SPE Service Manual

Service Manual en
SPE125/160/125L/160L
Valid from serial number: 711956-
Order number: 218367-040

Issued: 2004-04-05 ITS
© BT Europe AB
Issue date Resp. Changes
2004-04-05 ITS Completely new issue
© BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

Table of Contents
Valid from serial number T-code
711956- 789, 791
Order number Date
218367-040 2004-04-05
1- Table of Contents
Presentation of the truck – M2 2-1
Intended application of the truck ................... 2

Forbidden application of the truck................. 2
Truck data..................................................... 3
Truck dimensions ......................................... 4
Identification plate......................................... 6
Capacity plate............................................... 6
Addition and information plate ...................... 6
Capacity plate for double pallet handling ...... 7
Main components ......................................... 8
Warning and information plates ................... 10
Technical data – M4 3-1
General tightening torques ........................... 5
Installation and maintenance

instructions – P1 4-1
Truck installation........................................... 1
4.1.1 Lifting the truck ................................................... 1
4.1.2 Battery installation .............................................. 2
4.1.3 Putting into service ............................................. 2
Introduction, maintenance ............................ 4
4.2.1 Safety rules during maintenance work ............... 4
Cleaning and washing .................................. 6
4.3.1 External cleaning ................................................ 6
4.3.2 Cleaning the motor compartment ....................... 6
4.3.3 Electric components ........................................... 6
Safe lifting..................................................... 7
© BT Europe AB Service Manual SPE125/160/125L/160LApproved by: L-G Andersson 1- 1

Table of Contents
T-code Valid from serial number
789, 791 711956-
Date Order number
2004-04-05 218367-040
Maintenance schedule – P2 5-1
Lubrication chart ........................................... 7
Oil and grease specification – P3 6-1
Tools – P4 7-1
Super Seal connectors ................................. 1
AMP connectors ........................................... 2

7.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors.......................................... 3
Other tools .................................................... 4
Electric drive motor – 1760 8-1
Included components.................................... 1
Disassembly/assembly of the truck motor..... 3

8.2.1 Disassembly ....................................................... 3
8.2.2 Assembly ............................................................ 3
Service/repairs.............................................. 4
8.3.1 Disassembly of the motor ................................... 4
8.3.2 Motor installation ................................................. 5
8.3.3 Cleaning .............................................................. 5
Technical data .............................................. 6
Drive unit/gear – 2550 9-1
Included components.................................... 1
9.1.1 Technical data .................................................... 3
Leakage from top cover ................................ 3
Replacing the drive axle jointing ring ............ 3

9.3.1 Disassembly ....................................................... 4
9.3.2 Assembly ............................................................ 4
1- 2 © BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

Table of Contents
711956- 789, 791
Order number Date
218367-040 2004-04-05
Electromagnetic brake – 3370 10-1
Main components of the brake...................... 1
Maintenance ................................................. 2
10.2.1 Basic adjustment of the play .............................. 2
10.2.2 Brake disc replacement ...................................... 3
Electrical systems – 5000 11-1
Electrical equipment overview ...................... 1
Equipment list and electrical diagram ........... 3

11.2.1 Electrical wiring diagram 1 of 8 .......................... 7
11.2.4 Electrical wiring diagram 4 of 8 ........................ 10
Functional description.................................. 15
11.3.1 Description of steering system ......................... 22
Speed limitation ........................................... 23
Hour meter and battery condition................. 24
Diagnostic and troubleshooting ................... 26

11.6.1 Fault codes ....................................................... 26
11.6.2 Fault code history ............................................. 26
11.6.3 List of fault codes ............................................. 27
11.6.4 Transistor regulator troubleshooting and error
codes 35
11.6.5 Built-in Test Function ....................................... 38
11.6.6 Display test mode ............................................. 43
Part numbers ............................................... 44
Parameters .................................................. 45
11.8.1 General ............................................................ 45
11.8.2 Viewing parameters -CAN key not connected . 45
11.8.3 Viewing parameters -CAN key connected ....... 46
11.8.4 Setting Driver parameters ................................ 46
11.8.5 Setting Service parameters .............................. 47
11.8.6 Summary of driver parameters ......................... 47

