first and simplest is to use TruckCom where it clearly shows what to do.
See the separate manual for using TruckCom.
The other alternative is to use the truck's keypad.
Carry out the following to start the programming:
1. Connect the CAN service key to socket [X41].
2. State code 341671 and press the ON button.
3. Choose the programming code from the table below:
Function Programming Remark

Return to factory settings. Press 1 + ON button Block 1-9 is
deactivated. The
original PIN codes
are reset according
to the table for
standard
assignment of PIN
codes.
PIN codes in the block can be Press 2 + b + ON button B = Block 0-9
used.
PIN codes in the block cannot Press 3 + b + ON button B = Block 0-9
be used.
Programming new PIN codes Press 4 + b + P + NNNN + ON button B = Block 0-9
Note! P = Driver profile 1-
The block that applies must be activated 10
first (see function 2 above in the table). NNNN = PIN code
Note!
You may only state
one number per
driver profile. Driver
profile 10 must
therefore be stated
as 0 (zero).

Installation
Programming PIN codes
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4. Turn off the truck by pressing the OFF button.

Programming the PIN codes is now finished. Verify that the
programming is correct by logging in with some of the new PIN
codes.
Note!
It is important to establish that the correct driver profile is activated
when a certain PIN code is stated. This especially applies when a
driver profile is set up for a specific application.
4.3.1 Standards for PIN codes

The table below shows the PIN codes that are found as standard in the
programme. The PIN codes can be activated or changed according to
the driver's wishes. A driver profile is activated with the normal log in of
all PIN codes, whose block number is activated.
The truck programme does not permit a login using the PIN code 0000.
Note!
It is recommended that service personnel keep notes about activated
blocks, changed PIN codes and specially adjusted driver profiles.
Standard assignment for PIN codes

Driver 1 2 3 4 5 6 7 8 9 10
profile Note!
no. Stated
as 0
Block 0 0001 0002 0003 0000 0000 0000 0000 0000 0000 0000
Block 1 7901 1437 3731 1049 9439 7265 1322 2869 1574 5421
Block 2 4854 2907 9175 5799 1490 3031 7392 5622 5023 1787
Block 3 3174 1026 3815 6703 1179 5152 7514 5668 3215 4659
Block 4 7110 5477 3846 9491 5918 8222 6923 8139 7025 9197
Block 5 6276 9879 9658 1690 4042 5201 9807 4332 9715 2549
Block 6 4142 8620 3754 8432 8788 7430 1948 2595 8527 7474
Block 7 1482 7135 2395 7365 7092 4611 2831 4185 6067 1930
Block 8 4731 1022 5377 3257 7334 9009 7881 8843 7436 2876
Block 9 3162 5878 2828 1910 6907 2136 5730 2957 7691 3242

Installation
Setting the parameters
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4.4 Setting the parameters

The parameters that are handled in this chapter are only the
parameters that need to be adjusted when putting the truck into
operation and that require more detailed description. For more
information about parameters, see the chapter Functions and
parameters.
Check that parameters are adjusted to desire values with regards to
• maximum speed, driver parameter - see chapter Functions and
parameters
• acceleration, driver parameter - see chapter Functions and
parameters
• internal braking, driver parameter - see chapter Functions and
parameters
• Collision sensor (option)
• battery
• battery charger (option)
Note!
When you check or adjust parameters, remember to write down, in a
truck report for example, the truck's specific parameter values.
Separate information about the truck specific parameters are good to
have e.g. in case of truck breakdown, since the information cannot be
received in another way.

Installation
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4.4.1 Adjusting the parameters for collision

sensor (option)
This parameters for collision sensitivity must be adjusted on truck
installation.
If a collision sensor is installed on the CAN bus, this registers when the
truck knocks against something. If a knock exceeds a certain level,
indicated by parameters 105 and 106, this is calculated as a collision
and the truck's speed is reduced to creep speed, a signal sounds and
error code 8.001 is shown on the display.
Information about the collision is stored in the truck's internal memory.
The last ten registered collisions can be read directly on the display and
the driver's identity can also be read via the PIN code. Other
information is received via TruckCom where the collision levels and
times can also be seen.
Collision sensor parameters 105, 106 och 111

See the table below for information about the values that can be stated:
Service parameters
Parameter Name/unit Min/ Step Std Description
Max
105 Collision 0/100 1 0 States the degree
sensor of sensitivity for
X level what should be
interpreted as a
collision for a
shock to the side.
106 Collision 0/100 1 0 States the degree
sensor of sensitivity for
Y level what should be
interpreted as a
collision for a
shock to the front
or back.
111 Resetting 0/1 1 0 0 = Special
following a pincode required
collision for resetting after a
collision.
1 = The truck can
be reset using all
activated pincodes.
Note!
If you set the parameter value for the collision sensor at 0 (zero) this
means that the collision sensor and the log function are turned off.

Installation
258947-040 2009-10-05 6061850 844
Programming PIN for resetting the truck

When the truck has stopped after a collision, the truck must be reset by
entering a special PIN code. This PIN code must be programmed by a
service technician at installation.
The PIN that is activated is found in driver profile 1 and special block
10. The PIN code has a standard value 0000, which must be changed
to a chosen PIN code by a service technician.
Note!
The PIN code must not contain the same number combination as any
of the preprogrammed PIN codes.
4.4.2 Adjusting the parameters for the battery

and battery charger
The following parameters must be adjusted or checked on battery
installation.
NOTE!
Even if the battery comes with the truck from the factory, the
parameters must be adjusted or checked.
NOTE!
Ensure that service parameter 109 is set to the value of the battery
fitted, and that the correct battery capacity has been set in parameter
110.
NOTE!
Only 134 Ah, 174 Ah and 201 Ah battery sizes may be used when
using a Hawker Evolution battery.

Installation
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Parameter Name/unit Min/ Step Std Description

Max
107 service Battery 1/20 1 9 13 = Medium battery
parameter adjustment, Ah 17 = Small battery
For more information, see the text
below the table. See
section“4.4.3 Parameter 107 - battery
size”.
109 service Battery 0/3 1 0 State battery type
parameter charger, 0 = No charge. Standard type. Error
battery type code is displayed if this parameter is
set at 0 when there is a battery charger
and factory parameter 1101 is set at 1.
1 = Lead/acid battery
2 = Hawker Evolution battery. Sizes
134 Ah, 174 Ah, 201 Ah
3 = Exide GEL battery
110 service Built-in battery 0/300 1 0 Determines the battery capacity.
parameter charger, (100/ (100) 0 (100) = No charge. Default setting.
battery 300) An error code is displayed if this
capacity, Ah parameter has been set to 0 (100)
when a battery charger has been
installed and factory parameter 1101
has been set to 1.
The values in brackets () apply if the
truck has software version -006 or later.
1101 factory Built-in battery 0/1 1 0 0 = No battery charger
parameter charger 1= Battery charger present
NOTE!
If factory parameter 1101 has been set to 0 (zero), service parameters
109 and 110 should also be set to 0 (zero). If the truck has software
version -006 or later, and if the factory parameter 1101 has the value 0
(zero), service parameter 109 must have the value 0 (zero) and 110
must have the value 100 (one hundred). The values of service
parameters 109 and 110 only need to be changed if the truck is
equipped with a built-in charger and the value of factory parameter
1101 has been set to 1.

Installation
258947-040 2009-10-05 6061850 844
4.4.3 Parameter 107 - battery size

You must state which type of battery the truck is equipped with. To
adjust the meter for battery charge level, consideration must be given
to the following:
• Acid concentration when the battery is fully charged, in order to
check the battery's quality. The value should lie between 1.27-1.29.
Note that the acid concentration can vary depending on the make of
battery.
• When the lifting capability is disconnected (the battery is discharged
to 80 %) the value should be close to 1.14 but no lower.
Free ventilated batteries
See the table below for the recommended parameter settings.
Parameter 107 Battery size Battery size Battery size
Lead/acid battery Hawker Evolution Exide
1
2
Lower discharge 3
4
5
6 271-280 Ah 271-290 Ah
7 251-270 Ah 251-270 Ah
8 231-250 Ah 231-250 Ah
9 286-320 Ah 211-230 Ah 211-230 Ah
10 251-285 Ah 191-210 Ah 191-210 Ah
11 221-250 Ah 171-190 Ah 171-190 Ah
12 206-220 Ah 151-170 Ah 151-170 Ah
13 191-205 Ah 131-150 Ah 131-150 Ah
14 176-190 Ah 120-130 Ah 110-130 Ah
15 161-175 Ah
16 146-160 Ah
17 131-145 Ah
Deeper
discharge 18 115-130 Ah
19
20
DANGER!
The battery's service life will be reduced if the value of parameter 107
is set to a value that is too high. The standard adjustment of
parameter 107 is set for normal handling of the truck. Other
applications may require a different adjustment of parameter 107.
Check that the parameter adjustment is right using the instructions
below.

Installation
844 6061850 2009-10-05 258947-040
Verifying the parameter adjustment for free

ventilated batteries (Lead/acid batteries)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator
shows a discharged battery (0% on the display).
3. Disconnect the battery from the truck and let the battery rest for at
least two hours.
Note!
Do not charge or discharge during this time.
4. Measure the acid weight of the battery at room temperature.
If the acid weight is under 1.15 g/cm3, the parameter must be

reduced. A value substantially above 1.15 g/cm3 reduces the risk of
damage to the battery. At the same time the operating time of the
truck is reduced. If a longer operating time is desired, the
parameter value can be increase by up to one unit.
Note!
Each change must be followed by renewed verification of the
parameter setting.
Verifying the parameter adjustment for valve

controlled batteries (Hawker/Exide)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator
shows a discharged battery (0% on the display).
3. Disconnect the battery from the truck and let the battery rest for at
least two hours.
Note!
Do not charge or discharge during this time.
4. Measure the voltage of the battery at room temperature.
If the voltage is under Uend (see table below) the parameter value
must be reduced. A value substantially above Uend reduces the
risk of damage to the battery. At the same time the operating time
of the truck is reduced. If a longer operating time is desired, the
parameter value can be increase by up to one unit.
Note!
Each change must be followed by renewed verification of the
parameter setting.
Battery type Battery voltage at rest, Uend

Hawker Evolution/Exide 24.24 V
4 – 10 Repair manual SWE080L © BT

Installation
Function and safety check
258947-040 2009-10-05 6061850 844
4.5 Function and safety check
a,e b c
d
g
n
03272.wmf
m
j
h
p
o
j
Before the truck is put into operation, the following points must be
checked.
Pos. Inspection point Action Duration scale

a Operating control Check function 2:25 minutes
b Safety reversing switch Check function
c Horn Check function
d Steering Check function
e Brake Check function
f Emergency switch Check function
g Hydraulic system Check all components
h Drive unit Investigate possible noises and oil leaks
j Wheel Investigate damage, remove dirt etc.
k Chassis Investigate damage, remove dirt etc.
m Battery cover and lock Check function
n Battery Check acid and charging level
o Fork carriage Investigate damage, remove dirt etc.
p Support arms Investigate damage, remove dirt etc.
q Mast Investigate damage, remove dirt etc.
© BT Repair manual SWE080L 4 – 11

Installation
Function and safety check
844 6061850 2009-10-05 258947-040

Maintenance
General
258947-040 2009-10-05 6061850 844
5 – Maintenance
5.1 General
This chapter contains a general periodic maintenance schedule and a
more detailed description of the maintenance to be carried out.
5.2 Service intervals

The service intervals are for guidance only and do not need to be
followed strictly. The service technician must adapt these to local
conditions, but it is important that the intervals meet BT's minimum
demands.
The service intervals are based on the operating times and can be
adapted to most normal 8 hour shifts. The following operating hours
have been used when calculating the interval:
Daytime: 08.00-17.00 (20 h/week)
2 shifts: 06.00-14.00, 14.00-22.00 (40 h/week)
3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 h/week)
Ensure the truck receives a regular maintenance service after every
750 driving hours. The truck's safety, efficiency and service life is
dependent on the service and maintenance it receives.
When service is completed, the truck must be test driven and a function
check must be carried out. See the section Function and safety check
in the Installation chapter.
Only use BT approved spare parts during servicing and repairs.

Maintenance
Maintenance schedule
844 6061850 2009-10-05 258947-040
5.3 Maintenance schedule

Service maintenance must happen at continuous intervals of 750 h or
12 months, depending on whichever comes first.
The sequence shown in the maintenance chart is not the optimised
working plan and is only sorted according to ‘C’ codes.
Work area Pos. Action 750h/12m Time

used
0000 Chassis a Check hood attachments. X 5:20
b Check signs and decals. X minutes
including
c Check for cracks and damage. X hood
d Check the mast fixing bolts. X removal.
e Check for cracks and damage X
to the motor fixing points.
f Tighten the paper holder ten- X
sioner if necessary
b
b
b
Qmax XXXX kg
b
a
d
b
f
b
03273.wmf
b
e A
B
b b
C
M-PLATE
c
D
E A
E B
F C D
*M-plate to be fixed to specially manufactured trucks only.

Maintenance
258947-040 2009-10-05 6061850 844

used
0350 Support arm a Check for cracks and damage. X 01:30:00
b Check the play in bushings X minutes.
and links.
c Check for cracks and damage X
to the push rods.
d Check all axles, links and X
locking pins.
f
03274.wmf
a
e
d c
b
d
b

used
0380 Fork carriage e Check for cracks and damage. X 01:30:00
f Check play in rollers. X minutes.
g Check the load support X

(Option).

Maintenance
844 6061850 2009-10-05 258947-040

used
1700 Drive a Check the drive motor's X 4:30
motor attachment. minutes.
b Clean the drive motor. X
c Check for noise from the drive X
motor's bearings.
2550 Drive d Check for abnormal noise X
gear e Check the mountings and play in X
the steering bearings.
3180 Brake f Check for wear on the brake disc. X
Minimum brake disc thickness:
7.9mm
g Check play in released position. X
Nominal brake play: 0.3mm
h Cleaning brakes. X
03276.wmf
h
f,g
b,c
a
e
d

Maintenance
258947-040 2009-10-05 6061850 844

used
3500 Wheel a Check for wear on the drive wheel. X 2
b Check the nuts. X minutes
c Check for wear on the castor wheel. X
d Check for wear on the support arm wheel. X
e Check that the castor wheel rotates freely X
03277.wmf
c
e b a H
Wheel Normal size, mm Min size, mm

Drive wheels 30 15
Castor wheel 10 5
Support arm wheel 11 5,5

Maintenance
844 6061850 2009-10-05 258947-040

used
4110 Tiller arm a Check the mountings. X 01:45:00
b Check the mounting of X minutes
the operating console.
c Check the mounting of X
the handle.
d Check the gas X
suspension's force and
locking.
The tiller arm should
return to the top position
from both the bottom
position and from the
lower position where the
brake is activated.
Check that the braking
function is activated in
both upper and lower tiller
arm positions.
c
03282.wmf
d
b

Maintenance
258947-040 2009-10-05 6061850 844

used
5000 Electrical a Check the contacts, wiring X 04:30:00
system harness (including battery minutes
cables), cable insulation
and that all cables are
running freely.
b Check the contactors' X
function.
c Check error code log, X
operating times and all the
segments on the display.
d Clean and check that there X
is no play between the
steering box and the heat
dissipation plate.
e Check and tighten the cable X
connections.
f Check all switches and X
sensors.
f
03278.wmf
b
a,e

Maintenance
844 6061850 2009-10-05 258947-040

used
6000 Hydraulic a Check wear on hoses and pipes. X 16
system b Check oil level X minutes
Recommended range for oil level with
lowered forks, see picture
c Check the mountings of the hydraulic X
unit.
d Check for any leaks in the hydraulic X
system.
e Change the oil and clean the oil tank. X
NOTE: First time after 750 h/12 m,
then after 4,500 h/36 m.
f Clean the oil strainer. X
NOTE: First time after 750 h/12 m,
then after 4,500 h/36 m.
6600 Lift cylinder g Check lift cylinder for leaks. X
h Check the mounting of the lift cylinder. X
j Check the lift cylinder for leaks X
(support arm lift)
k Check the mounting of the cylinder X
(support arm lift)
20 mm
g,h b
j,k
03283.wmf
a,c,d,e,f

Maintenance
258947-040 2009-10-05 6061850 844

used
7100 Mast a Check for any cracks or damage. X 16 min-
b Check that there is no play in the mast's X utes
mounting points.
c Check the inner runner's side play. x
d Check for wear on lifting chains and 500h
sprockets. See section “18.3 Main lift chain
system 7120”.
e Check adjustment of lifting chains. See 500h
section “18.3 Main lift chain system 7120”.
Lubricate the inside surfaces of the beam X
flanges.
Lubricating the beam

1 The inner sides of the beam flanges must be lubricated with
BT part no. 223690
(Q8 Rembrandt EP2). b
d
03284.wmf

Maintenance
844 6061850 2009-10-05 258947-040

Functions and parameters
General
258947-040 2009-10-05 6061850 844
6 – Functions and parameters
6.1 General
The chapter "Functions and parameters" provides a basic description
of the truck's main functions and the control system's parameters.
6.2 Function description

The section Function description gives a basic description of the truck's
main functions.
• Event – the use of any of the truck's main functions are called
events. All events are indicated using a figure.
• Preceding event – Indicates an event that must have happened
immediately before the current event in order for this to be carried
out correctly.
• Action(s) – An action that the driver must perform in order for an
event to happen.
• Influencing factors – Conditions that must be fulfilled in order for an
event to happen. Certain parameter settings also influence the
event's outcome.
• Resulting conditions - Describe the key events that can be checked
in order to confirm a function.
Note that the resulting conditions are showing what is assumed to
happen when there are no errors.
Text within square brackets [ ] refers to the electrical component names
in the truck's wiring diagram.
{High} means ≈ 24 V and {low} ≈ 0 V unless otherwise stated.