Table of Contents
789, 791 711956-
Date Order number
2004-04-05 218367-040
11.8.7 Description of driver parameters ...................... 49

11.8.8 Summary of service parameters ...................... 50
11.8.9 Description of service parameters .................... 52
11.8.10 “Option” Parameters ....................................... 59
Technical specifications – Curtis 1243......... 67
Hydraulic system – 6000 12-1
Hydraulic diagram......................................... 1
12.1.1 SPE125L/160L ................................................... 1
12.1.2 SPE125/160 ....................................................... 2
12.1.3 Main components ............................................... 3
12.1.4 Description ......................................................... 4
Main lift chain system – 7120 13-1
General ......................................................... 1
Checking the chain setting............................ 1
Chain inspection ........................................... 1

13.3.1 Noise .................................................................. 1
13.3.2 Surface rust ........................................................ 1
13.3.3 Rusty links .......................................................... 1
13.3.4 Stiff links ............................................................. 2
13.3.5 Bolt rotation ........................................................ 2
13.3.6 Loose bolts ......................................................... 2
13.3.7 Outline wear ....................................................... 3
13.3.8 Stretching ........................................................... 4
13.3.9 Damage .............................................................. 5
13.3.10 Damaged discs ................................................. 5
13.3.11 Damaged bolts ................................................. 5
13.3.12 Dirty chain ........................................................ 6
Cleaning ....................................................... 6
Lubrication .................................................... 6

Table of Contents
711956- 789, 791
Order number Date
218367-040 2004-04-05
Control/computer equipment – 8700 14-1
General......................................................... 1
Connection ................................................... 1
Layout........................................................... 2
14.3.1 Main program screen ......................................... 2
14.3.2 Nodes ................................................................. 2
14.3.3 Icons ................................................................... 3
14.3.4 Tool buttons and menu bar ................................ 4
14.3.5 Information window ............................................ 4
14.3.6 Status bar ........................................................... 4
Connection function ..................................... 4
Disconnection function ................................. 5
Downloading program function ..................... 5

14.6.1 Normal downloading (truck with key) ................. 5
14.6.2 Normal downloading (truck with keypad) ........... 6
14.6.3 Emergency downloading (truck with keypad) ..... 6
14.6.4 Downloading in old versions of logic card .......... 7
14.6.5 Emergency downloading (truck with keypad) ..... 7
Truck report function..................................... 8
Parameters function ..................................... 9
Diagnostics function .................................... 11

14.9.1 Representation of signal colours ...................... 11
14.9.2 “Tiller arm” tab .................................................. 12
14.9.3 “Drive Controller” tab ........................................ 13
14.9.4 “EPS” tab (only OL 20 / 25) .............................. 14
Other menu functions .................................. 16
14.10.1 Save to file ..................................................... 16
14.10.2 Download from file ......................................... 16
14.10.3 Reset CAN adapter ........................................ 16
14.10.4 Delete error code log ...................................... 16
14.10.5 Reset hour meter ........................................... 16
14.10.6 Read error code log ....................................... 16
14.10.7 Adjust date and time ...................................... 16
14.10.8 Adjusting the hour meter on older cards ........ 17
14.10.9 Help ................................................................ 17
14.10.10 Exit ............................................................... 17
Specifications .............................................. 17

Table of Contents
789, 791 711956-
Date Order number
2004-04-05 218367-040
Installation ................................................... 18
14.12.1 Installation on a PC with Windows® 95/98 ..... 18
14.12.2 Installation on a PC with Windows XP/2000 .. 18
14.12.3 Installation on a PC with Windows NT ........... 24
14.12.4 In case of communication problems with CAN 24
14.12.5 To uninstall ..................................................... 24

Presentation of the truck – M2
711956- 789, 791
Order number Date
218367-040 2004-04-05
2- Presentation of the truck – M2

The truck is a battery driven support arm truck. The truck is equipped
with a tiller arm for optional control: standing on the ride-on platform or
walking. Best advantage can be taken of the truck’s properties by the
operator standing on the ergonomically designed platform as this pro-
vides the operator with a clear view over the truck and load, allowing
work to be carried out with ease and safety.
The truck is also equipped with protective gates to protect the operator
when driving standing on the platform. When the gates are retracted
the truck’s maximum speed is always 6 km/h. When the gates are
raised and the operator is standing on the platform the truck’s maxi-
mum speed is 8 km/h.
The tiller arm is specially designed to provide the best possible opera-
tor ergonomy, having all the controls and buttons within easy reach
without the operator needing to release the handle. The tiller arm is also
equipped with a display showing running time and battery status
among other things. The display is also used when the operator wishes
to change any of the operator parameters with which the truck can be
programmed.
The truck is equipped with BT’s patented PowerTrak system, which
means that the drive wheel pressure is adjusted according to the
weight of the load and the wear on the drive wheel. This reduces the
wear and tear on the drive wheel and ensures safer load handling.
The truck has a 24V electrical system and the speed is regulated by
means of a transistor controller to provide gentle control of acceleration
and speed while driving.
The forks are lifted using a compact, yet powerful hydraulic unit. Lifting
is controlled by a transistorised variable speed controller. The truck's
proportional valve is used to adjust the lowering speed and fork posi-
tioning during stacking.
The battery compartment is designed to allow the battery to be
changed from either side as well as from above, which means the truck
is well suited to most types of battery changing situations.

Intended application of the truck
789, 791 711956-
Date Order number
2004-04-05 218367-040
The truck’s maximum speed is 6 km/h when the protective gates are
retracted in the direction of the forks and the driver is standing on the
platform.
The truck’s maximum speed is 8 km/h when the protective gates are
retracted in the direction of the drive wheel and the driver is standing on
the ride-on platform.
CAUTION!
Pinch risk.
There is a risk of pinching if you drive the truck with the platform
raised and the gates extended.
Always retract the gates when the platform is raised.
2.1 Intended application of the truck

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

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

Truck data
711956- 789, 791
Order number Date
218367-040 2004-04-05
2.3 Truck data

The table provides information regarding some technical data, which is
of value with daily use of the truck.
Table 1: Truck data

Truck type SPE125/ SPE160/160L
125L
Rated capacity, kg 1250 1600
Lift height, mm 2350-5400 2350-5400
Travel speed without load (<800kg), with gates 8 8
Transporting position (Lh < 1,5 m), km/h
Travel speed with rated load (>800kg) with gates 7 7
Travel speed without gates 6 6
Travel speed 5 5
Stacking position (Lh >1,5 m), km/h
Gradient with rated load, % 8 8
Weight without battery, kg 980 1130
Weight with battery, kg (Ah) * 1230 1390
Turning radius (Wa), mm (Small battery space, fork length 1755 1755
1150 mm, mast DX)
Continuous noise level, dB A <70 < 70
Full body vibration value acc. to document N47E CEN/ 0,7 0,7
TC150/WG8, m/s2
Permitted drive wheel, material Power friction
Tractothan
siped rubber
Rubber, non marking
The truck’s lifting capacity, lift height and weight can be found on the
truck’s identification plate.

Truck dimensions
789, 791 711956-
Date Order number
2004-04-05 218367-040
2.4 Truck dimensions

The illustration shows external dimensions for the truck in its standard
design.
SPE125/125L/160/160L
E
A
F
B
H I G
J
K
O
M N P

Truck dimensions
711956- 789, 791
Order number Date
218367-040 2004-04-05
Table 2: Truck dimensions