Function description
844 6061850 2009-10-05 258947-040
Symbols on key pads and display
Symbol Description
ON button
This button is used to both start the truck
and to confirm settings
OFF button
Error code
Battery charge as a percentage
Parameter
Timer

Principle functions
258947-040 2009-10-05 6061850 844
6.3 Principle functions
Event: 1. The battery is connected

Action(s) Connect the truck battery [G1]
Contributing Main fuses OK [F1]
factors Working fuses OK [F50, F51]
Resulting The status LED for the transistor regulator remains lit [T1].
conditions
Event: 2. Start truck
Preceding event(s) The battery is connected.
Action(s) Enter a valid PIN code and press the ON button on the keypad [S223].
Contributing Emergency stop [S21] is not active [T1:INP. SUPPLY+24V DC] {high}.
factors
Resulting The current lamp shines. The main display shows the counter for 4
conditions seconds and then shows the battery's charge condition as a percentage of
its full charge.
The mechanical brakes remain connected [Q1] [T1:OUT.BRAKE
RELEASE] {high}.
Event: 3. Fold down tiller arm to drive position
Preceding event(s) Start the truck.
Action(s) Lower the tiller arm.
Contributing Sensor for tiller arm in drive position [B60].
factors
Resulting Sensor for tiller arm in drive position is activated [B60] [T1:INP. TILLER
conditions ARM IN DRIVE POS] {low}.
The main contactor's output voltage becomes {low} [T1:OUT. MAIN
CONTACTOR]
The main contactor is closed [Q10].

Principle functions
844 6061850 2009-10-05 258947-040
Event: 4. Running in fork direction

Preceding event(s) Fold down tiller arm to drive position.
Action(s) Turn the speed control in the fork direction
Contributing Speed control with Hall-sensor [A5:S10-18].
factors Settings in the driver parameters 4, 5 and 6 affect the drive performance
Resulting [T1:OUT.BRAKE RELEASE] becomes {low}.
conditions The brake [Q1] is activated, the mechanical brake is released.
The pulse current feed to the drive motor is proportional to the speed
control's torsion.
Event: 5. Running in the castor wheel's direction
Preceding event(s) Fold down tiller arm to drive position.
Action(s) Turn the speed control in the castor wheel's direction
Contributing Speed control with Hall-sensor [A5:S1-9].
factors Settings in the driver parameters 4, 5 and 6 affect the drive performance
Resulting [T1:OUT. BRAKE RELEASE] becomes {low}.
control's torsion.
Event: 6. Neutral braking
Preceding Running in the fork or castor wheel direction
event(s)
Action(s) Let the speed control go back to the free position.
Contributing Adjust driver parameter 5.
factors
Resulting The drive motor [M1] works as a generator and via the transistor regulator
conditions [T1] converts the truck's kinetic energy into electricity, which causes the
truck to brake. The excess energy, in the form of electricity, is fed back to
the battery [G1] which is then charged. The mechanical brake [Q1] is
activated when the truck stops. [T1:OUT.BRAKE RELEASE] becomes
{high}.

Principle functions
258947-040 2009-10-05 6061850 844
Event: 7. Reverse braking

Preceding event(s) Running in the fork or castor wheel direction
Action(s) The speed control is turned to the other driving direction.
Contributing Parameter 201.
factors
Resulting The drive motor [M1] works as a generator and via the transistor regulator
conditions [T1] converts the truck's kinetic energy into electricity, which causes the
truck to brake. The excess energy, in the form of electricity, is fed back to
the battery [G1] which is then charged. The braking effect increases the
more the speed control is turned.
The mechanical brake [Q1] [T1:OUT. BRAKE RELEASE] is activated
when the truck stops.
Event: 8. Mechanical internal braking
Preceding event(s) Running in the fork or castor wheel direction
Action(s) The tiller arm is folded completely up or down.
Contributing Sensor for tiller arm in drive position [B60].
factors
Resulting Sensor for tiller arm in drive position [B60] deactivated [T1:. INP. TILLER
conditions ARM IN DRIVE POS] {low}.
When the tiller arm is folded completely up or down, this applies the
highest permitted braking reduction at 200 ms or until the drive speed is
lower than 0.8 m/s. Then the mechanical brakes are activated [Q1].
[T1:OUT.BRAKE RELEASE] {high}.
Event: 9. Anti-collision safety switch
Preceding event(s) Running in the castor wheel's direction.
Action(s) When running in the castor wheel's direction, press in the anti-collision
safety switch [A5:S17].
Contributing Safety switch [A5:S17].
factors
Resulting The hall sensor [A5:S17] is activated directly. The logic card [A5] interprets
conditions this signal as a command to the transistor regulator [T1] to run the drive
motor at reduced speed in the fork direction as long as the anti-collision
safety switch [A5:S17] is depressed. The command signal for normal
running of the drive motor from the speed control is blocked until the speed
regulator is released and returnes to the neutral position.
Event: 10. Fork lift
Action(s) Press the button for fork lift [A5:S19].
Contributing Main contactor [Q10].
factors Fuse [F1].
Fork lift button [A5:S19].
Battery status OK (battery's discharge i

Principle functions
844 6061850 2009-10-05 258947-040
Resulting [T1:OUT. PUMP CONTACTOR] becomes {low}

conditions [T1:OUT.FORK.VALVE] becomes {low}, the magnetic valve [Q22] opens.
The pump contactor [Q25] closes, the pump motor [M3] starts.
Event: 11. Fork lower
Preceding event(s) Start the truck or fork lift.
Action(s) Press the button for fork lowering [A5:S20].
factors Button for fork lowering [A5:S20].
Magnetic valve [Q22]
Resulting [T1:OUT. PROP VALVE] becomes {low}, the proportional valve [Q4]
conditions opens.
[T1:OUT.FORK.VALVE] becomes {low}, the magnetic valve [Q22] opens.
Event: 12. Support arm lift
Action(s) Press the support arm lift button [A5:S21].
factors Fuse [F1].
Support arm lift button [A5:S21].
Battery status OK (battery's discharge indicator > 0 or battery charge >
20 %).
Resulting [T1:OUT.SUPPORT ARM VALVE] becomes {low}, the magnetic valve
conditions [Q23] opens,
[T1:OUT. PUMP CONTACTOR] becomes {low}.
The pump contactor [Q25] closes, the pump engine [M3] starts.
Event: 13. Support arm lower
Preceding event(s) Start the truck or support arm lift.
Action(s) Press the button for support arm lower [A5:S22].
factors Button for support arm lowering [A5:S22].
Resulting [T1:OUT.SUPPORT ARM VALVE] becomes {low}, the magnetic valve
conditions [Q23] opens,
[T1:OUT. LOWER VALVE] becomes {low}, the proportional valve [Q4]
opens.
Event: 14. Click-2-Creep
Preceding Start the truck.
event(s)
Action(s) Quick double operation of speed control in order to activate the function.
Put the tiller arm in the upright position and drive the truck at low speed
(2.5 km/h).
factors Adjusting factory parameter 1002.

Principle functions
258947-040 2009-10-05 6061850 844
Resulting [T1:OUT.BRAKE RELEASE] becomes {low}.

control's torsion. “SLO” is shown on the display (blinking).
Event: 15. Turtle function (option)
Preceding Fold down tiller arm to drive position.
event(s)
Action(s) Press [S206] to activate the function.
Turn the speed control in one direction.
Contributing Option button 1 [S206].
factors Adjusting driver parameter 7 and service parameter 202.
Resulting [T1: OUT. BRAKE RELEASE] becomes {low}.

control's torsion. The maximum speed is limited by driver parameter 7.
“SLO” is shown on the display (shines constantly).

Timer
844 6061850 2009-10-05 258947-040
6.4 Timer
When the truck is started, the timer is shown on the display and the time
measurement symbol shines for 4 seconds.
The truck's control system stores five different time values. The time
values are controlled by parameter 103. To choose which value should
be shown, follow the instructions below.
1. Ensure that the battery is connected.
2. Ensure that the truck is turned off. Press the OFF button.
3. Punch in the chosen PIN code. Note! Without pressing the ON
button.
4. Keep the horn button pressed down until "H" appears, and then
release the button. The time measurement symbol shines.
The different time measurement symbols are shown when you press
repeatedly on the speed control. The current time values are shown for
a short time after the setting has been chosen.
Time measurement value Display

Value 1 = Key time
The total time that the truck has been in use.
Value 2 = Operating time

The combined time during which the pump or drive motor has
been in operation.
Standard display.
Value 3 = Drive motor time
The total time that the drive motor has been in use.
Value 4 = Pump engine time

The total time that the pump engine has been in use.
Value 5 = Time remaining until service.

Parameter 101 controls the output value.

Parameters
258947-040 2009-10-05 6061850 844
6.5 Parameters
6.5.1 General
The truck's control system stores a number of parameters. These
parameters are used to configure the truck for the right function with
regards to environment and application. The parameters are divided up
into three groups.
• Driver parameters – Adjusts the driving properties in the truck to a
certain driver or application. Driver parameters can be changed
directly without a CAN service key.
• Service parameters – Used to adjust the truck's function
properties. Service parameteters can only be adjusted using a
suitable CAN service key that is connected to the truck. Note that the
service parameters can be checked without a CAN service key
having to be connected, but the values cannot be changed.
• Factory parameters – Parameters that are entered during
production in the factory and may, if specific needs arise, be
changed by service technicians. The parameters state e.g. the truck
model and which controls to use for the hydraulic function. The
factory parameters cannot be changed via the CAN service key.
All parameters can be changed via PC/PDA and TruckCom.
6.5.2 Show parameters

If you only want to see the truck's different settings, use the following
instructions:
1. Connect the CAN key or press in the PIN code and then press on
the horn button and keep it pressed in.
The display shows:
- Operating times and remaining time to the next service (H)
- Error codes (E)
- Parameters (P)
- The hardware and software numbers (Pn)
- Display test function (d)
- Collision sensor log (c)
- Emergency (limp home) mode (ed)
- Calibrating (CAL), Shortcut for setting parameter 108 = 1
2. Release the horn button to select what you wish to view.
3. Turn the speed control to move between the different positions in
the function above.

Parameters
844 6061850 2009-10-05 258947-040
6.5.3 Enter the parameters

To enter the parameters, use the following instructions:
1. Connect the CAN key or press in the PIN code and then press on
the horn button and keep it pressed in. Release the horn button
when the display shows “P”.
The parameter symbol remains lit.
2. Turn the speed control to move between parameters. Release the
control when the display shows the correct parameter number.
3. Press once on the horn button to change the value.
The parameter symbol starts blinking.
4. Change the value by turning the speed control.
5. Confirm the setting by pressing once more on the horn button.
The parameter symbol lights again, and stays on.
6. Complete the programming by pressing the OFF button.

Parameters
258947-040 2009-10-05 6061850 844
6.5.4 Operator parameters

Note!
Changing specific truck parameters changes the trucks driving
properties. Do not change any parameter values without the relevant
prior knowledge.
Parameter Name/unit Min/Max Step Std Description

4 Acceleration, % 10/100 5 70 States the truck's
acceleration capacity.
Note that the lower the
parameter value, the
longer it takes for the truck
to reach its maximum
speed.
5 Internal 10/100 5 90 States the engine's
braking, % internal braking force
when the speed control is
in neutral. The lower the
parameter value, the lower
the internal braking time.
6 Maximum 30/100 5 90 States the trucks
speed, % maximum speed.
7 Maximum 30/100 5 50 States the truck's
speed turtle maximum speed when the
function, % turtle function is activated.

Parameters
844 6061850 2009-10-05 258947-040
Factory installed driver parameters

Different driver profiles have different values input from the factory for
driver parameters 4, 5 and 6. See the table below.
The values for driver profiles 1 and 4-10 apply as standard values.
Driver Parameter Factory PIN

profile setting code
Driver profile 1 4 70 1
5 90
6 90
5 90
6 80
5 100
6 100
Note!
When changing software, the factory settings for driver profiles 2 and
3 disappear. All driver profiles are then given the same standard
values, i.e. the standard values for driver profiles 1 and 4-10. If you
want to restore the factory settings, the values must be stated again,
either manually or via PC/PDA.

Parameters
258947-040 2009-10-05 6061850 844
6.5.5 Service parameters

NOTE!
Changing specific truck parameters changes the trucks driving
properties. Do not change any parameter values without the relevant
prior knowledge.
NOTE!
Parameter 201 must be set at a value that is as great or greater than
the value in parameter 5. If the value in any of the parameters is
changed so that the value in parameter 201 becomes less than the
value in parameter 5, the value in parameter 201 is automatically set
at 100. When the parameter value changes automatically, the error
code 2.002 is generated.
NOTE!
Ensure that service parameter 109 is set to the value of the battery
fitted, and that the correct battery capacity has been set in parameter
110.
NOTE!
Only 134 Ah, 174 Ah and 201 Ah battery sizes may be used when
using a Hawker Evolution battery.
The CAN service key must be connected to the contact [X41] before
adjustment of the service parameters can be carried out.
Param Name/unit Min/ Step Std Description

eter Max
101 Service interval, 0/ 50 0 States a limit when the next service should
hours 2000 take place. When it is time for service, the
error code 2.003 is shown in the display.
0 = Service indicator off.
102 Driver access 1/10 1 3 States which login method should be used
and if the driver will have the possibility to
change the driver parameter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad using 100 PIN
codes
Values 5 and 6 = Keypad using DHU
Values 7 and 8 = ID unit
Values 9 and 10 = ID unit using DHU
Odd values = Open driver parameters
Even values = Driver parameters must be
changed using the CAN key.
103 Timer option 1/5 1 2 States a time value for the timer.
For more information, see the section
about the Timer in this chapter.
104 Automatic log 0/20 1 20 States the time it takes before the truck is
out, minutes turned off when the keypad is used. The
time is calculated from when the last power
consuming unit is used. Value 0 gives 4
hours.

Parameters
844 6061850 2009-10-05 258947-040

eter Max
105 Collision sensor 0/100 1 0 Option. States the degree of sensitivity for
X level what should be interpreted as a collision
for a shock to the side. This parameter
should be set on truck installation. For
more information see the chapter
Installation.
106 Collision sensor 0/100 1 0 Option. State the degree of sensitivity for
Y level what should be interpreted as a collision
for a shock to the front/back. This
parameter should be set on truck
installation. For more information see the
chapter Installation.
107 Battery 1/20 1 9 13 = Medium battery
adjustment, Ah 17 = Small battery
For more information, see text following
the table.
108 Calibration 1 1 1 = Calibrating the proportional valve.
Returns automatically to zero after
calibration has been completed. See
chapter on the hydraulic system for
complete instructions on how a calibration
is carried out
109 Battery charger, 0/3 1 0 State what type of battery is to be charged.
battery type 0 = No charge. Standard type. Error code
is displayed if this parameter is set at 0
when there is a battery charger and factory
parameter 1101 is set at 1.
1 = Lead/acid battery
2 = Hawker Evolution battery. Sizes 134
Ah, 174 Ah, 201 Ah
3 = Exide GEL battery
For more information, see the chapter
Installation.
110 Battery charger, 0/300 1 0 State battery capacity
battery (100/ (100) 0 (100) = No charge. Standard type. Error
capacity, Ah 300) code is displayed if this parameter is set at
0 (100) when there is a battery charger
and factory parameter 1101 is set at 1.
The values in brackets () apply if the truck
has software version -006 or later.
For more information, see the chapter
Installation.