Measure SPE125 SPE160 SPE125L SPE160L
(mm) (mm) (mm) (mm)
A 1435 1435 1435 1435
B 150 150 150 150
C- Maximum lifting height dependant on 2350- 2350-5400 2350-5400 2350-5400
mast type 5400
D- Minimum mast height dependant on lift- 1710- 1710-2365 1710-2365 1710-2365
ing height 2365
E 600-1400 800-1400 800-1400 1150-1400
F- Minimum 90 90 90 90
F- Raised support arms (max) - - 210 210
G 85 85 85 85
H 24 24 17 17
I -Small battery space 1440 1440 1481 1481
I- Large battery space 1538 1538 1579 1579
J - Small battery space Dx Tele; Dx Hilo 860 907 901 948
J-Small battery space Tx 880 907 921 948
J - Large battery space Dx Tele; Dx Hilo 958 1005 999 1046
J- Large battery space Tx 978 1005 1019 1046
K- (E + J) fork length 1150, small battery 2010 2057 2051 2098
space Dx
L - Small battery space 1716 1716 1755 1755
L - Large batteryspace 1813 1813 1852 1852
M 850/1150 850/1150 850/1150 850/1150
N 790 790 790 790
O 180 180 180 180
P 450-685 570-685 520-570 570
Q- (E + J+ 417) fork length 1150, small bat- 2427 2774 2468 2515
tery space Dx

Identification plate
789, 791 711956-
Date Order number
2004-04-05 218367-040
2.5 Identification plate

The illustration shows the identification plate for the truck in
CE-design.
Table 3:
Item Text Unit
A MODEL
B SERIAL NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V
2.6 Capacity plate

The illustration shows the capacity plate used on the truck.
Table 4:
Item Text Unit
H SERIAL NUMBER
I LIFTING HEIGHT mm
J ACTUAL CAPACITY kg
K LOAD CENTRE SPACING mm
L THE TRUCK MUST ALWAYS BE DRIVEN
WITH LOWERED FORKS EXCEPT WHEN
PLACING OR REMOVING LOAD
2.7 Addition and information plate
Item Text Unit

M M WHEN STACKING, COMPLETELY LOWER
THE SUPPORT ARMS

Capacity plate for double pallet handling
711956- 789, 791
Order number Date
218367-040 2004-04-05
2.8 Capacity plate for double pallet

handling
The picture shows the capacity plate that applies with double pallet
handling.
Table 5:
Permitted max. Permitted max. Permitted min.
load on forks load on support load on support
arms arms
M1 - M9 L1 - L9 V1 - V9

Main components
789, 791 711956-
Date Order number
2004-04-05 218367-040
2.9 Main components

1. Hydraulic control:
For controlling lifting and lowering functions.
2. Tiller arm:
The truck is manoeuvred by the driver while walking. 204 degree
steering area.
The brakes are applied in the tiller arm’s upper and lower positions.
3. Identification plate:
With model designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, battery volt-
age and manufacturer.
4. Emergency switch off
5. Side guards:
The truck can travel at the higher speed of 8 km/h when the side
guards have been raised. When the side guards are lowered, the
truck can only travel at a maximum speed of 6 km/ h. When the side
guards have been raised, the truck can lift the forks to a maximum
height of 1800 mm. In order to lift to the maximum lifting height the
side guards must be lowered.
6. Cover:
Removable which provides good accessibility when servicing.
7. Battery disconnector and battery connector:
The battery is charged via the permanently fitted charging connec-
tor.
8. Electric panel:
With fuses and contacts positioned for easy access during service.
24 Volts transistor controlled system with regenerative feedback.
9. Drive unit with brake:
Suspended drive unit with spring-loaded mechanical brake, travel
motor, gears and drive wheel combined into a compact unit. Steer-
ing bearings between motor and gears.
10. Power steering unit (optional)
11. Support castor wheels:
Two support castor wheels to ensure stability.
12. Serial number:
The serial number plate fitted to the chassis.
13. Hydraulic unit:
Pump motor, pump and oil tank are integrated in a compact unit.
14. Hydraulic valves:
The valves are located to provide easy access.
15. Battey:
24V with different Ah values. The battery is automatically locked in
the battery compartment.
16. Mast:
Fitted with a finger guard to cover the driver's normal reach.
Main components
711956- 789, 791
Order number Date
218367-040 2004-04-05
16
11
12
15 13
10
14
9
8

Warning and information plates
789, 791 711956-
Date Order number
2004-04-05 218367-040
2.10 Warning and information plates

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

2. Hydraulic lever: Lifting/lowering of the support arms
(SPE125L/160L)
3. Travel direction
4. Signal/Horn
5. Capacity plate
6. Identification plate, A: CE, B: ASME, depending on market
7. Serial number
8. Hydraulic oil filling
9. Maximum height for rated lifting capacity
10. Do not walk under an elevated load
11. Lifting points