Parameters
258947-040 2009-10-05 6061850 844

eter Max
111 Resetting 0/1 1 0 0 = Special pincode required for resetting
following a after a collision.
collision 1 = The truck can be reset using all
activated pincodes.
2 = The horn sounds once every five
seconds.
3 = Alternatively, 1 and 2 combined.
201 Reverse 70/ 5 100 States how powerful the truck brakes when
braking 100 the speed control is turned in completely
the opposite direction
NOTE: This value must not be set less
than the value of parameter 5. If it is lower
error code 2.002 will be displayed on start-
up and the value will not be changed.
202 Creep speed -200/ 5 0 States the speed that the truck has when it
200 reaches the first speed sensor.
-200 = low speed at the first speed sensor.
200 = high speed at the first speed sensor.
301 Ramp for 3/20 1 7 Indicates the proportional valve's closing
lowering stop ramp.
302 Fork, lowering 70/ 5 190 Indicates the fork's maximum lowering
speed 255 speed. This parameter can be adjusted
manually or by using the calibration function
(parameter 108 = 1).
303 EVP start 30/ 5 90 Indicates the proportional valve's start
position 150 position. This parameter can be adjusted
manually or by using the calibration function
(parameter 108 = 1).
304 EVP support 50/ 5 130 Indicates the support arm's lowering speed.
arm, lowering 220 This parameter can be adjusted manually or
speed by using the calibration function (parameter
108 = 1).
305 EVP slow 40/ 5 105 Indicates the low speed when using the
lowering speed 220 “Click-2-Creep” lowering speed. This
parameter can be adjusted manually or by
using the calibration function (parameter 108
= 1).
306 Activate the two 0/1 1 1 Activate “Click-2-Creep” raising/lowering
raising/lowering 0 = Off
speeds 1 = On
307 Activate 0/1 1 1 Activate automatic lowering of support arm.
automatic 0 = Off
lowering of 1 = On
support arm

Parameters
844 6061850 2009-10-05 258947-040
6.5.6 Factory parameters

Adjusting the truck's factory parameters is done during production in
the factory. You can only change the factory parameters via the
software TruckCom in a PC or PDA.
Note!
Remember that a change of specific truck parameters changes the
truck's properties. Do not change any parameter values without the
necessary prior knowledge. Only authorised service technicians with
personal TruckCom user identities have the rights to change factory
settings. This must only be done if specific needs arise.
The user identity and the time of parameter change is logged in the
handle's circuit board.

eter Max
1001 Truck type 0/8 1 0 0 = Unknown truck type
1 = SWE100
2 = SWE120
3 = SWE140
4 = SWE120L
5 = SWE140L
6 = SWE200D
7 = SWE080L
8 = SWE120S
1002 Non-configurable 0/3 1 1 You have access to 3 functions via
option parameter 1002. These functions are
either activated or deactivated. The
functions require no further adjustment
and are therefore called non-
configurable options.
0 = No option function
1= Click-2-Creep
2= Turtle function
3 =Both Click-2-Creep and turtle
function.
1003 ConfOption Func1 0/13 1 0 Requires SEU
NOTE:
At the option “Auto Height
Adjustment”, set parameter 1003 to
11.
1004 ConfOption 0/255 1 0 Requires SEU
Func1Arg1
Func1Arg2
NOTE:
At the option “Auto Height
Adjustment”, set parameter 1005 to
4.

Parameters
258947-040 2009-10-05 6061850 844

eter Max
Func1Arg3
Func1Arg4
Func2Arg1
Func2Arg2
Func2Arg3
Func2Arg4
Func3Arg1
Func3Arg2
Func3Arg3
Func3Arg4
Func4Arg1
Func4Arg2
Func4Arg3
Func4Arg4

Parameters
844 6061850 2009-10-05 258947-040

eter Max
1023 Control for hydraulic 1/4 1 1 1 = Rear lift and lowering control is
function connected to the second hydraulic
function and forward control is
connected to the first hydraulic
function.
2 = Rear lift and lowering control
connected to the first hydraulic function
and forward control connected to
second hydraulic function.
3 = Both lift and lowering control
connected to the first hydraulic
function. There is no second hydraulic
function.
4 = Analogue lift and lowering control is
connected to the first hydraulic function
and forward control is connected to the
second hydraulic function.
1101 Battery charger, on 0/1 1 0 0= Battery charger missing
board 1= Battery charger present

Troubleshooting
General
258947-040 2009-10-05 6061850 844
7 – Troubleshooting
7.1 General
The chapter Troubleshooting describes the error codes that are shown
on the display when the truck is completely or partly not working. The
causes of faults and actions for rectifying them are also described here.
The truck's electronic control system has an integrated error code
display and log. When a fault occurs, the error code is shown on the
display and the error code lamp blinks.
The first time that an error code is shown on the display, it can be good
to check if the error persists by restarting the truck.
Note!
The request to Restart the truck always means that the battery sleeve
should be pulled out before the truck is started again.
Software compatibility
Ensure that the logic card ICH [A5] and transistor regulator ACT [T1],
and battery charger BCU [A30], has software from the same
softwarepackage.
In order to guarantee all truckfunctions make sure to have last software
package downloaded.
Emergency travel mode

If truck for some reason stops operating and remains immobile in an
unsuitable place, it is possible to activate the emergency travel mode
to move the truck out of the way.
1. Enter your PIN code.

2. Press the horn button and keep it depressed. “Ed” is displayed.
3. Release the horn button.
All lamps flash and “SLO” is displayed.
It is now possible to drive the truck, but exercise extreme caution. It is
not possible to brake by raising the tiller arm.
If the truck is on an incline, be even more careful when using the
emergency travel mode. If too much acceleration is used, there is a
risk the truck could roll away. To stop the truck, accelerate in the
opposite direction.
NOTE:
Certain errors prevent the emergency travel mode from operating. In
this case, it is not possible to receive information about the error.

Troubleshooting
Troubleshooting methods
844 6061850 2009-10-05 258947-040
7.2 Troubleshooting methods
7.2.1 Troubleshooting general introduction

Begin troubleshooting
Has an error code Follow the instructions

Eliminate unlikely causes
been displayed? in the chapter
Yes “Troubleshooting”
No
Are the symptoms in Follow the instructions Choose and prioritise

the troubleshooting in the troubleshooting the most likely causes
diagram? Yes diagram
No
Collect as much When you have identified

information about the Where in the workplace
did the problem occur? the error, see the
problem as possible instructions in the
chapter “Actions”
When did the problem
occur?
What functions are

affected?
What circumstances
triggered the problem?
Identify all parts which

may cause the problem.
Use the wiring diagram
when needed.

Troubleshooting
Troubleshooting methods
258947-040 2009-10-05 6061850 844
7.2.2 Completed troubleshooting

Drive the truck in the same way
Conclude troubleshooting it was being driven when the
problem first occurred. Verify
that the problem does not
occur again
Ensure that all cables and

hoses are placed back in Let the driver drive the truck.
the correct way. Verify that the problem does
not occur again
By giving feedback,
If you have contacted the you can contribute to a shared
Ensure that all parts that technical support department knowledge database. This is important
have been emptied of liquids to discuss the problem, speak for continually improved support to
have been refilled to the to them again and tell them service technicians in the field
correct level that you have solved the
problem
Recreate the
circumstances that existed
when the problem first
occurred

Troubleshooting
Error code history
844 6061850 2009-10-05 258947-040
7.3 Error code history

Up to 50 of the last error code events can be stored together with the
timer values for when the error occurred. In the error code log, the error
codes are shown chronologically with the most recent error code first.
To show the error code log, work according to the following
instructions:
button.
4. Keep the horn button pressed down until "E" appears, and then
release the button. The error code symbol is lit.
The most recent error is shown The display alternates between the
error code and the timer value when the error occurred. If the error code
log contains more than one code, these codes can be shown by
pressing repeatedly on the speed control.

Troubleshooting
Error code system
258947-040 2009-10-05 6061850 844
7.4 Error code system

See the tables below for an explanation of the error code system.
Structure Description
G.ANN Example 3.510
G (3) Group. States which system is affected by the error.
A (5) Error category. Describes the type of fault that occurred
and what happened.
NN (10) Error code
Group Description
1 Not used
2 Main control system and other
3 The drive system
4 The hydraulic system
5 Not used
6 Not used
7 Not used
8 Option
Error Description
category
0 Use caution. Mainly an information code, which
indicates that some of the truck's functions are reduced
or do not work.
1-2 Lifting errors. Raising and lowering of the forks is
impaired or not working and the truck's speed is
reduced to safety speed.
3 Do not use.
4 Critical error. The main contactor is open. The truck
stops.
5 Critical error. The main contactor is open. The truck
stops.
Code Description
00-09 Miscellaneous error codes.
10-19 CAN related error codes.
20-39 Error codes regarding specific units.
40-59 Error codes for short-ciruited outputs.
60-79 Error codes for open electrical circuits.
80-99 Faulty signals from sensors.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040
7.5 Error codes

Note that certain error codes are stored in the programme and
disappear from the display, while other error codes remain on the
display and require that the truck is first stopped and then restarted for
the error code to disappear.
Code Event Possible cause

Action
Main control unit
E141 Software download interrupted Transfer cable disconnected.
Restart the download in “Emergency
download” mode
2.001 The transistor regulator stops all functions. Emergency switch pressed.
Check:
• that the emergency switch is
unaffected.
• cable 24.
• Fuse [F51]
2.002 No event. The truck can be driven. Certain parameter values may be
outside the predefined values. Reset
the parameters to standard values.
• Check the parameter settings.
• If the code is immediately followed
by error code 2.004, copy
configuration via TruckCom to
transistor regulator[T1].
2.003 No event. The truck can be driven. Time for service.
Check the service meter (hour meter
S). This may not have been reset after
the last service.
2.004 No event. The truck can be driven. The values in the transistor regulator's
backup file is different from the values
in the handle's logic card with regards
to parameters, hour meters and/or
machine number.
Check via TruckCom where the correct
data is. See section “16.2 Replacing
the transistor regulator”. See Table
7.6.4.

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
2.101 Safety speed, raising and lowering the The truck type has not been indicated.
forks not working.
Reset data from backup, See section
“15.5.2 Replacing the logic card”. If this
does not help, indicate the type of truck
by entering factory parameter 1001
(Truck type). or see Table 7.6.4
2.102 Safety speed, raising and lowering the The stated truck type does not support
forks not working. the analogue raising and lowering
functions.
Check the factory parameter settings
1001 (Truck type) and 1023 (Hydraulic
function control).
2.501 Open the main contactor Low battery voltage <16.8V> for more
than 2 seconds
Charge the battery. Check cables and
connections
2.511 The main contactor is open. CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle.
2.514 The main contactor is open. CAN communication error.
Check:
• cables 119 and 120.
• logic card in the handle.
2.515 The truck will not start CAN communication error.
Check:
• connections and cabling between
DHU[K110] and ICH logic card [A5]
2.520 The main contactor is open. Fault in the software for the control
handle or microprocessors.
Download new software.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
2.521 The main contactor is open. The safety reversing function is faulty.
Mechanical fault of fault with the hall
sensor that controls the safety
reversing function.
Check via TruckCom that the hall
sensor works.
2.522 The main contactor is open. Faulty power supply to the hall sensor.
Check via TruckCom that the hall
sensors work.
2.523 The main contactor is open. The main contactor is not activated.
• Check that the main contactor
works.
• Open the main contactor.
Drive system
3.001 Driving is prevented until the speed • The speed control is not in neutral
control is in neutral. when starting.
• Faulty hall sensor.
Check:
• speed controller's function
• via TruckCom that the hall sensors
work.
3.002 The transistor regulator reduces the The transistor regulator's temperature
maximum current to 50 %. exceeds +85°C. The driving may be
too intensive.
• Drive the truck less intensively.
• Check for dirt around the transistor
regulator. Too much dirt means that
the transistor regulator does not cool
down properly.
3.003 The transistor regulator reduces the The motor's temperature exceeds
maximum current to 50 %. +150°C. The driving may be too
intensive.
• Drive the truck less intensively.
• Check for dirt around the motor. Too
much dirt means that the motor does
not cool down properly.

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
3.040 No event. The truck can be driven. Faulty energy saving function in the
holding position.
• Internal fault in the transistor
regulator.
• Restart the truck.
• If the error persists, change the
transistor regulator.
3.080 The transistor regulator reduces the The temperature sensor for the
maximum current to 50 %. transistor regulator shows abnormal
values.
regulator.
3.081 The transistor regulator reduces the The temperature sensor for the motor
maximum current to 50 %. shows abnormal values. The sensor
may be faulty.
Check cables (63/64) to the
temperature sensor in the motor.
3.101 Safety speed, raising and lowering the The transistor regulator is using
forks not working. predefined current gain. Internal fault
regulator.
3.120 Safety speed, raising and lowering the Faulty control total for parameters in
forks not working. the transistor regulator.
regulator.
• Reprogramme the truck.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
3.121 Safety speed, raising and lowering the The transistor regulator cannot use the
forks not working. internal memory.
regulator.
• Reprogramme the truck.
3.140 The horn does not work. The safety The horn output has short-circuited.
speed.
Check:
• cable 50
• the horn.
3.501 The main contactor is open. Faulty transistor regulator.
Check:
• the transistor regulator
• factory parameter 1001 (Truck type).
If the error persists, change the
3.502 The main contactor is open. The control handle's logic card cannot
download parameters to the transistor
regulator.
• Change logic card in the handle.

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
3.510 The main contactor is open. CAN communication problem with the
transistor regulator when starting.
Check:
• make sure that the ICH [A5] and
ACT [T1] have compatible software.
See section “7.1 General”.
• logic card in the handle and possibly
change the card.
3.511 The main contactor is open. The handle's logic card does not see
CAN data from the transistor regulator.
Check:
change the card.
3.512 The transistor regulator stops all functions. The transistor regulator does not see
CAN data from the control handle's
logic card.
Check:
change the card.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
3.514 The main contactor is open. The logic card in the control handle
cannot send CAN data to the transistor
regulator.
Check:
change the card.
3.515 The transistor regulator stops all functions. The transistor regulator discovers CAN
communication error.
Check:
change the card.
3.520 The transistor regulator stops all functions. The transistor regulator discovers
short-circuit in the output step.
Check:
• motor cables
• motor
• the transistor regulator.
3.521 The transistor regulator stops all functions. The transistor regulator discovers low
motor voltage.
Check:
• motor cables
• motor
3.522 The transistor regulator stops all functions. The transistor regulator discovers high
motor voltage.
Check:
• motor cables
• motor

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
internal problems with its own software
or hardware.
Internal fault in the transistor regulator.
Reprogramme the truck both in the
handle and the transistor regulator.
internal problems with its own software
or hardware.
Reprogramme the truck both in the
handle and the transistor regulator.
3.525 The transistor regulator stops all functions. The transistor regulator discovers that
the motor phase is always 0 (zero).
Check:
• motor cables
• motor
3.526 The transistor regulator stops all functions. The transistor regulator's voltage feed
is wrong.
Change transistor regulator.
3.527 The transistor regulator stops all functions. Faulty transistor regulator software.
Check that the last software for the
transistor regulator exists.
3.528 The transistor regulator stops all functions. Internal problem for the transistor
regulator's microprocessor.
regulator. Check that the last
software for the transistor regulator
exists.
3.529 The transistor regulator stops all functions. The transistor regulator discovers an
internal problem.
regulator. Check the software.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
internal problem.
internal problem.
3.532 The transistor regulator stops all functions. The transistor regulator has an internal
problem in the AD transformer.
regulator.
• Change transistor regulator.
3.533 The transistor regulator stops all functions. The charging voltage for the transistor
regulator's capacitor shows abnormal
values.
Check:
• cable 20
• pump contactor
3.534 The transistor regulator stops all functions. The transistor regulator discovers a
problem with the speed sensor. The
jump in frequency is too great.
Check:
• the speed sensor and possibly
change it.
3.535 The transistor regulator stops all functions. Faulty control total for parameters in
the transistor regulator.
Download new programme in the
handle and transistor regulator.

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
3.536 The transistor regulator stops all functions. The transistor regulator's current
sensor is outside valid intervals.
3.537 The transistor regulator stops all functions. Multiple direction commands from the
handle.
Internal fault in the handle.
3.538 The main contactor is open. Unknown fault in the transistor
regulator.
regulator. Reprogramme the
3.539 The transistor regulator stops all functions. The transistor regulator discovers that
the battery voltage value are not
between 18 V - 28.8V.
Check:
• the wiring harness between the
battery and transistor regulator.
• the battery.
3.540 The transistor regulator stops all functions. The transistor regulator's output to the
main contactor has short-circuited.
Check:
• the main contactor.
parking brake has short-circuited.
Check:
• the parking brake.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
3.542 The transistor regulator stops all functions. One of the transistor regulator's circuits
to the main contactor, parking brake or
lowering valve has shortcircuited
at+24 V when starting.
Check
• main contactor
• parking brake
• lowering valve.
main contactor has short-circuited.
Check:
3.561 The transistor regulator stops all functions. The circuit between the transistor
regulator and the coil in the main
contactor is open.
Check:
3.562 The transistor regulator stops all functions The transistor regulator's output to the
parking brake is open.
Check:
• parking brake.
3.563 The transistor regulator stops all functions. The transistor regulator's coil circuit to
the parking brake is open.
Check:
• parking brake.
3.580 The transistor regulator stops all functions. Main contactor closed.
Check:

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
3.581 The transistor regulator stops all functions. Main contactor open.
Check:
• main fuse [F1]
3.582 The transistor regulator stops all functions. The transistor regulator's output for
power supply has the wrong voltage
level.
Check:
• the main contactor
• lowering valve
• brake
• pump contactor.
3.583 The transistor regulator stops all functions. The transistor regulator's internal
power supply does not increase.
Hydraulic system
4.001 Lifting is prevented until the analogue The analogue control for lifting and
control of lifting and lowering is back in the lowering is not in the neutral setting
neutral setting. when starting. (Applicable for the SWE
trucks).
Speed control not affected when
starting the truck.
Check:
• cable in the handle
• potentiometer. For fault, change
potentiometer.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
4.101 Safety speed, raising and lowering the Analogue control signals for lifting and
forks not working. lowering shows abnormal values.
Speed control not affected when
starting the truck.
Check:
• cable in the handle
• potentiometer. For fault, change
potentiometer.
4.102 Safety speed, raising and lowering the The handle type does not correspond
forks not working. with the adjustment for factory
parameter 1023 "Control for hydraulic
function".
Check the adjustment for factory
parameter 1023 and compare with the
truck's handle.
4.125 Safety speed, raising and lowering the The pump engine's current feedback is
forks not working. always zero when the pump engine is
in operation.
The current sensor in the transistor
regulator is faulty. Change transistor
regulator.
4.126 Safety speed, raising and lowering the The pump motor's current feedback is
forks not working. too high when starting and in holding
position.
The current sensor in the transistor
regulator is faulty. Change transistor
regulator.
4.521 The main contactor is open. The pump motor's voltage is too low.
Check:
transistor regulator and pump motor.
• the pump motor.
4.522 The main contactor is open. The pump motor's voltage is too low.
Check:
transistor regulator and pump motor.
• the pump motor.

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
4.540 The transistor regulator stops all functions. • The transistor regulator's output to
the lowering valve has short-
circuited.
• Internal short-circuit in the transistor
regulator.
• Check connections and wiring
harness
• Loosen the connection to the
lowering valve and try to restart.
lowering valve or change the
lowering valve has short-circuited to B-.
Check connections and wiring harness
lowering valve is open.
Check:
• the lowering valve's coil.
Option
8.001 Safety speed, raising and lowering the The collision sensor has registered
forks not working. collision levels that are above the
stated limits.
• Drive carefully.
• Check the limits for registering
collisions (service parameters 105
and 106).
8.002 Safety speed, raising and lowering the The truck has deliberately been put in
forks not working. an unusable state by TLS.
Reset the truck to normal operation.
8.003 No event. The truck can be driven. Argument warning from the Spider
expansion unit.
Check the settings for selected
parameters.

Troubleshooting
Error codes
844 6061850 2009-10-05 258947-040

Action
8.010 No event. The truck can be driven. CAN communication problem with the
battery charger when starting.
• Check connections and wiring
harness
• Make sure that the ICH [A5] and
BCU [A30] have compatible
software. See section “7.1 General”.
8.011 No event. The truck can be driven. The handle's logic card does not see
CAN data from the battery charger.
8.014 No event. The truck can be driven. The logic card in the control handle
cannot send CAN data to the battery
charger.
8.020 No event. The truck can be driven. The battery charger is not connected to
the battery.
8.021 No event. The truck can be driven. The battery charger has discovered
low battery voltage.
Check the battery status.
high battery voltage.
Check the battery status.
low charging temperature.
Charge the battery at normal
temperature.
high charging temperature.
Check:
• dirt in the battery charger. Clean if
needed.
• that the fan works.
8.027 No event. The truck can be driven. Serious fault in the battery charger.
Change battery charger.
8.028 No event. The truck can be driven. The battery cahrger has exceeded the
time limit for charging.
Check the battery.

Troubleshooting
Error codes
258947-040 2009-10-05 6061850 844

Action
8.029 No event. The truck can be driven. The battery charger charges more than
maximum capacity.
Check:
• battery
• service parameter 110.
8.030 No event. The truck can be driven. There is a battery charger in the truck,
but has not been activated via factory
parameter 1101.
Check factory parameter 1101.
8.031 No event. The truck can be driven. Faulty parameter adjustment for the
battery charger.
Restart the truck. Check that the truck
and battery charger have the right
software.
8.032 No event. The truck can be driven. If the error code is displayed when
charging using a built-in charger,
parameter 109 is set incorrectly
Check service parameter 109
8.110 Safety speed, raising and lowering the CAN communication problem with
forks not working. Spider expansion unit 1 when starting.
forks not working. Spider expansion unit 1.
forks not working. Spider expansion unit 2 when starting.
forks not working. Spider expansion unit 2.
8.123 Safety speed, raising and lowering the Spider expansion unit 1 programme
forks not working. warning.
Check parameter selections.
8.124 Safety speed, raising and lowering the Spider expansion unit 2 programme
forks not working. warning.
Check parameter selections.

Troubleshooting
Troubleshooting diagram.
844 6061850 2009-10-05 258947-040
7.6 Troubleshooting diagram.

The following section describes different types of error that may arise
and what these errors can be caused by.
The troubleshooting is grouped according to different symptoms that
can occur:
• The truck cannot be driven
• The truck can be driven but only at reduced speed
• The truck can be driven but behaves abnormally
• Faulty hydraulic functions.

Troubleshooting
258947-040 2009-10-05 6061850 844
7.6.1 The truck cannot be driven
Symptom Contributing factors Possible cause

The mechanical brakes Sensor [B60] • The sensor is in the wrong
cannot be activated. position and is affected by
metal.
• The sensor is faulty.
The control handle in drive The cable is damaged and gives
position is always “Plus” faulty plus/minus measurement
Transistor regulator, input Broken transistor regulator
[T1:95].
The mechanical brakes Brake If the play is greater than 0.6
cannot be released. mm, the brakes may be hard to
use.
Sensor [B60] • The sensor is in the wrong
position and cannot be
influenced normally
• The sensor is faulty
• Break in the sensor's cable
Transistor regulator, input Broken transistor regulator
[T1:95]
Transistor regulator, output
[T1:90]
Corrosion The brakes are locked due to
corrosion
The truck cannot be Sensor [B60] • The sensor is in the wrong
driven after starting, position and is affected by
despite the control handle metal
being folded up.
• The sensor is faulty
The control handle in drive The cable is damaged and gives
position is always “Plus” faulty plus/minus measurement
Transistor regulator, input Broken transistor regulator.
[T1:95].

Troubleshooting
844 6061850 2009-10-05 258947-040
7.6.2 The truck can only be driven at reduced

speed

Always reduced speed Click-2-Creep function Click-2-Creep function activated
Turtle function Turtle function activated
Driver parameter 6 - speed Driver parameter 6 not set at the
maximum value
Pulse sensor [B11] The pulse sensor [B11] is
broken, dirty or not connected
Connection of motor cables • One of the phases U, V, W is
unconnected
• Broken cable
Mechanical brakes • Partly working brakes
• Faulty play.

Troubleshooting
258947-040 2009-10-05 6061850 844
7.6.3 The truck can be driven but behaves

abnormally

The truck goes in the wrong Connection of motor cables Connections U, V, W are
direction. wrongly connected
Always reduced Driver parameter 4 Set at a low value.
acceleration
Always reduced reverse Service parameter 201 Set at a low value.
braking.
Always reduced neutral Driver parameter 5 Set at a low value
braking
The truck cannot be Parameter 102. Red ‘Off’ button Parameter 102 is incorrectly set
switched off. on the keyboard not working. to the log-in unit on the truck.
Always reduced speed Pulser [B11] The pulser [B11] is broken, dirty
or not connected
Connection of motor cables • Some of the phases U, V, W
are disconnected
• Cable breakage
7.6.4 The truck can be driven but lacks

certain functions
Software compatibility
Make sure that the right software for the logic card [A5] and transistor
controller [T1], and battery charger [A30] are installed on the truck. See
section “7.1 General”.

Troubleshooting
844 6061850 2009-10-05 258947-040
Matrix for hardware compatibility

Make sure the correct hardware for logic card [A5] and transistor regu-
lator [T1] has been installed in the truck by referring to the matrix below.
Not replaced ACT Replaced ACT

transistor regulator [T1] transistor regulator [T1]
Not replaced ICH OK Warning 2.004. Use TruckCom
logic card [A5] to download backup values. In
TruckCom, select “Copy confi-
guration to secondary unit ACT”
Replaced ICH Error code 2.101. Use Truck- Replace a node at a time and
logic card [A5] Com to upload backup values. carry out the corresponding
Select “Copy configuration to step. See 17.2 and 16.5.2
primary unit: ICH”
7.6.5 Faulty hydraulic functions
Symptom Contributing factors Possible cause/Action

The forks can be lowered but No or low hydraulic pressure • Low oil level
not raised.
• Blocked intake filter
• Faulty or wrongly adjusted
pressure limiting valve
• Faulty hydraulic pump,
change hydraulic unit
Pump motor [M3] does not work • The hydraulic unit's fuse [F1],
125 A, has burned out:
change the fuse.
For more information read
more in the following table
Pump motor [M3] does not
work:
• Measure the current and
voltage respectively across
the pump motor [M3].
• The pump motor's [M3]
current/voltage is normal
• No current or voltage through/
across the pump motor [M3]
• Voltage across the pump
motor [M3], but no current
through it

Troubleshooting
258947-040 2009-10-05 6061850 844

The forks can be raised but The proportional valve [Q4] for • Measure the current and
not lowered. lowering the forks does not open voltage respectively across
the valve's coil.
For more information See
“ Continued. The proportional
valve [Q4] for lowering the
forks does not open:” on
page 28.
• The magnetic valve's voltage/
current is normal
• No current or voltage through/
across the magnetic valve's
coil
• Voltage across the magnetic
valve's coil, but no current
through it
The forks can neither be Fuse [F50] 7.5 A is faulty change the fuse
raised or lowered
Logic card [A5] defective Replace logic card [A5]
Transistor regulator [T1] is faulty Change transistor regulator
Factory parameter 1023 Check the setting of the parame-
ter value

Troubleshooting
844 6061850 2009-10-05 258947-040
Continued. Pump motor [M3] does not work:

The pump motor's [M3] current/ Mechanical fault in the pump Change hydraulic unit
voltage is normal
No current or voltage through/ Damage in the pump motor's Take control measurement of
across the pump motor [M3]” [M3] wiring harness or the wiring harness with regards
connections to breakage or short circuit to
another cause
Voltage across the pump motor Break in the pump motor [M3] Change hydraulic unit
[M3], but no current through it
Continued. The proportional valve [Q4] for lowering the forks does not open:
The proportional valve's [Q4] Mechanical fault in the Change hydraulic unit
current/voltage is normal proportional valve [Q4]
No or low current/voltage Damage to the proportional Take control measurement of
through/across the valve's [Q4] wiring harness or the wiring harness with regards
proportional valve's coil [Q4] connections to breakage or short circuit to
another cause
The control arm's Hall element Replace logic card [A5]
for fork lowering is faulty
Transistor regulator [T1], output Change transistor regulator [T1]
108 “OUT.LOWER VALVE” is
faulty
Transistor regulator [T1], output See troubleshooting table The
82 “OUT. +24 V HIGH SIDE truck cannot be driven
DRIVER” is faulty
Voltage across the Break in the proportional valve's Change hydraulic unit
proportional valve's coil [Q4], coil [Q4]
but no current through it

Troubleshooting
Built-in test function
258947-040 2009-10-05 6061850 844
7.7 Built-in test function

The control system of the truck has a number of built-in test functions
that are useful in the troubleshooting process. To activate the test
functions:
1. Connect the CAN service key to [X41] and log in.
2. The battery status symbol is lit.
3. Press the signal horn button [S18] repeatedly to select the mode of
the built-in test function.
Note!
All truck functions work as normal while the built-in test function is
active. Be careful when driving the truck and reading the display at
the same time.
Setti Flashing symbol Data shown in the display Normal value

ng
1 Battery voltage (V)
2 Current over battery (A) -
3 The set speed value that is sent to the Min: -142

transistor regulator Max: 142
4 Speed value from the speed sensor Min: approx. -140

Max: approx. 140
5 Fork lowered to/from To: 1 From: 0

Fork lift to/from To: 2 From: 0
6 Fork under mast sensor #1 To (0V): Down

From (>5V): Up
7 N/A -
8 N/A -
9 Status of inputs/outputs, transistor -

regulator [T1]
10 Input/output status, logic card [A5] -

Troubleshooting
Status of digital inputs/outputs
844 6061850 2009-10-05 258947-040
Setti Flashing symbol Data shown in the display Normal value

ng
11 Maximum value registered by the collision Min: 0
sensor (optional) Max: 100
12 Status of inputs/outputs, expansion unit 1 -

(optional)
13 Status of inputs/outputs, expansion unit 2 -

(optional)
7.8 Status of digital inputs/outputs
7.8.1 Test function “9” – Transistor regulator

In this setting, the digital inputs and outputs are tested by checking
specific segments on the display according to the following tables.
A
F G B
E C
1 2 3 4 D H
Position:
1 and 2: The transistor regulator's actiual value. What is the actual
value in each input/output.
3 and 4: The transistor regulator's set point. Relating to what the
software value should be.
A – H: Reference to segment
One or more segments can be lit in each position. Indications can also
be combined over several positions.
[xxx] in the table is a component name
{nn} in the table is a cable number in the wiring diagram.

Troubleshooting
258947-040 2009-10-05 6061850 844
Actual values
Function Pos 1 Pos 2 Pos 3 Pos 4
Fork under mast sensor #2 On: Forks down
A * * *
[B64] INP. MAST SWITCH 2 Off: Forks up
Main contactor [Q10] On: Contactor closed
B * * *
Off: Contactor open
Parking brake [Q1] On: Brake off
C * * *
Off: Brake on
Tiller arm in drive position On: Tiller arm in drive
[B60] position
D * * *
INP. TILLER ARM IN DRIVE Off: Tiller arm in one of
POS. the end positions
- E * * * Not assigned
Support arm in lower position.
On: Down
[B62] INP. SUPPORT ARM IN F * * *
Off: Up
LOWEST POS
Fork under mast sensor #1 On: Down
G * * *
[B63] INP. MAST SWITCH 1 Off: Up
- H * * * Not assigned
- * A * * Not assigned
- * B * * Not assigned
- * C * * Not assigned
- * D * * Not assigned
- * E * * Not assigned
Fork valve active. On: Valve open
* F * *
[Q22] OUT. FORK VALVE Off: Valve closed
Support arm valve active.
On: Valve open
[Q23] OUT. SUPPORT ARM ‘ G * *
Off: Valve closed
VALVE
- * H * * Not assigned
A
F G B
E C
D H

Troubleshooting
844 6061850 2009-10-05 258947-040
Set points
- * * A * Not assigned
Main contactor [Q10] * * B * On: Contactor closed
OUT. MAIN CONTACTOR Off: Contactor open
- * * C * Not assigned
Parking brake [Q1] * * D * On: Brake off
OUT. BRAKE RELEASE Off: Brake on
- * * E * Not assigned
Pump motor [M3] active * * F * On: Active
Off: Not active
Proportional valve [Q4] * * G * On: Affected
Off: Not affected
- * * H * Not assigned
Pump contactor [Q25]. * * * A On: Contactor closed
OUT. PUMP CONTACTOR Off: Contactor open
Fork valve [Q22] * * * B Not assigned

OUT. FORK VALVE
Support arm valve [Q23] * * * C Not assigned
OUT. SUPPORT ARM VALVE
Spare * * * D Not assigned
(Digital out 4)
- * * * E Not assigned
- * * * F Not assigned
- * * * G Not assigned
- * * * H Not assigned
A
F G B
E C
D H

Troubleshooting
258947-040 2009-10-05 6061850 844
7.8.2 Test function “10” - Logic card

- A * * * Not assigned
- B * * * Not assigned
- C * * * Not assigned
Front fork lift button [A5:S19] D * * * On: Button pressed
Front fork lowering button On: Button pressed
E * * *
[A5:S20]
Rear fork lift button [A5:S21] F * * * On: Button pressed
Rear fork lowering button On: Button pressed
G * * *
[A5:S22]
Control for horn [S18] H * * * On: Button pressed
Outermost selection button, On: Button pressed
* A * *
right side [S116]
Central selection button, right On: Button pressed
* B * *
side [S115]
Innermost selection button, On: Button pressed
* C * *
right side [S114]
Outermost selection button, left On: Button pressed
* D * *
side [S113]
Central selection button, left On: Button pressed
* E * *
side [S206]
Innermost selection button, left On: Button pressed
* F * *
side [S111]
- ‘ G * * Not assigned
A
F G B
E C
D H

Troubleshooting
844 6061850 2009-10-05 258947-040
7.8.3 Test function “12” – Expansion unit

SEU (optional).

Digital input 1 A * * * -
Digital input 2 B * * * -
Digital input 3 C * * * -
Digital input 4 D * * * -
Digital input 5 E * * * -
Digital input 6 F * * * -
Digital input 7 G * * * -
Digital input 8 H * * * -
Digital output 1 * A * * -
Digital output 2 * B * * -
Digital output 3 * C * * -
Digital output 4 * D * * -
- * E * * Not assigned
- * F * * Not assigned
- ‘ G * * Not assigned
A
F G B
E C
D H

Troubleshooting
Testing display function
258947-040 2009-10-05 6061850 844
7.9 Testing display function

The digital display function can be tested in order to verify that
segments are lit correctly.
To test the display, work according to following instructions:
button.
4. Keep the horn button pressed down until "d" appears, and then
release the horn button.
All segments and icons should blink in sequence.