711956- 789, 791
Order number Date
218367-040 2004-04-05
A
B
C
12 13
D
E M
E
F

789, 791 711956-
Date Order number
2004-04-05 218367-040
This page is intentionally left blank

Technical data – M4
711956- 789, 791
Order number Date
218367-040 2004-04-05
3- Technical data – M4
Table 6: Technical data
Model SPE125 SPE125L SPE160 SPE160L
Drive motor
Type TSL140B- TSL140B- TSL140B- TSL140B-
DS41 DS41 DS41 DS41
Output, kW 1,7 1,7
Duty cycle S2,60 min S2,60 min S2,60 min S2,60 min
Minimum carbon brush length, mm 13 13 13 13
Nominal commutator diameter, mm 63 63 63 63
Minimum commutator diameter, mm 60 60 60 60
Resistance, shunt field winding, Ω at 25 C° 0,498 0,498 0,498 0,498
(26C°) (26C°) (26C°) (26C°)
Resistance armature winding, Ω at 24 °C 0,0161 0,0161 0,0161 0,0161
(26C°) (26C°) (26C°) (26C°)
Insulation resistance between the wind- >= 1Mohm >= 1Mohm >= 1Mohm >= 1Mohm
ings and motor casing
Weight, kg 17 17 17 17
Brake
Type BFK458-12 BFK458-12 BFK458- BFK458-12
12
Braking force, Nm 32 32 32 32
Output, W 40 40 40 40
Resistance coil, Ω 14,4 14,4 14,4 14,4
Nominal play in actuated position, mm 0,3-0,5 0,3-0,5 0,3-0,5 0,3-0,5
Minimum thickness brake disc, mm 8.8 8.8 8.8 8.8
Thickness of a new brake disc, mm 10.0 10.0 10.0 10.0
Transmission/drive gear
Type 2-stage 2-stage 2-stage 2-stage
angle trans- angle trans- angle trans- angle trans-
mission mission mission mission
Gear ratio 16,29:1 16,29:1 16,29:1 16,29:1
Oil volume, litre 1,0 1,0 1,0 1,0
Oil type Hypoid oil Hypoid oil Hypoid oil Hypoid oil

789, 791 711956-
Date Order number
2004-04-05 218367-040

Oil type at normal temperature SAE 80W/ SAE 80W/ SAE 80W/ SAE 80W/
90 90 90 90
Oil type at temperature < -15oC SAE 75W SAE 75W SAE 75W SAE 75W
Wheels (See note 1)

Drive wheel, mm Dia 215x70 Dia 215x70 Dia Dia 215x70
215x70
Axle pressure without load, kg 390 385 390 390
Axle pressure at rated load, kg 620 530 620 620
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm 65 Nm 65 Nm
Fork wheel, mm Dia 85x75 Dia 85x75 Dia 85x75 Dia 85x75
Axle pressure without load, kg 2x180 (250) 2x215(250)
Axle pressure at rated load, kg 2x720 (250) 2x915 (250)
Support castors, mm Dia 125x50 Dia 125x50 Dia Dia 125x50
125x50
Axle pressure without load 2x310 (250) 2x330 (250)
Axle pressure at rated load, kg 2x325 (250) 2x315 (250)
Hydraulic system
Output, kW 3,0 3,0 3,0 3,0
Duty cycle,% 11 11 11 11
Minimum carbon brush length, mm 10 10 10 10
Minimum commutator thickness/diame- 47 47 47 47
ter, mm
Pressure at rated load, bar 110 110 110 110
Overflow pressure, bar 200 200 200 200
Pump flow, at rated load, litre/minute 13 13 13 13
Tank volume, litre 12 12 12 12
Oil type Hydraulic Hydraulic oil Hydraulic Hydraulic
oil oil oil
Oil type at normal temperature ISO-L- ISO-L- ISO-L- ISO-L-
HM32 HM32 HM32 HM32
Oil type at temperature < -15oC ISO-L- ISO-L-HV32 ISO-L- ISO-L-