Troubleshooting
Testing display function
844 6061850 2009-10-05 258947-040

Actions
Chassis 0000
Order number Date Valid from serial number T-code
258944-040 2009-10-05 6053221- 838, 839, 840
8 – Chassis 0000
8.1 General
To gain access for certain inspection items, it may be necessary to dis-
assemble the drive unit from the fork frame.
Pos. Designation
A Cylinder locking
B Mounting hole
C Axle 2
D Stop screw 2
E Nut 2
© BT Repair Manual SWE080L 8– 1

Actions
Chassis 0000
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2009-10-05 258944-040
8.2 Disassemble the drive unit from the

fork frame
Proceed as follows to separate the fork frame from the drive unit:
1. Ensure that the truck is standing on a level surface.
2. Remove the inspection covers and the battery door
The top cover is secured with Velcro tape. Be careful when detach-
ing the cover. Use of a suitable tool is recommended.
3. Raise the forks.
4. Unscrew and remove the axle lockings on each side (D, E).
5. Lower the forks and disconnect the battery connector.
6. Unfasten the battery cables and clips as well as the emergency
stop cables from the fork frame.
7. Remove the cylinder locking (A).
8. Turn the drive unit until the drive wheel points to the side.
9. Insert a block under the rear edge of the drive unit (NB! Remember
to use the same size of all blocks when raising the truck, so that the
truck remains stationary).
10. Place the jack between the forks and lift the fork frame.
11. Lift up the truck approx 140 mm with blocks under the fork carriage
and forks.
Align the mounting hole (B) on the fork frame side with the axle.
12. Remove the axles (C).
13. Then pull apart the drive unit and fork frame.
NOTE!
Never lift the drive unit by the tiller arm when separating the drive unit
from the fork frame.
Assemble in reverse order.
NOTE!
Be careful when reassembling so that no cables are trapped.
8– 2 Repair Manual SWE080L © BT

Electrical drive motor 1700
Components
258947-040 2009-10-05 6061850 844
9 – Electrical drive motor 1700
9.1 Components
b
a
c
Pos Name
a Speed sensor
b Connection, motor cables
c Motor: SWE080L 1.0kW
d Temperature sensor

Disassemble engine and truck
844 6061850 2009-10-05 258947-040
9.2 Disassemble engine and truck

1. Remove the inspection covers.
The upper inspection cover is fastened using velcro. Take care
when you loosen the inspection cover. By all means use a tool to
help you.
2. Cut the cable duct tie on the transistor regulator's side and loosen
the cable connections X5 and X60.
03288.wmf
a
3. Loosen the operating console's mounting screws (a) and remove
the operating console and tiller arm.
4. Loosen the brake's cable connection [Q1].
5. Loosen the speed sensor's cable connection [B1].
03289.wmf

Disassemble engine and truck
258947-040 2009-10-05 6061850 844
6. Loosen the motor cables and the motor's mounting screws.

7. Lift the motor out of the truck.
8. If needed, remove the brake and speed sensor.
NOTE!
Cover the drive gear so that no loose objects can fall into the drive
gear when the drive motor is removed.
Install the motor in the reverse order.
See section “9.3 Tightening torque Drive motor”.
NOTE:
When fitting it is very important that the motor is adjusted so that the
slots in the motor and motor bracket are exactly opposite each other
before tightening the mounting screws. See the picture below.
Screw the drive motor into place using the four (4) mounting screws
(a). Always tighten the screws alternately in two stages. In other
words, do not tighten the screw to its full torque in the first stage. See
section “9.3 Tightening torque Drive motor”.

Tightening torque Drive motor
844 6061850 2009-10-05 258947-040
9.3 Tightening torque Drive motor

The tightening torques for the drive motor are indicated in the picture:
3.5Nm
T30
3 + 0,5 Nm
10 mm
8 Nm
T30
9.4 Fitting the tempreature sensor

1. Unclip the cable from the broken temperature sensor and fit the
new temperature sensor
2. Place the new temperature sensor in the engine.
3. Clean thoroughly and ensure that the surface is dry.
4. Apply the plastic padding by squeezing out a strand of the hardener
half the length of the filler and mix well (be careful not to mix more
than can be used within 5 minutes).
5. Apply a layer of the plastic padding at least 4 mm thick, and overlap
the repaired surface by at least 2 cm.
6. Fix the plastic padding with masking tape and allow to harden.
7. Remove the masking tape.
The temperature sensor should now be covered by plastic
padding.
8. After hardening, it is a good idea to add a further layer of the plastic
padding

Cleaning
258947-040 2009-10-05 6061850 844
9.5 Cleaning
It is crucial to the correct function that the engine is kept as clean as
possible. The engine and engine housing must be regularly inspected
for dust, oil and other contaminants.
Dirty and/or oily components must be cleaned using a clean cloth,
moistened with solvent. Use a lint-free cloth. Do not apply so much
solvent that it finds its way into the engine parts.
After cleaning, the components must be dried well, which is most
effectively done by heating.
Note!
Windings and insulation should not be heated above 125°C and for no
more than 6 hours.

Cleaning
844 6061850 2009-10-05 258947-040
This page is intentionally left blank

Drive gear 2550
General
258947-040 2009-10-05 6061850 844
10 – Drive gear 2550
10.1 General
The drive gear is combined with the motor and the brake into a
complete drive unit.
A complete renovation of the drive gear must be carried out by the
supplier.
10.2 Components
Pos Name
a Drive gear
b Screw

Drive gear 2550
Removing the gear from the truck ..
844 6061850 2009-10-05 258947-040
10.3 Removing the gear from the truck ..

1. Raise the support arms and chock up the drive unit approx. 190
mm.
2. Loosen the drive wheel.
3. Remove the inspection covers.
The upper inspection cover is fastened using velcro. Take care
when you loosen the inspection cover. By all means use a tool to
help you.
4. Cut the cable duct tie on the transistor regulator's side and loosen
the cable connections X5 and X60.
5. Loosen the operating console's mounting screws and remove the
operating console and tiller arm.
6. Loosen the speed sensor and cable connections Q1 and B1.
7. Loosen the motor cables and the motor's mounting screws.
03289.wmf
8. Lift the motor out of the truck.

9. Put a plug in the hole in the gear to prevent any oil spills when
taking the gear out of the truck.
10. Loosen the gear's mounting screws.
11. Put down the gear and pull it out to the rear edge.
Place a block under the gear in order to simplify fitting.

Brake 3180
Components
258947-040 2009-10-05 6061850 844
11 – Brake 3180
In normal environments, the brake in principle is maintenance free.
11.1 Components
A
B
G
E
Pos no. Description

A Locking ring
B Complete brake
C Screw
D Key
E Hub
F Brake disc
G Flange

Brake 3180
Release of brakes
844 6061850 2009-10-05 258947-040
11.2 Release of brakes

Note!
The brakes must only be released when the truck has to be moved for
service and repair work.
A
The truck's brakes can be released manually when needed by screwing
in two (M5) screws into holes (A). The screws must be 30-35 mm long.
Note!
Remember to remove the screws before the truck is put back into use
again.

Drive wheel 3530
Changing drive wheel
258947-040 2009-10-05 6061850 844
12 – Drive wheel 3530

A
12.1 Changing drive wheel

1. Lift the truck up on blocks (approx. 100 mm).
2. Loosen the drive wheel (A).
The drive wheel is most easily loosened diagonally from one of the
sides.
3. Put the new wheel in position (A) and tighten the nuts (B)
81 ±19 Nm.

Drive wheel 3530
Changing drive wheel
844 6061850 2009-10-05 258947-040

Castor wheel 3540
Components
258947-040 2009-10-05 6061850 844
13 – Castor wheel 3540
13.1 Components
A
B
C
L M
K J
Pos. Name Pos. Name

A Locking ring H Screw
B Washer I Distance
C Screw J Distance
D Bracket K Storage
E Nuts L Protection
F Storage M Nuts
G Locking ring
© BT Repair Manual SWE080L 13 – 1

Castor wheel 3540
Castor wheel mounting
844 6061850 2009-10-05 258947-040
13.2 Castor wheel mounting

A
B
C
F
H
G
I
Pos. Name Pos. Name

A Nuts G Screw
B Nuts H Cradle
C Steering I Bushing
D Spring J Fitting
E Steering K Screw
F Washer
13 – 2 Repair Manual SWE080L © BT

Castor wheel 3540
Changing castor wheel
258947-040 2009-10-05 6061850 844
13.3 Changing castor wheel

1. Elevate the truck securely.
2. Unscrew the castor wheel.
13.4 Changing castor wheel cradle

1. Raise the forks.
2. Remove the inspection cover.
3. Loosen the spring fasteners.
4. Loosen the bracket for the castor wheel mounting.
5. Lift the drive unit so that the cradle is free.
13.5 Changing springs
13.5.1 Removing springs

1. Loosen the upper lock nuts.
2. Lift the drive unit so that the springs are released from the upper
bracket.
3. Loosen the lower lock nut on the spring that is to be changed.
NOTE!
The spring is pre-tensioned, take care when loosening the lower lock
nut.
13.5.2 Fitting the spring

1. Place a block under the spring bolt so that the spring screw is held
in place.
2. Fit the spring with the lower lock nut and washer.
Use a short sleeve in order to screw the lower lock nut tight whilst
pressing the spring together.
3. Screw down the lower lock nut so that the distance between the
edge of the washer and the top of the screw is 15 mm.
4. Ensure that the springs are sitting correctly in the upper fasteners
when the drive part is lowered.
Screw the upper lock nuts tightly.

Castor wheel 3540
Changing springs
844 6061850 2009-10-05 258947-040

Support arm wheel 3550
258947-040 2009-10-05 6061850 844
14 – Support arm wheel 3550

c
Pos Name
a Screw
b Bracket
c Bogie wheel
d Single wheel
e Axle
f Locking ring

Support arm wheel 3550
844 6061850 2009-10-05 258947-040

Tiller arm 4000
Components in tiller arm
258947-040 2009-10-05 6061850 844
15 – Tiller arm 4000
15.1 Components in tiller arm

A
T
B
E
S
D I
F J
R G
H K
Q
L
P M
N
O
V
OO
Pos. Name Pos. Name

A Steering arm M Indicator socket
B Rubber fender N Plate
C Cylindrical bolt O Ok
D Gas spring P Cable clamp
E Locking ring Q Screw
F Rubber fender R Ok
G Bushing S Screw
H Wire thread inserts T Cover
I Tension pin U Cover
J Holder V Cable clamp
K Safety sensor B60 W Mounting screw for
cable clamp
L Axle

Tiller arm 4000
Removing tiller arm
844 6061850 2009-10-05 258947-040
15.2 Removing tiller arm

2. Remove the housing (A).
3. Loosen the yoke's (D) mounting screws (B).
4. Detach cable clamp (P) by pressing the clamp with your thumbs
and lifting it upwards. Remove the cable clamp through the hole in
the tiller arm.
NOTE:
Do not try to prise off the cable clamp using a screwdriver.
5. Loosen the cable connections [X5] and [X60].
15.3 Changing gas spring

1. Remove the casing (T).
2. Loosen the cable clamp mounting screws (W).
3. Loosen the adjustment screw (E).
4. Remove the catch (O) from the gas suspension's lock axle (S).
5. Loosen the gas suspension's lock axle (S).
6. Remove the gas suspension (n) and rubber fender (M).
Before fitting, screw (E) must be replaced with a new one and other
components inspected for damage.
The new gas suspension must be lubricated with grease in sockets
sideshift cylinder.
Note!
Be careful when assembling so that no cables are crushed.

Tiller arm 4000
Changing the safety sensor
258947-040 2009-10-05 6061850 844
15.4 Changing the safety sensor
15.4.1 Dismantling
1. Remove the gas spring. See section“15.3 Changing gas spring”.
2. Knock the axle's (L) spiral pin (I) into place. Use a drift to knock the
spiral pin to a depth at which the spiral pin goes into the axle
completely.
3. Knock out axle (L) approximately 5 mm to expose the hole for the
spiral pin. Take care not to trap indicator sleeve (M).
4. Turn the axle (L) so that the reverse of the indicator sleeve (M)
becomes accessible.
5. Loosen the indicator sleeve (G).
Prize the indicator sleeve away from both sides simultaneously to
avoid damaging the sleeve. Check the sleeve's guide pin, if it is
damaged the sleeve must be replaced.
6. Remove the axle (H).
NOTE:
Ensure that the handle does not fall down and pull apart the cables.
7. Remove the cable clamp mounting screw (W).
8. Remove the sensor mounting screw (S).
9. Loosen the contact B60 from the sensor (U).
10. Remove the sensor.
15.4.2 Assembly
1. Fit the sensor (K)
2. Fit contact B60 to the sensor.
3. Apply Loctite to the sensor mounting screw (S), or replace it. Screw
in the screw.
4. Screw in the cable clamp mounting screw (W).
NOTE:
Route the cable to the right of the sensor (K), against the spiral pin.
5. Knock the spiral pin (I) out of the axle (L) before fitting the axle.
6. Fit the indicator sleeve and then turn the axle so that the sleeve is
turned in towards the sensor. Turn it exactly so far that the spiral
pin can go into the axle.
7. Use a drift to knock the spiral pin into the yoke (O) and axle (L).
Knock in the spiral pin so that the drift goes approximately 19 mm
into the yoke. See picture.
19
8. Fit the gas spring. See section“15.3 Changing gas spring”.

m
m
9. Check the function of the safety sensor.

Tiller arm 4000
Components in tiller arm handle
844 6061850 2009-10-05 258947-040
15.5 Components in tiller arm handle

H
G
A
F I
C
A B
D
K
J
L
S
T
M
X
K
L
Q P
O
Pos Description Pos Description

A Symbol board M Speed regulator/
direction selector
B Push button N Display
C Push button O Cable holder
D Push button for safety P Cable holder
reversing
E Spring Q Cover
F Logic card R Plug
G Seal S Cap, transparent
plastic
H Spring T Seal
I Cover U Handle
J Seal V Cap
K Signal button X Wiring harness
L Signal switch

Tiller arm 4000
258947-040 2009-10-05 6061850 844
15.5.1 Removing the tiller arm handle

1. Unscrew the keyboard.
2. Loosen the screws and press down the upper cover (Q).
3. Disconnect the cable connected to the logic card (F).
4. Loosen the screws and carefully lift away the undercover (I),
Place a finger between the undercover (I) and the safety reversing
switch (D) to hold the switch in place.
Note!
Static electricity!
Risk of static discharge that can damage the electronics.
Ensure that necessary measures are taken before working with
electronics.
15.5.2 Replacing the logic card

Note!
Access to TruckCom is required to be able to perform this action!
1. Loosen the housing's (I) mounting screws.
2. Disconnect the logic card connections.
3. Remove the logic card.
Use TruckCom in order to load the software and reset the parameters
from backup that are stored in the main unit.
1. Load new software into the logic card.
2. When downloading is complete, press the red button and wait for
error code 2.002 to be shown clearly.
3. Press “Connect” again in TruckCom and choose the current
software if TruckCom does not locate it.
4. Select “Copy truck configuration” in TruckCom.
5. Select “Copy configuration to primary unit: ICH”
6. Start the truck.

Tiller arm 4000
844 6061850 2009-10-05 258947-040
15.5.3 Changing signal button/switch

1. Remove the button according to the picture.
2. Disconnect the switch connector on the logic card (4).

3. Push the switch out from its fastening.

Tiller arm 4000
258947-040 2009-10-05 6061850 844
15.5.4 Changing raising/lowering button.

1. Remove the button by placing a screwdriver in holes (A) according
to the picture below.
A A
2. Unscrew the holder (18) so that the arm (12) is loose.

15.5.5 Changing push button

1. Push the button sideways manually.
2. Place a screwdriver according to the image and carefully prise the
button loose.
3. Unscrew the button's holder and arm.


Tiller arm 4000
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15.5.6 Changing the position of the controls -

support arm lift/fork lift
1. Undo the buttons for the lifting control using a narrow chisel and
swap with the rear buttons.
2. Ensure that the projections hook into position when fitting the new
buttons.
3. Connect a PDA or PC and use TruckCom to change parameter
1023 to 2.
4. Start the truck to verify the change.

Tiller arm 4000
258947-040 2009-10-05 6061850 844
15.5.7 Changing a switch for safety reversing

1. Remove the display by undoing the screws.
×1
2,5 mm
2. Undo the screws to the upper part of the control lever.
×4
4 mm
3. Disconnect the CAN contact.

Tiller arm 4000
844 6061850 2009-10-05 258947-040
4. Undo the screws so that the holder for the switch comes loose.
×3
3 mm
5. Remove the button by unhooking the locks on both sides
6. Assemble in reverse order.

Electrical components
Changing wiring harness
258947-040 2009-10-05 6061850- 844
16 – Electrical components
16.1 Changing wiring harness
A
B
X5
C
X21
X60
Pos. Name
A Contack locking
B Contact, flange
C Bracket
D Contact, handle
When changing the wiring harness, work according to the following

instructions:
1. When spacing the X contacts, press the contact locking (A) into the
flange (B) and pull upwards.
2. Loosen the contact's flange (B) from the handle (D).
3. Then release the handle (D) by pulling it downwards.
The remainder is fastened (C) to the contact panel.
Changing wiring harness
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16.1.1 Changing the transistor regulator's

wiring harness.
When you are loosening the contact (A) to the transistor regulator, think
about the following:
• Press in the ring-lock first (B).
• Then lift up the contact ring (C).

Replacing the transistor regulator
258947-040 2009-10-05 6061850- 844
16.2 Replacing the transistor regulator

Note!
Access to TruckCom is required to be able to perform this action!