HV32 HV32 HV32

711956- 789, 791
Order number Date
218367-040 2004-04-05

Fuses
Drive motor circuits, A 125 125 125 125
Pump motor circuits, A 160 160 160 160
Control circuits, A 7,5 7,5 7,5 7,5
Battery compartment, Batteries
Dimensions LxWxH, mm, small 168x763x6 168x763x66 168x763x 168x763x6
large 60 0 660 60
264x763x6 264x763x66 264x763x 264x763x6
60 0 660 60
Capacity, Ah 250/450 250/450 250/450 250/450
Weigh, max./min. kg 200/320 200/320 200/320 200/320
Driving speed
Without load, km/t 8,0 8,0 8,0 8,0
Without load, m/s 2,22 2,22 2,22 2,22
With rated load, km/t 7,0 7,0 7,0 7,0
With rated load, m/s 1,94 1,94 1,94 1,94
Lift/lowering speed
Lifting without load, above free-lift, m/s TBA 0,32 TBA 0,26
(see note 2 &3)
Lifting without load, under free-lift, m/s TBA 0,28 TBA 0,24
(see note 2 &3)
Lifting with rated load, above free-lift, m/s TBA 0,19 TBA 0,15
(see note 2 &3)
Lifting with rated load, under free-lift, m/s TBA 0,17 TBA 0,14
(see note 2 &3)
Lowering without load, above free-lift, TBA 0,44 TBA 0,36
m/s (see note 2 &3)
Lowering without load, under free-lift, TBA 0,16 TBA 0,15
m/s (see note 2 &3)
Lowering with rated load, above free-lift, TBA 0,57 TBA 0,45
m/s (see note 2 &3)
Lowering with rated load, under free-lift, TBA 0,43 TBA 0,37
m/s (see note 2 &3)

789, 791 711956-
Date Order number
2004-04-05 218367-040

Power consumption
Driving without load, A TBA 30 TBA 55
Driving with rated load, A TBA 50 TBA 70
Lifting without load, above free-lift, A TBA 100 TBA 100
Lifting without load, under free-lift, A TBA 80 TBA 80
Lifting with rated load, above free-lift, A TBA 215 TBA 215
Lifting with rated load, under free-lift, A 170 170 170 170
Incline climbing ability
With rated load 10% 10% 10% 10%
Measurement, L2
Small battery compartment TBA 921 TBA 888
Large battery compartment (See note 1) 1019 986
Turning radius WA (See note 1) TBA 1696 TBA 1627
Max. lifting height depends on the mast TBA 2350-5400 TBA 2350-5400
type
Weight
Truck without battery, Max./min TBA 980/1230 TBA 1130/1390
Note 1 applies to the specification: Triplex mast 415, fork length 1150, small
battery compartment, battery weight 220 kg, truck width 850.
Note 2 applies to the specification:Duplex hilo 415 mast.
Note 3 applies to the specification:Duplex hilo 335 mast.
TBA = (To Be Announced) will be determined later

General tightening torques
711956- 789, 791
Order number Date
218367-040 2004-04-05
3.1 General tightening torques

Millimetre threads M3 to M24.
The following applies under ideal conditions, e.g. steel against steel.
Table 7: General tightening torques

M3 M4 M5 M6 M8 M10
B C B C B C B C B C B C
A Tightening torque in Newtonmetre Nm
8.8 1.15 1.2 2.8 2.9 5.5 5.7 9.5 9.8 23 24 45 47
12.9 2.0 2.1 4.7 4.9 9.3 9.7 16.3 17.0 38.5 40.0 75.8 79.0
M12 M14 M16 M20 M24

B C B C B C B C B C
A Tightening torque in Newtonmetre Nm
8.8 77,7 81 123 128 189 197 369.6 385 638.5 665
12.9 130.5 136 208 217 319.7 333 623 649 1075 1120
A = Strength grade
B = Galvanised, non-oiled bolts
C = Untreated, oiled bolts
NOTE!
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will get the correct torque value for galva-
nised bolts.Do not tighten more than the values set out in the table
otherwise the bolts can be destroyed.

General tightening torques
789, 791 711956-
Date Order number
2004-04-05 218367-040

Installation and maintenance instructions –
P1
711956- 789, 791
Order number Date
218367-040 2004-04-05
4- Installation and maintenance

instructions – P1
4.1 Truck installation
4.1.1 Lifting the truck

600+-100
600+-100
• Lift the truck at its centre of gravity using another fork lift truck.
• Fasten the truck to the forks of the lifting truck.
• Lift it very carefully.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted incorrectly.
Always lift the truck when it has been fastened to the forks of the lift-
ing truck and its centre of gravity between the forks.
• Only lift the truck at the indicated lifting points using suitable lifting
equipment.
WARNING!
Risk of tipping..
The truck may tip over if it is lifted in the wrong places.
Always lift the truck at the indicated lifting points.

P1
789, 791 711956-
Date Order number
2004-04-05 218367-040
4.1.2 Battery installation

Check to make sure the battery cabling has been correctly connected
to the battery.
VARNING!
Risk of short-circuiting.
An incorrectly connected battery may cause short-circuiting.
The polarity must match. Compare the markings on the cables with
those on the battery poles.
The battery can be replaced from the sides or from above.
4.1.3 Putting into service

Prior to putting the truck into use, verify the items listed below.
Table 8: Pre-delivery inspection check-list

Pos. Inspection item Measure
no.
1 Hydraulic functions Check its function
2 Operating control Check its function
3 Switch for safety reversing Check its function
4 Horn Check its function
5 Steering Check its function
5 Brakes Check its function
6 Emergency switch off Check its function
7 Hydraulic system Inspect the oil level and check for oil leakage
8 Drive unit Check for noise and oil leakage
9 Wheels Check for damage, remove oil, chips, etc.
10 Chassis Check for damage, remove dirt, etc.
11 Battery cover and locking Check its function
12 Battery Inspect the battery acid level and charge level
13 Fork carriage Check for damage and wear
14 Lifting device Check for damage, remove dirt, etc.
15 Finger guard Check for damage and wear
16 Hydraulic cylinders Look for damage and oil leakage
17 Running time Perform maintenance as described in the Mainte-
nance section

P1
711956- 789, 791
Order number Date
218367-040 2004-04-05
2
1
4
14
13 15
12
6
10
9 7
11
• Check to make sure all parameters are set to the desired values:
- Maximum speed.
- Acceleration.
- Automatic speed reduction.
- PIN codes (option).

P1
789, 791 711956-
Date Order number
2004-04-05 218367-040
4.2 Introduction, maintenance

To assure maximum safety and minimum downtime, all items in the
service programme should be covered. The service intervals are only
guidelines and need not be strictly followed. The operator of the truck
should adapt these to local requirements, however, it is important that
the minimum requirements as stated by BT are observed.
The service intervals are based on truck operating hours and can be
adapted to most common 8-hour shifts. When calculating the service
intervals, the following operating hours have been used:
Day time: 08.00-17.00 (20 hours/week)
Double shift: 06.00-14.00, 14.00-22.00 (40 hours/week)
Triple shift: 06.00-14.00, 14.00-22.00, 22.00-06.00
(60 hours/week)
Make sure the truck receives the necessary regular maintenance serv-
ice according to the maintenance schedule. The truck's safety, efficien-
cy and service life rely on the service and maintenance the truck
receives.
For service and repairs, only use spare parts approved by BT.
4.2.1 Safety rules during maintenance work

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

P1
711956- 789, 791
Order number Date
218367-040 2004-04-05
• Prior to commencing any work on the hydraulic system of the truck,

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

P1
789, 791 711956-
Date Order number
2004-04-05 218367-040
4.3 Cleaning and washing

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

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

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

• Use compressed air to blow clean the electric motors.
• Clean electric panels, logic cards, connectors, valves, etc. with a rag
moistened with water and a suitable detergent.
NOTE!
Electric components can become damaged.
Avoid breaking the warranty seals on the logic cards.