2. Cut the cable duct tie on the transistor regulator's side.
3. Remove the contacts (a) from the contact holder.
4. Loosen all cables and contacts in the transistor regulator.
5. Loosen the fastening nuts on the fixing plate (b).
6. Remove the transistor regulator.
Angle the fixing plate on the upper edge and turn it in the drive
wheel direction in order to remove it from the truck.
Assemble in reverse order
After fitting a new transistor regulator, the truck will display error code
2.004.
1. Connect TruckCom.
2. Select “Copy truck configuration”.
3. Select “Copy configuration to secondary unit: ACT”

Replacing the transistor regulator
844 6061850- 2009-10-05 258947-040

Hydraulic system 6000
General
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17 – Hydraulic system 6000
17.1 General
Remember to take the following safety measures before you beging
working with the truck's hydraulic system:
• Release the system's pressure gradually.
• Use paper or a stiff piece of cardboard when checking for possible
leakage. Do not use hands.
• Take care as the oil in the transmission and hydraulic systems may
be hot.
DANGER!
If you come into contact with hot transmission and hydraulic oil there
is a risk of burns. Allow the truck to cool down before changing the
oil.

Hygiene when working on hydraulics
844 6061850- 2009-10-05 258947-040
17.2 Hygiene when working on

hydraulics
NOTE!
Risk of malfunction.
If contaminants get into the hydraulic system there is a risk of
malfunctions in parts of or in the entire hydraulic system. There is also
a risk of serious damage to incorporated components.
Observe the following instructions at all times when working on
hydraulic systems.
NOTE!
Only new and clean oil should be put into the hydraulic system. If the
oil is polluted, the hydraulic components will be damaged.
17.2.1 Washing
Wash hydraulic components, including hydraulic hoses and pipes,
using filtered cleaning fluid, in a manner suitable for that component.
The cleaning fluid is to have a cleanliness code of 19/16/13 according
to ISO4406:1999, or alternatively 16/13 according to ISO4406:1987.
Components can be blown clean using dry filtered air when this is the
only practically feasible cleaning method.
17.2.2 Packaging
After cleaning all openings must be sealed using protective plugs.
Connection faces must be protected against damage caused by
handling and against the ingress of dirt.
Completely dry components can be packaged in plastic bags or boxes
with lids.
Packaging (protective plugs, masking, plastic bags etc.) must not be
removed until immediately before components are to be fitted, and then
in a workplace that is adapted for the handling of hydraulic
components.
Tape must never be used without subsequent cleaning.
Protective plugs are to be stored in plastic bags or boxes with lids until
they are used.
Plugs and plastic bags are to be discarded after use.
17.2.3 Handling
Hydraulic components are to be handled and transported with great
care.
Transport packaging is to be used throughout the chain of operations.
This packaging is to be clean and free of swarf etc.

Hygiene when working on hydraulics
258947-040 2009-10-05 6061850- 844
17.2.4 Storage
Hydraulic components are to be handled and stored so:
• that corrosion does not occur
• that they are shielded from dust and dirt particles
• that mechanical deformation does not occur
17.2.5 Carrying out work

When work is being carried out on hydraulic systems, observe a level
of cleanliness such that contaminants do not get into the system.
Machining by chip removal must never take place at the same, or close
to a workplace at which work is carried out on hydraulic systems.
The service technician is to ensure that components being used are
thoroughly deburred and cleaned.
Closures for pipe ends or other openings must not be removed until the
component is being connected to its mated component.
Note!
All hydraulic components that have not been washed such as pipe
unions and nipples must be blown clean prior to fitting.

Hydraulic unit 6100
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17.3 Hydraulic unit 6100
a
o
n
b
c
m
i
d h
g
f
e
03290.wmf
Pos. Name Pos. Name

a Pump motor [M3] h Hydraulic fork connection
b Magnetic valve, support arm selection i Pressure limit valve
[Q23]
c Magnetic valve, fork selection [Q22] k Max. oil level
d Proportional valve, lowering [Q4] m Filling cap
e Tank (suitable oil volume 2 l) n Pump motor cable connection
f Screw o Pump motor cable connection
g Hydraulic connection, support arm

Hydraulic unit 6100
258947-040 2009-10-05 6061850- 844
17.3.1 Emptying the hydraulic tank

1. Loosen all cables and tubes to the hydraulic unit.
2. Loosen the hydraulic unit from the truck by releasing the clamps
that surround the pump motor.
3. Loosen the tank from the hydraulic unit by loosening screw (f).
17.3.2 Hydraulic system, bleeding

Cylinders with bleeding valve
1. Loosen all bleeding screws 2 revolutions.
2. Lift slowly at a constant rate until the forks begin to rise (30-40 cm).
3. Close the bleeding screws.
4. Lower the forks and continue to press the lowering button for 10-15
s.
5. Top up with oil.
6. Lift the forks to max.
7. Lower and check the oil level.
Cylinders without bleeding valve

1. Lift slowly at a constant rate until the forks begin to rise.
2. Lower the forks and continue to press the lowering button for 10-15
s.
3. Repeat a couple of times.
4. Top up with oil.
5. Lift the forks to max.
6. Lower to min.
7. Allow to stand approx. 30 min (info for customer).

Hydraulic connections 6230
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17.4 Hydraulic connections 6230
17.4.1 Quick change connector

Assembling the quick change connector
1. Place the assembly stop (1) on the male fitting and make
sure that the dismantling ring (2) runs freely in the groove.
2. Push the male fitting into the female fitting until the assembly
stop makes contact with the female fitting.
3. The coupling is now made and locked.

Hydraulic connections 6230
258947-040 2009-10-05 6061850- 844
Dismantling the quick change connector
1. Remove the assembly stop (with the aid of a screwdriver or

similar tool).
2. Push the male fitting all the way into the female fitting.
3. Pull the male fitting out of the female fitting.
4. Refit the assembly stop on the male fitting.
5. Place protective plugs on the valve and hose.

Hydraulic calibration
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17.5 Hydraulic calibration

In order to handle the proportional valve’s tolerance a calibration func-
tion can be used. To activate calibration mode, service mode “cal” must
be set at “1” and the truck restarted. When a calibration is carried out
the service key must be connected and maximum rated weight loaded
on the forks.
In calibration mode “strt” will appear on the display pending one of the
two signal buttons being pressed. The calibration starts when one of
the signal buttons is pressed. The lowering valve then opens slowly. As
soon as the operator feels the lowering movement of the forks the sig-
nal button must be released.Wait until the display “end” appears on the
display and then restart the truck. Service parameter 108 resets auto-
matically after a calibration has been carried out.
The calibration process affects the following parameters:
• The fork’s maximum lowering speed (parameter 302)
• The proportional valve’s start position (parameter 303)
• The supporting leg’s lowering speed (parameter 304)
• Slow lowering speed (parameter 305)
All parameters can be adjusted manually after a calibration.

Adjustment of the pressure limit valve
258947-040 2009-10-05 6061850- 844
17.6 Adjustment of the pressure limit

valve
Location of the valve

The truck must be able to handle the rated load on the forks.
Place a rated load on the forks and verify that the truck is able to lift it.
If the truck cannot lift the rated load:
c
b
1. Prise off the white sealing cap (a) around the pressure limiting
valve using a screwdriver.
2. Loosen the protective cover (b) (17 mm) by turning it anti-
clockwise. Remove the protective cover and washer inside it.
3. Loosen the lock nut (c) (17 mm) by turning it anti-clockwise.

Adjustment of the pressure limit valve
844 6061850- 2009-10-05 258947-040
4. Screw in the adjustment screw clockwise until the truck is able to lift
the load without problems.
5. Tighten the lock nut (c) clockwise.
6. Refit the washer and protective cover (b).
Once the truck is able to lift the rated load, add a further 100 kg onto
the forks. Verify that the truck cannot lift the load.
If the truck is able to lift 100 kg more than its rated load:
1. Prise off the white sealing cap (a) around the pressure limiting
valve using a screwdriver.
2. Loosen the protective cover (b) (17 mm) by turning it anti-
clockwise. Remove the protective cover and washer inside it.
3. Loosen the lock nut (c) by screwing it anti-clockwise.
4. Unscrew the adjusting screw anti-clockwise until the truck cannot
lift the load.
5. Tighten the lock nut (c) clockwise.
6. Refit the washer and protective cover (b).
7. Push a new sealing cap (a) around the pressure limiting valve

Disassembling the hydraulic unit
258947-040 2009-10-05 6061850- 844
17.7 Disassembling the hydraulic unit

Before commencing any work on the hydraulic unit, make sure the
forks have been fully lowered.
Step 1. Step 2.
×n
s mm
s: 13 mm, n: 2off
Step 3.
1. Detach the hydraulic hoses. See section “17.4.1 Quick change

connector”.
2. Undo the motor cables using a spanner.

Disassembling the hydraulic unit
844 6061850- 2009-10-05 258947-040
3. Disconnect the electrical connections to the valves.
Step 5.
×n
Step 4.
s mm
×n
s: 7mm, n: 1off
s mm
s: 6mm, n: 1off
Step 6.
4. Loosen the hydraulic unit bracket and lift the unit out of the truck.
5. Loosen the clamp in order to detach the tank from the motor, and
lift the motor and valve block away from the tank.
6. Remove and clean the strainer, then reattach it in the correct
position.
7. Change the oil and clean the tank.
8. Reassemble everything in reverse order. See section
“17.8 Hydraulic unit tightening torques”.
NOTE:
Take care of the hydraulic unit seals when refitting it
Hydraulic unit tightening torques
258947-040 2009-10-05 6061850- 844
17.8 Hydraulic unit tightening torques

The hydraulic unit tightening torques are depicted in the picture below:
10 + 2 Nm
10 mm
8,5 +- 0,5
0,5 Nm
13 mm
45 + 5 Nm
24 mm
45 + 5 Nm
24 mm
5 +- 0,8
0,8
Nm
4 +- 0,5
0,5 Nm
7 mm

Hydraulic unit tightening torques
844 6061850- 2009-10-05 258947-040

Lift mast – 7000
Main mast 7100
258947-040 2009-10-05 6061850- 844
18 – Lift mast – 7000
18.1 Main mast 7100
c
d
b a
03291.wmf
18.1.1 Components
Pos Name Tightening torque

a The bolt's tightening M6S 16x60 = 150 ±15 Nm
torque
M6S 16x70 = 189 ±15 Nm
b Shims Required quantity
c Angle 90° + 45’ / - 0”
d Angle 90° ± 10’

Lift mast – 7000
Main mast 7100
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18.1.2 Maintenance
Mounting
The maintenance schedule states that only a visual inspection of the
mast mounting bolts (a) must be carried out and that they must not be
tightened when they are checked. If the mast needs to be changed or if
the bolts have become loose, new bolts and washers must be used.
The tightening torque should be according to the table.
The angle of the mast must be checked as per the table.

Lift mast – 7000
Fork carriage 7420
258947-040 2009-10-05 6061850- 844
18.2 Fork carriage 7420
mf
9 3 .w
032
a
b
Pos Name
a Shims
b Roller
18.2.1 Maintenance
• Check that there is not too much play in the fork carriage.
• Adjust using the shims (a) if needed.
• There are rollers with different diameters (c) to compensate for wear
to the runner.

Lift mast – 7000
Main lift chain system 7120
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18.3 Main lift chain system 7120
18.3.1 Checking the chain setting

The lift chains must be adjusted at regular intervals due to elongation,
see below. Chain adjustment is checked as part of regular
maintenance as specified 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
where applicable.
18.3.2 Inspecting the chain

The chains are subject to two types of wear – plate wear and chain
elongation. Elongation is caused by wear to the bolts and plate holes.
The chains are also affected by the environment in which they are
used.
Noise
If there has been insufficient lubrication, there will be metallic friction on
the chain and this will result in noise.
The chain must be replaced.
Surface rust
Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally begun and the strength of the chain is
impaired.
Rusty links
Fretting corrosion results in a reddish brown powder being visible near
the outer plates. The chain can also appear to bleed when lubricated.
Stiff links
If it is not possible to pull the chain out to its normal position this can be
due to link rust or jamming.

Lift mast – 7000
258947-040 2009-10-05 6061850- 844
Bolt rotation
Bolt rotation can be a phenomenon related to stiff links. The fault is
easy to see when comparing with a new chain.
.
Loose bolts
If a bolt is loose it will protrude from the side of the chain, and this is due
to a stiff link or bolt rotation.
Plate wear
H2 H3
P = Pitch.
H2 = Nominal plate height.
H3 = Minimum plate height.
A new lift chain has a specific nominal plate height, indicated by H2 in
the figure. As the truck is used, the lift chain is subject to radial wear on
the side that passes over the chain wheel. The minimum plate height,
H3 in the figure, indicates the minimum permitted value of the plate
height.
Lift mast – 7000
844 6061850- 2009-10-05 258947-040
Maximum permitted plate wear is 5% of the H2 height. If a lift chain has

reached the maximum degree of wear, the chain must be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.
Elongation
The elongation of a lift chain is measured on the part of the chain that
passes over the chain wheel. Elongation in the section of chain where
wear is greatest may not exceed 2%.
The measurement is best made over 300-1000 mm of chain.
The nominal and maximum permitted chain lengths for the relevant lift
chain are specified in the table below.
Type of Nominal Minimum Pitch P Nominal chain Maximum

chain plate plate (mm) length for 20/30/ permitted chain
height H2 height H3 50 plates (mm) length for 20/30/50
(mm) (mm) plates (mm)
3/4”, 2x3 17,8 16,9 19,05 381/572/953 389/583/972
3/4”, 3x4 17,8 16,9 19,05 381/572/953 389/583/972
3/4”, 4x6 17,8 16,9 19,05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
One cause of chain elongation is wear on the bolts and around the
holes in the plates. The chain must be replaced if elongation exceeds
2%.

Lift mast – 7000
258947-040 2009-10-05 6061850- 844
Damage
If there is any other damage, the chain should be replaced
Damaged plates
If a plate has broken on the chain, this may be due to overloading or
corrosion.
Damaged bolts
It can be difficult to determine whether a bolt has broken. A broken bolt
can manifest itself as bolt rotation and/or a loose outer plate.
Dirty chain
If a chain is very dirty the recommendation in the first instance is that it
should be replaced. It can also be dismantled and cleaned as set out in
the chapter “Cleaning”.
18.3.3 Cleaning
If a chain is very dirty you are recommended to replace it.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.

Lift mast – 7000
844 6061850- 2009-10-05 258947-040
The chain should be blown dry using compressed air and lubricated
directly after cleaning
Note!
Take care with degreasing agents as these may contain abrasives.
18.3.4 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
Note!
Lubricant must not contain substances such as molybdenum
disulphide, PTFE, or similar.
A lift chain must be released from the weight of the fork carriage
(suspended) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, including the fixing bolts. It is particularly important that the
part of the chain that runs over the chain wheel is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient Viscosity Recommended Products*

temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber
Lubrication
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
Lubrication
<+ 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
* Similar products from another manufacturer may be used.
Note!
Do not use a special rust protective agent to prevent rust attack on
the lift chains.
These agents impair lubrication of the chains. Regular lubrication is
the best way of preventing rust attack.

Lift mast – 7000
Changing the fork-lift trolley using an overhead crane or another truck
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18.4 Changing the fork-lift trolley using

an overhead crane or another truck
1. Remove the stand cover by undoing the four screws with a hex key
3.
2. Raise the forks with a strap to slacken the chain.
3. Undo the pin for the chain bolt and release the chain (NB! take care
when handling the chain as there is a great risk of getting your fing-
ers caught).

Lift mast – 7000
Changing the cylinder
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4. Remove the mast’s cylinder head by undoing the four screws with
a hex key 6.
5. Lift the fork-lift trolley straight up.
18.5 Changing the cylinder

1. Lift out one of the batteries in order to be able to disconnect the hy-
draulic connection to the stand with pliers.
2. Carry out changes to the fork-lift trolley up to and including stage 4

in the description in 17.4

Lift mast – 7000
Changing the stand
258947-040 2009-10-05 6061850- 844
3. Undo the two screws fastening the cylinder in the stand with a hex
key 8.
18.6 Changing the stand

1. Lift out one of the batteries in order to be able to disconnect the hy-
draulic connection to the stand with pliers.
2. Undo the four screws for the stand cover with a hex key 3.

Lift mast – 7000
Changing the stand
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3. Fasten a strap to the top of the stand and secure it with an over-
head crane.
4. Undo the stand fastening’s two screws and lift off the stand.
5. Assemble the new stand in reverse order

Accessories
Spider expansion unit
258947-040 2009-10-05 6061850- 844
19 – Accessories
19.1 Spider expansion unit

The spider expansion unit, called SEU, allows the main logic card to
manage a large number of inputs and outputs. There is no truck control
logic in SEU, which means that a faulty SEU can be changed without it
affecting the truck's function.
SEU is used for modifying the truck in accordance with special
requirements from the customer. .
Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector
Motor
Controller
The image above shows how SEU is used to allow a large number of
functions to be controlled via the CAN bus. SEU has a 42 pin, multipin
contact that manages all inputs, outputs, CAN and power supply
signals.

Accessories
TLS - Truck log system
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19.2 TLS - Truck log system

See the separate manual that comes with the truck log system.
19.3 ID unit
See the separate manual that comes with the software.
19.4 Toyota Wireless Information

System T.W.I.S.
See the separate manual that comes with the software.
19.5 Automatic height preselector

The truck can be fitted with a photocell, which in the automatic mode
controls lifting and lowering of the forks to maintain a preset height
when the sensor detects the load.
The photocell bracket can be adjusted to set the desired operation
height. The holder features an emergency stop switch [S22] and an
indicator lamp [H97], which lights when the function is active.
NOTE! This function is configured by adjusting the factory parameters.
The table below shows the default settings for the factory parameters
when the truck is equipped with the automatic height preselector
option.
Parameter Parameter Parameter Parameter Parameter

1003 1004 1005 1006 1007
Value 11 0 4 0 0

Accessories
Built-in battery charger
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19.6 Built-in battery charger

Note!
When retrofitting a built-in battery charger, TruckCom is required to
be able to set all necessary parameters. When replacing the existing
charger, TruckCom is not required.
If the truck is supplied with a battery from the factory, the battery
charger is adapted to suit the battery.
If the truck is delivered without the battery from the factory, the
customer/technician must enter the correct parameters according to
the type and size of the battery.
19.6.1 Technical data

Name SMCO 24/30
Size, mm 240x111x77
Weight, kg 1,7
Ambient temberature, ºC -25 - +40 (free ventilated batteries)
+15 - +30 (valve regulated batteries)
Mains voltage, V AC 195-264
Rated voltage, V DC 24
Rated current, A 30
Maximum output, W 800

Accessories
Built-in battery charger
844 6061850- 2009-10-05 258947-040
19.6.2 Battery charging

Open the battery door and connect the charger's contact to wall socket
to begin charging.
Note!
Always switch off the truck before charging and disconnect other
electrical connections to the truck.
When the truck is being charged, the following is shown on the display:
Main charge
On the left of the sign window, lines are shown in sequence as the
battery is charged. The battery symbol and OFF button blinks.
Uneven charging
Four lines on the left of the sign window shine constantly while four
lines on the right are shown in sequence. The battery symbol and OFF
button blinks.
Charging complete
The sign window shows the capacity value and the unit (Ah) alternately.
The battery symbol shines at a fixed brightness and the OFF button
blinks.
Remove the contact from the wall socket when the battery charge is
complete. The OFF button now shines permanently. The truck is ready
for use.

Appendices
General
258947-040 2009-10-05 6061850- 844
20 – Appendices
20.1 General
In the chapter Appendices, you can quickly find the following
information:
• technical data
• general tightening torques
• tools
• oil and grease specifications
• electrical components and wiring diagrams
• hydraulics chart
• instructions for disposal.

Appendices
General
844 6061850- 2009-10-05 258947-040

Technical data
SWE080L
258947-040 2009-10-05 6061850- 844
21 – Technical data
21.1 SWE080L
Model SWE080L
Drive motor
Type Iskra AML7108
Output, kW 1,0
Duty cycle S2-60 min
Weight, kg 9
Brake
Type Warner PK10
Braking force, Nm 15
Output, W 51/13
Resistance, coil, Ω 10,5-12,0
Nominal play in actuated position, 0,3
mm
Minimum thickness of brake disc, 7,9
mm
Thickness of a new brake disc, 8,2
mm
Transmission/gear
Type Kordel Genius 5.72.02.1
Gear ratio 30,204
Oil volume, litres 0,8
Oil type 100 % synthetic
API GL-5,SAE 75W-90

Technical data
SWE080L
844 6061850- 2009-10-05 258947-040
Model SWE080L
Wheel
Drive wheel, mm 230
Wheel pressure (kg/mm²) 0,32
Axle pressure without load, kg 375
Axle pressure at rated load, kg 525
Tightening torque wheel bolts, Nm 81±19
Support arm wheel, mm 125
Axle pressure without load, kg 180
Axle pressure at rated load, kg 830
Castor wheel, mm -85
Axle pressure without load, kg -150
Axle pressure at rated load, kg -150
Hydraulic system
Output, kW 1,4
Duty cycle, %
Minimum carbon brush length,
mm
Minimum commutator thickness/
diameter, mm
Pressure at rated load, bar
Overflow pressure, bar
Pump flow, litres/minute
Tank volume, litres
Oil type ISO VG32
Normal temperature ISO 6743-4 category HM
< 0oC ISO VG27.5
ISO 6743-4 category HV
Fuses
Drive motor circuit, A 125
Pump motor circuit, A 125
Control circuits, A 7,5

Technical data
SWE080L
258947-040 2009-10-05 6061850- 844
Model SWE080L
Battery compartment, Batteries
Capacity, Ah 180
Weight, kg 182
Driving speeds
Without load, km/h 6,0
Without load, m/s 1,7
With rated load, km/h 6,0
With rated load, m/s 1,7
Lift/lowering speed
Lift without load, m/s 0,21
Lift with rated load, m/s 0,14
Lowering without load, m/s 0,20
Lowering with rated load, m/s 0,29
Gradient capabillity
With rated load, % 9
Measurement
L1 1777
Lift height 1580
Weight
Truck without battery, Medium 492

Technical data
SWE080L
844 6061850- 2009-10-05 258947-040

General tightening torque
General
258947-040 2009-10-05 6061850- 844
22 – General tightening torque

22.1 General
Millimetre threads M3 to M24. The following applies under ideal
conditions, e.g. steel against steel.
Note!
Experience has shown that if you adjust the torque wrench to the
values for untreated bolts, you will also achieve the correct torque
value for galvanised bolts. Do not tighten more than the values set
out in the tables otherwise the bolts may be destroyed.
22.2 Galvanised non-oiled bolts

Tightening torque (Nm)
Strength class:
8,8 10,9 12,9
M3 1,1 1,6 2,0
M4 2,8 3,8 4,7
M5 5,5 7,7 9,3
M6 9,5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075
22.3 Untreated, oiled bolts

Tightening torque (Nm)
Strength class:
8,8 10,9 12,9
M3 1,2 1,7 2,1
M4 2,9 4,0 4,9
M5 5,7 8,1 9,7
M6 9,8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120

General tightening torque
Untreated, oiled bolts
844 6061850- 2009-10-05 258947-040

Tools
MQS contacts
258947-040 2009-10-05 6061850- 844
23 – Tools
23.1 MQS contacts
Tools Number Use

257841 MQS Basic toolbox.
The box contains:

1 set pliers with tools
25 x splice 0.5-1.5 mm2
2 x 2, 3, 4, 6, 8 and 12 pin complete
contacts (male and female) with cables
and splice attached.
Used for replacing damaged contacts
in the truck.

Tools
MQS contacts
844 6061850- 2009-10-05 258947-040
Tools Number Use

257842 MQS assortment box.
Used for the complete MQS 257843
toolbox.
The assortment box contains:

200 x sleeves 0.2-0.5 mm2
200 x SWS sleeves 0.2-0.5 mm2
400 x SWS sleeves 0.5-0.75 mm2
100 x Clean body sleeves 0.5-0.75
mm2
200 x SWS pins 0.2-0.5 mm2
400 x SWS pins 0.5-0.75 mm2
1200 x seals
200 x blindplugs
257843 Complete MQS toolbox.
Contains 4 pliers with tools:

MQS SWS 0.25-0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&Clean body 0.25–0.5 mm2,
MQS Std&Clean body 0.5-0.75 mm2
Extraction tool for 2, 3, 4, 6, 8 and 12

pin male and female contacts.

Tools
AMP contacts
258947-040 2009-10-05 6061850- 844
23.2 AMP contacts

PT = Power Timer (4.8, 5.8, 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)
Figure Number Use

151080 (PT) Tool for removing pins/
sleeves
213296 (JPT) Tool for removing pins/

sleeves
213298 (MPT) Tool for removing pins/

sleeves
1=163787 (JPT) Tool for applying sleeves

2=163788 (JPT)
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tool for fitting pins
2=213549 (JPT) For 0.5–2.5 mm2
1
2

Tools
Molex contacts
844 6061850- 2009-10-05 258947-040
23.2.1 AMP contacts Multilock series 040
Figure Number Use

213130 Tool for removing pins
213129 Tool for fitting pins
23.3 Molex contacts

16
9
8
1
Figure Number Use

156937 Tool for fitting pins/sleeves
156936 Tool for fitting pins/sleeves

Tools
Grease guns
258947-040 2009-10-05 6061850- 844
23.4 Grease guns
Figure Number Use

24981 Tool with pointed nozzle to apply
grease. Length 170 mm.
755132 One-handed grease gun with straight

pressure tube and nozzle.
755142 One-handed grease gun with straight

pressure tube and nozzle.
755152 Two-handed grease gun with hose

and nozzle.
755145 Lubricating hose 450 mm.

755146 Lubricating hose 750 mm.
755147 Lubricating hose 1,500 mm.
202154PM Pointed nozzle for grease guns, to

apply grease in recessed nipples.
Fits grease guns with hose and
pressure tube. Length 125 mm.
755140 Nozzle for tall grease nipples. Fits
grease guns with hose and pressure
tube.

Tools
Other tools
844 6061850- 2009-10-05 258947-040
23.5 Other tools
Figure Number Use

156263 Service key CAN)
08-13022 Puller, drive gear

Oil and grease specification
258947-040 2009-10-05 6061850- 844
24 – Oil and grease specification
Table 1: Oil and grease specification

Lubricant type Specification Use
Grease S213366 Storage and bushings
Q8 Rubens WB
Hydraulic oil See table below Hydraulic system
Transmission oil Synthetic Gear
API GL-5
SAE 75W-90
Grease See table below Chains
Grease Grafloscon Gear rim
A-G1 (Klüber)
Grease 755701-040 Castor wheel
Grease S213366 Mast
Q8 Rubens WB
Hydraulic oil
Ambient Viscosity class Specification
temperature
< 0°C VG 27.5 ISO 6743-4 category HV
DIN 51524 part 3= HVLP
> 0°C VG 32 ISO 6743-4 category HM
DIN 51524 part 2 = HLP
Chain grease
Ambient Viscosity class Recommended products*
temperature
> - 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
* Similar products from another manufacturer may be used.

Oil and grease specification
844 6061850- 2009-10-05 258947-040

Electrical components and wiring diagram
258947-040 2009-10-05 6061850- 844
25 – Electrical components and

wiring diagram
25.1 Electrical components

The table below shows a compilation of the most important electrical
components on the truck.
Symbol Description Function Remarks

A5 Logic card Logic card tiller arm
A5:S1-18 Hall sensor Speed control forwards/back-
wards
A5:S17 Hall sensor Safety reversing
A5:S19 Hall sensor Fork lifting control
A5:S20 Hall sensor Fork lowering control
A5:S21 Hall sensor Control of support arm lift
A5:S22 Hall sensor Control of support arm lowering
A30 Battery charger Onboard battery charger Option
A36 PCB ”Spider expansion unit (SEU) Option
B1 Temperature sen- Temperature sensor for drive

sor motor
B11 Pulse converter Speed sensor
B18 Switch Forks in lower end position Automatic height
preselector
(option)
B19 Switch Forks in lower end position Automatic height
preselector
(option)
B91 Photocell Monitoring load height Automatic height
preselector
(option)
B60 Inductive switch Mechanical brake activation
B90 Collision sensor Option
E50 Lamp Automatic mode Automatic height

preselector
(option)
F1 Fuse Main fuse 125 A

844 6061850- 2009-10-05 258947-040
F50 Fuse Working circuit A5 7.5 A

F51 Fuse Working circuit T1 7.5 A
F52 Fuse Optional equipment Option
G1 Battery 2 x 12V connec-

ted in series
K110 Data handling unit Unit for handling data Option

(DHU)
M1 Motor Drive motor

M3 Motor Pump motor
Symbol Description Function Remarks
P4 Horn
P5 Warning lamp Option
P6 Display Truck function display
Q1 Electromechanical Mechanical brakes

brakes
Q4 Proportional valve Lowering
Q10 Contactor Main contactor
Q22 Magnetic valve Fork selection
Q23 Magnetic valve Support arm selection
Q25 Contactor Contactor, pump motor
S18 Switch Horn button

S21 Switch Emergency switch
S22 Switch Emergency switch Automatic height
preselector
(option)
S97 Switch Warning lamp P5 Option
S206 Switch Turtle function (Turtle) Option
S111 Switch Option button Option
S223 Keypad/Smart card Login with PIN code

258947-040 2009-10-05 6061850- 844
T1 Transistor regula-
tor
T7/T8 DC/DC transformer T7=24V/12V Option
T8=24V/24V
T20 Antenna T.W.I.S. Option
X1 Connection Battery
X21 Connection point DC/DC transformer Option
X40 Connection point CAN communication (Extra I/O)
X41 Connection point CAN communication (External)

844 6061850- 2009-10-05 258947-040
A5:S22 A5:S21 A5:S1-9 A5:S10-18 A5
1
10
18
A5:S17 A5:S20 A5:S19

P6
S113 S116
S206 S115
S111 S114
S18:1 S18:2
A5:S20
A5:S22
A5:S19 A5:S21
A5:S17
S223
B60
X41

258947-040 2009-10-05 6061850- 844
B19 B91
A36 B18
E50
S22
(B1)
B11
X41
S21
P4
X1
03295.wmf
G1
M1
M3
Q1
F50, F51, F52

Q25
F1
Q23
Q10
Q4 Q22
B60
X21
X40
B90
T1 A30
T7/T8

Wiring diagram
844 6061850- 2009-10-05 258947-040
25.2 Wiring diagram
25.2.1 Index of symbols
Table 2: Index of symbols

Symbol Description Symbol Description
Truck battery Emergency switch NC
Fuse Switch, pressure (weight) oper-

ated
Horn Sensor, inductive NO
Motor, a.c.1 Sensor, inductive NC

M
Contactor Variable resistance (potentiome-

ter)
Brake (normally joined) Push switch NO
Coil for hydraulic magnetic valve Contact, multipolar
Pressure sensor, analogue NO = Normally open

P NC = Normally closed
1.AC = Alternating Current

Wiring diagram
258947-040 2009-10-05 6061850- 844
25.2.2 Overview diagram

F51 21 24
6 (+) B+ F1 S21
24 (83) +24V T1
40 (-) B- U
DRIVE MOTOR V M1 1
W
+
X1
Q10
MAIN CONTACTOR (106) 31
- +
B60
72 (95) TILLER ARM Q1
-
IN DRIVE POS.
BRAKE RELEASE (90) 32 40
Q4 G1
1
PROP. LOWER VALVE (108) 33
74 (94) SUPPORT ARM
IN LOW POS +24V (82) 30
HIGH SIDE DRIVER F
M3
10 6
70 (86) MAST SWITCH 1 EXT.

Q25 EQUIP.
OUT PUMP CONTACTOR (107) 34
71 (101) MAST SWITCH 2 Q22

24
FORK VALVE (98) 80
Q23
81 24
SUPPORT ARM VALVE (110)
20 (84) ENABLE/PRE-CHARGE
P4
B11
61 (104) CH A, SPEED SENSOR
62 (103) CH B, SPEED SENSOR SIGNAL HORN (112) 50 F52
B1 63 (92) THERMAL SENSOR

(DRIVE MOTOR) +5V SPEED SENSOR (85) 60
25
+24VDC
64 40
CAN HIGH/LOW NEGATIVE SPEED/ (105) 0VDC T7/T8 X23
(99/100) THERMAL SENSOR 12VDC/24VDC 26
119/120 0VDC 41
OPTION
20 20 F50 1 1
24 24
119/120
(3/4) 119/120 119/120
CAN HIGH/LOW (X3/X3) A2:S17 A5 P5 (3/4)
B90
20 (1) +24V DC
CAN HIGH/LOW Hall SAFETY 20 CAN HIGH/LOW
RED (+) POS. VOLT.
REVERSE 40
40 (2) 0V DC 20 (X3) +24V DC A2:S21 BLACK (-) NEG. VOLT.
40 (X3) 0V DC Hall SUPPORT ARM
OPTION LIFT S97 OPTION A30
A2:S22 MAINS, VAC
(X1 1) HORN 2 Hall SUPPORT ARM MAINS, VAC
(X4 1) HORN 1 LOWER MAINS, EARTH
A2:S19
S18:2 OPTION
Hall FORKS LIFT
S18:1
(X4 2) A2:S20 119/120
(X1 2) Hall FORKS (2/3)
LOWER CAN HIGH/LOW
A2:S1-S9 A2:S10-S18
20 (1) +24V DC
Hall Hall SPEED 40 (8) 0V DC
REF. T20
VALUE K110
X41 ANTENNA
+24V DC (X3) 20 OPTION
(X2:1/2) TURTLE 0V DC (X3) 40
CAN HIGH (X3) 119
CAN LOW (X3) 120
S206
(X2:1/3) TURTLE (X12)
DISPLAY
(X11)
P6
KEYBOARD /
SMART CARD Based on 243986 rev.C
S223 03296.wmf

844
40
Sh. 2
25 – 8
T-code
1 MOTOR CONTROLLER
Sh. 3 T1
7,5A
X21 S21 X21 F51 G1
24 24/BN 1 2 21/WH 21 1 2 1 + - 40
Sh. 2 INP. B-
7,5A
Wiring diagram
F50
20
F1 84 INP. ENABLE / PRE-CHARGE
125A
PUMP MOTOR
A1/1D1 A2/2D2 10 1 2 6 6
M3 INP. B+
20
Sh. 4
Q10
30 1 2 31
Sh. 2 106 OUT. MAIN CONTACTOR
Q25
1 2 34
6061850-
107 OUT. PUMP CONTACTOR
Repair Manual
2
OUT. U
DRIVE MOTOR
3
M1 OUT. V
Valid from serial number
4
OUT. W
SWE080L
B11
1 60
85 OUT. +5V SPEED SENSOR
B11
B11
25.2.3 Wiring diagram
RD BU 2 61
104
INP. CH A, SPEED SENSOR

Date
B11
BK WH 3 62
103 INP. CH B, SPEED SENSOR
|R
2009-10-05
B1 B1
GN 1 63
92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR RD
B11
4 64
105 OUT. NEGATIVE SPEED / THERMAL SENSOR
1/12 PROD D
243986
03297.wmf
258947-040
Order number
© BT
© BT
258947-040
Order number
ONLY STACKER WITH "SUPPORT ARM LIFT"
MOTOR CONTROLLER
Date
T1
24 24
Sh. 1 3 83 INP. +24V, "HIGH SIDE DRIVER"
2009-10-05
X20 Q22 X20

1 2 80
98 OUT. FORK VALVE
X20 Q23 X20

1 2 81
110 OUT. SUPPORT ARM VALVE
Repair Manual
P4
IN
40
Sh. 1 3
50
112 OUT. SIGNAL HORN
6061850-
30 30
Sh. 1 82 OUT. +24V, "HIGH SIDE DRIVER"
SWE080L
Q1
1 2 32
90 OUT. BRAKE RELEASE
Q4
1 2 33
108 OUT. PROP. VALVE
119/RD 119/RD
Sh. 4 99 INP. CAN HIGH
120/WH 120/WH
Sh. 4 100 INP. CAN LOW
2/12 PROD D
243986
03298.wmf
844
T-code
Wiring diagram
25 – 9
844
25 – 10
T-code
IF B63 NOT FITTED

MOTRO CONTROLLER
T1
Wiring diagram
X20 X63 X63 X20

24 70
Sh. 2 11 86 INP. MAST SWITCH, 1
X20 X63
40
Sh. 2 4
X20 X63 X63 X20
71
101 INP. MAST SWITCH, 2
X20 X63
IF B64 NOT FITTED

EXERNAL EQUIPMENT
6061850-
B60
X65 X65
1 2 72
95 INP. TILLER ARM IN DRIVE POS.
Repair Manual
3
NOTE! X65
EXTERNAL EQUIPMENT SHALL NOT BE ELECTRICAL
CONNECTED TO THE TRUCK FRAME.
IF B62 NOT FITTED

B62
SWE080L
X20 X20
1 2 74
94 INP. SUPPORT ARM, IN LOWEST POS.
3
X20
Date
B65
X20 X20
1 2 73
87 INP. SUPPORT ARM, AT TOP POS.
3
2009-10-05
X20
3/12 PROD D
243986
03299.wmf
258947-040
Order number
© BT
© BT
258947-040
ELECTRONIC CARD TILLER ARM

A5
Order number
X5 A5
120/WH 120 3 120
Sh. 2 7 X3 CAN LOW
X5 A5
119/RD 119 7 119
Sh. 2 7 X3 CAN HIGH
Date
X5 A5
40 2 40
Sh. 3 7 X3 INP. 0V DC
2009-10-05
X5 A5
20 6 20
Sh. 1 9 X3 INP. +24V DC
X41 A5
1 20 5 20
X3 OUT.+24V DC
A5
2 40 1 40
Repair Manual
X3 OUT. 0V DC
A5
3 119 8 119
X3 CAN HIGH
A5
6061850-
4 120 4 120
X3 CAN LOW
SWE080L
CAN, SERVICE CONNECTOR
4/12 PROD D
243986
03300.wmf
844
T-code
Wiring diagram
25 – 11
844
25 – 12
T-code
DISPLAY ELECTRONIC CARD TILLER ARM

P6 A5
Wiring diagram
X1 1 X12 1 +5V DC
X1 2 X12 2 SI
DISPLAY
P6
X1 3 X12 3 SCK
8 8 8 8
X1 4 X12 4 ENABLE
6061850-
X1 5 X12 5 LCLK
Repair Manual
X1 6 X12 6 0V DC
S18:1
1 2
X4 1 INP. HORN 1
X4 2 OUT. OV DC HORN 1
SWE080L
S18:2
1 2
X1 1 INP. HORN 2
X1 2 OUT. 0V DC HORN 2
Date
S113
1 2
X2:1/2 TURTLE
2009-10-05
OPTION
X2:1/3 TURTLE
5/12 PROD D
243986
03301.wmf
258947-040
Order number
© BT
© BT
258947-040
Order number
KEY BOARD / SMART CARD ELECTRONIC CARD TILLER ARM

S223 A5
X11 1 147-
Date
X11 2 2580
1 2 3
2009-10-05
X11 3 369#
4 5 6
7 8 9
X11 4 123
0 I
X11 5 456
Repair Manual
X11 6 789
SMART CARD
X11 7 -0#
6061850-
SWE080L
X11 8 LED_GREEN
X11 9 LED_RED
X11 10 0V DC
6/12 PROD D
243986
03302.wmf
844
T-code
Wiring diagram
25 – 13
844
25 – 14
T-code
OPTION
Wiring diagram
ONBOARD CHARGER
BCU
A30
1 (RED) RED
Sh. 3 8 + OUT. POSITIVE CHARGER VOLTAGE
40 (BLACK) BLACK
Sh. 4 8 - OUT. NEGATIVE CHARGER VOLTAGE
6061850-
X40
120/WH 120/WH
Sh. 4 9 4 INP. CAN LOW
Repair Manual
X40
119/RD 119/RD
Sh. 4 9 3 INP. CAN HIGH
SWE080L
MAINS CONNECTOR
MAINS, VAC
Date
MAINS, VAC
2009-10-05
MAINS, EARTH
7/12 PROD D
243986
03303.wmf
258947-040
Order number
© BT
Wiring diagram
258947-040 2009-10-05 6061850- 844
8/12 PROD D
243986
03304.wmf
OUT. 12VDC / 24VDC
DC/DC CONVERTER
INP. +24VDC
OUT. 0VDC
INP. 0VDC
T7 / T8
25
40
26
41
(T7=24V/12V, T8=24V/24V)
DC/DC CONVERTER
OPTION
26
41
X23
X21
X21

Wiring diagram
844 6061850- 2009-10-05 258947-040
9/12 PROD D
243986
03305.wmf
INP. +24V DC
INP. 0V DC
CAN HIGH
CAN LOW
SHOCK SENSOR
B90
4
20
40
120/WH
119/RD
SHOCK SENSOR
OPTION
X40
X40
X40
X40

Wiring diagram
258947-040 2009-10-05 6061850- 844
10/12 PROD D
243986
03306.wmf
INP. ANTENNA
INP. +24V DC
INP. 0V DC
CAN HIGH
CAN LOW
K110
DHU
8
20
40
120/WH
119/RD
DATA HANDLING UNIT (DHU)
T20
OPTION
X40
X40
X40
X40

844
25 – 18
T-code
OPTION
AUTO HEIGHT ADJUSTMENT
CONTROL BOX ON MAST ELECTRONIC CARD

A36
B91
Wiring diagram
X21 S21 X60 S22 X60

21 21/WH 1 2 221 RD/YE 1 2 1 4 BK 200 200
Sh. 1 5 INP. DIGITAL 1 (PHOTOCELL)
3
X60 E50 X60
24 GN/WH X1 X2 BU 210 210
16 OUT. DIGITAL 1 (AUTO ENABLED)
MAST SWITCHES
X60 B18 X62
24 BN 1 2 101
19 INP. DIGITAL 2 (FORKS > LOWER LIMIT)
B19 X62
1 2 102
33 INP. DIGITAL 3 (FORKS < TOP LIMIT)
X62
6061850-
X21 X:S21
24 24/RD 24
Sh. 3 1 INP. +24V
Repair Manual
X40
40
29 INP. 0V
X40
119/RD 119/RD
Sh. 10 27 INP. CAN HIGH
X40
120/WH 120/WH
Sh. 10 42 INP. CAN LOW
SWE080L
ELECTRONIC CARD
A5
S114
BLACK1 1 2 FACTORY PARAMETER
INP. AUTO UP REQ. X2:2/2

Date
PARAMETERVALUE
BLACK2 1003 11
OUT. 0VDC X2:2/3
1004 0
2009-10-05
S115 1005 4
BLUE1 1 2
INP. AUTO LOWER REQ. X2:2/4 1006 0
1007 0
BLUE2
OUT. 0VDC X2:2/5 11/12 PROD D
243986
03307.wmf
258947-040
Order number
© BT
Wiring diagram
258947-040 2009-10-05 6061850- 844
12/12 PROD D
243986
03308.wmf
1
P5
3
220
WARNING LIGHT
OPTION
2
S97
1
X40
X40

Wiring diagram
844 6061850- 2009-10-05 258947-040

Hydraulics chart
258947-040 2009-10-05 6061850- 844
26 – Hydraulics chart
p
a o
c
n
m
g
i k
h
Pos. Description Pos. Description

a Lift cylinder, support arm h Tank
b Magnetic valve, fork selection [Q22] i Filter
c Magnetic valve, support arm selection k Filter
[Q23]
d Proportional valve, lowering [Q4] m Air filter
e Non-return valve n Flow regulator valve
f Pressure limit valve, max 230 Bar o Lift cylinder, forks
g Pump p Hose fracture valve

Hydraulics chart
844 6061850- 2009-10-05 258947-040

Instructions for disposal
General
258947-040 2009-10-05 6061850- 844
27 – Instructions for disposal
27.1 General
The instructions for disposal have been developed in order to support
our company's objective to protect the environment. By recycling
materials, resources are utilised more efficiently whilst reducing the
emission of unwanted substances.
The following instructions specify in which category to sort the
materials present in different components. For optimum sorting the
components should be dismantled at a level that corresponds to the
sorting categories.
27.2 Marking of plastics
27.2.1 General marking of products and

packaging
The plastic marking consists of three arrows, a numeral, and usually
the name of the plastic material. The image shows the markings for
polypropylene.
• 01: PET – Polyethylene terephthalate
• 02: PE-HD – High-density polyethylene
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Low-density polyethylene
• 05: PP – Polypropylene (see image)
• 06: PS – Polystyrene
• 07: O – Other

Marking of plastics
844 6061850- 2009-10-05 258947-040
27.2.2 Marking to BT Standard

Standards: BT 58-02-001, BT58-02-003 and BT58-02-004.
Some examples of markings are given below. For more information,
refer to the standards above.
The item's material/trade name is shown between inward facing
arrows, e.g. >PP<.
Abbreviations
- ABS: Acrylonitrile butadiene styrene
- HDPE:High-density polyethylene
- LDPE: Low-density polyethylene
- PA: Polyamide
- PA6: Polyamide 6
- PA66: Polyamide 66
- PBT: Polybutylene terephthalate
- PC: Polycarbonate
- PET: Polyethylene terephthalate
- PMMA: Plexiglas
- POM: Polyoxymethylene, Polyformaldehyde
- PP: Polypropylene
- PUR: Polyurethane
Example of marking
Items produced from an element
ABS (Acrylonitrile-butadiene-styrene):
>ABS<
Polyurethane:
>PUR<
Plastic mixtures
A blend of Acrylonitrile-butadiene-styrene and Polycarbonate:
>ABS+PC<
Filled or reinforced material
Polypropylene with 30 % mineral powder:
>PP-MD30<

Pressure vessels
258947-040 2009-10-05 6061850- 844
27.3 Pressure vessels

Pressure vessels that are sent for recycling/destruction must be
depressurised and open if possible.
Examples of pressure vessels are gas dampers and accumulators in
the hydraulic system.
27.3.1 Gas damper

DANGER!
Gas dampers may have very high internal pressure. The
manufacturer's recommendations must always be followed to avoid
personal injury.
Protective goggles must be worn when the springs are opened.
Gas dampers must be opened according to the manufacturer's
recommendations in order to release the gas. On example of this is for
the “Stabilus Lift-O-Mat/Inter-stop”:
2 1
ca 20 mm
1: Drill or saw a hole in the cylinder approx. 20 mm from its bottom.

2: Drill or saw a hole in the recess in the sideshift cylinder.

Sorting categories
844 6061850- 2009-10-05 258947-040
27.4 Sorting categories

• Plastic and rubber
• Iron/steel, including bolts, washers and nuts
• Oils
• Oil filters
• Oil contaminated
• Electronic parts including switches and sensors
• Cables
• Hazardous waste
• Complex material – Large amounts of several categories and non-
combustible or hazardous waste
• Combustible material, including small parts of plastic or rubber
• Batteries are returned to the manufacturer.
Component Category Comment

Chassis • Iron/steel
Hoods and covers, • Iron/steel
sheet metal
• Handle: >ABS<
Hoods and covers, • Plastic Sort according to material
plastic markings
Forks and frames • Iron/steel
Platforms • Iron/steel, also any gas dampers Gas dampers must be
depressurised
• Flooring, cushions: combustible
Roof and protective • Iron/steel
frame
Gates and driver • Iron/steel
protection
• Plastic handle: >PA<
• Pinch guard: >PMMA<
Hydraulic unit • Oil Ensure that the system is
depressurised.
• Hydraulic hoses: Oil contaminated
Drain oil carefully.
• Oil tank: >PP< Any accumulators are
• Motor, valves: Electronic parts emptied of gas and left
open if possible.
• Pump: Iron/steel
• Accumulator: Iron/steel
Drive motors • Motor: Electronic parts
• Cables
• Parking brake: Hazardous waste

Sorting categories
258947-040 2009-10-05 6061850- 844
Component Category Comment

Drive gear • Iron/steel Drain oil carefully
• Oil Hazardous waste
Wheel • Tread: Plastic according to If it is not possible to
markings separate the tread and
the hub, sort the wheel as
• Hub: Iron/steel
complex material
Tiller arms • Electronic parts Gas dampers must be
depressurised
• Cables
• Iron/steel, also gas dampers
Electrical system • Logic board, transistor regulator, Hazardous waste
Expansion unit SEU, contactors:
Electronic parts
• Cables
• Small batteries Hazardous waste
• Fluorescent tubes Hazardous waste.
Due to the chemical
contents of fluorescent
tubes these must not
broken up.
Used fluorescent lamps
must be packaged and
transported according to
local regulations.
Mast • Beams, rollers, cylinders and Oil contaminated items
hydraulic pipes: Iron/steel are treated as hazardous
waste
• Hydraulic hoses: Oil contaminated
()
• Cables
• Sensors/switches: Electronic parts
• Plastic items: According to
markings or as combustible
Chargers and • Electronic parts
connections
• Cables

Sorting categories
844 6061850- 2009-10-05 258947-040

© BT
SE-595 81 Mjölby
Sweden
www.toyota-forklifts.eu

Repair Manual SWE080L Staxio

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Order number: 258947-040

Issue Order Changes

This manual contains information on the following trucks:

T-code Model Serial number

© BT Repair manual SWE080L

3 – General safety rules ........................................................................... 3-1

4 – Installation .......................................................................................... 4-1

5 – Maintenance ....................................................................................... 5-1

6 – Functions and parameters ................................................................ 6-1

© BT Repair manual SWE080L 1– 1

6.5 Parameters .................................................................................... 6-9

7 – Troubleshooting ................................................................................ 7-1

8 – Chassis 0000 ...................................................................................... 8-1

9 – Electrical drive motor 1700 ............................................................... 9-1

10 – Drive gear 2550 .............................................................................. 10-1

11 – Brake 3180 ..................................................................................... 11-1

1– 2 Repair manual SWE080L © BT

12 – Drive wheel 3530 ............................................................................ 12-1

13 – Castor wheel 3540 .......................................................................... 13-1

14 – Support arm wheel 3550 ................................................................ 14-1

15 – Tiller arm 4000 ................................................................................ 15-1

16 – Electrical components ................................................................... 16-1

17 – Hydraulic system 6000 .................................................................. 17-1

© BT Repair manual SWE080L 1– 3

17.5 Hydraulic calibration..................................................................... 17-8

18 – Lift mast – 7000 .............................................................................. 18-1

19 – Accessories ................................................................................... 19-1

20 – Appendices .................................................................................... 20-1

21 – Technical data ............................................................................... 21-1

22 – General tightening torque ............................................................. 22-1

23 – Tools ............................................................................................... 23-1

24 – Oil and grease specification ......................................................... 24-1

25 – Electrical components and wiring diagram ................................. 25-1

26 – Hydraulics chart ............................................................................. 26-1

27 – Instructions for disposal ............................................................... 27-1

© BT Repair manual SWE080L 1– 5

This page is deliberately left empty

1– 6 Repair manual SWE080L © BT

2.1 How to use the manual

© BT Repair manual SWE080L 2– 1

2.2 Warning symbols

2– 2 Repair manual SWE080L © BT

3 – General safety rules

3.1 Safety while working

© BT Repair manual SWE080L 3– 1

3.2 Electrical system

3– 2 Repair manual SWE080L © BT

3.3 Safe lifting

© BT Repair manual SWE080L 3– 3

This page is deliberately left empty

3– 4 Repair manual SWE080L © BT

4.2 Battery installation

© BT Repair manual SWE080L 4– 1

4.2.2 Install battery

4– 2 Repair manual SWE080L © BT

4.3 Programming PIN codes

Function Programming Remark

© BT Repair manual SWE080L 4– 3

4. Turn off the truck by pressing the OFF button.