P1
711956- 789, 791
Order number Date
218367-040 2004-04-05
4.4 Safe lifting

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

P1
789, 791 711956-
Date Order number
2004-04-05 218367-040

Maintenance schedule – P2
711956- 789, 791
Order number Date
218367-040 2004-04-05
5- Maintenance schedule – P2
Table 9: Maintenance schedule

I:Inspect, rectify and change if necessary T: Tighten. C: Clean L: Lubricate.
M:Control measurement, rectify if necessary
Pos. Work to carry out

no. Interval in hours - may vary due to appli- 5 20 80 500 1000 3000
cation
Interval in days/weeks/months - may 1d 1w 1m 6m 12m 36m
vary due to application
0000 Chassis
0000.1 Inspect all shafts, links and clamping pins I
0000.2 Inspect possible damage on the chassis; open I
the battery cover and use it as an aid
0000.3 Check the cover locks I
0000.4 Check finger guard I
0000.5 Check signs and stickers I
0000.6 Inspect the operator platform I
0380.3 Press grease into grease nipples (Note 6) I/L
0380 Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
0380.3 Press grease into grease nipples (Note 6) I/L
0380.4 Check the lift limit switch I
0380.5 Inspect the guides for wear and lubricate them I/L
(Note 6)
0380.6 Inspect the load support (Option) I
0450 Frame-mounted components
0450.0 Inspect the motor plate links and turning pipe I

789, 791 711956-
Date Order number
2004-04-05 218367-040


cation
1700 Drive motors
1700.1 Check clearance in connections I/T1 I/T
1700.2 Inspect the carbon brushes in the drive motor M
and lift motor
1700.3 Clean the drive motor and lift motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing I
2550 Drive unit
2550.1 Check for leakage I3 I
2550.2 Check the oil level I

2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steer- I
ing bearing
2550.5 Change the oil in the drive gear L4 L
2550.6 Lubricate the gear rim L
3100 Brake
3100.1 Clean and verify correct operation of the serv- C/I
ice brake and parking brake
3100.2 Inspect brake disc weak and verify correct M
tightening torque (32 Nm)
3100.3 Check the clearance in disengaged position. M
(0,2-0,3 mm)

711956- 789, 791
Order number Date
218367-040 2004-04-05


cation
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tight- M
ening torque on bolts
New wheel: Tread thickness = 30 mm
Tightening torque = 65 Nm) (3500,2)
3500.3 Check whether the castor wheel rotates and I
swings freely; lubricate the horizontal bearing.
Inspect the castor wheels for wear and correct
installation. New wheel: Tread thickness = 10
mm)
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Inspect the steering couplings for excessive I
play and the return spring
4110.3 Inspect the gear of the steering servo unit. (Option) I
5000 Electrical functions
5000.1 Inspect brake switch operation I I
5000.2 Inspect correct operation of the emergency I I
stop switch
5000.3 Check the function of the collision safety I I
switch
5000.4 Inspect lifting/lowering operation of the forks I I
(and support arms SPE125L/160L)
5000.5 Inspect correction operation of the platform switch I I
5000.6 Inspect the side guard switch for correct operation I I
5000.7 Check the function of the horn I I
5000.8 Check for wear on cabling I I

789, 791 711956-
Date Order number
2004-04-05 218367-040


cation
5000.9 Check the function of the driver’s control I I
5000.10 Inspect the error code log, operating hours I I
and all segments in the display panel
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over the M
cell plates
5110.2 Check connections to battery, truck and I
charge
5110.3 Check that the cell and pole guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery locking I
5400 Power system
5400.1 Clean and inspect the mounting devices C/T
5400.2 Re-tighten cable connections T
5400.3 Check the contactor points on K10 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
6000 Hydraulic system
6000.1 Check hoses and connections for wear I
6000.2 Check hoses for wear and damage I
6000.3 Check the oil tank for cracks, leakage and I
damaged mountings
6000.4 Check that the oil level is correct I I
6000.5 Replace the oil and clean the reservoir L5 L

711956- 789, 791
Order number Date
218367-040 2004-04-05


cation
6600 Lift cylinder
6600.1 Check for leakage I
6600.2 Check the mountings I
7100 Mast
7100.1 Check for any cracks and other damage I
7100.2 Tighten the mast mounting bolts (tightening T
torque = 197 Nm)
7100.3 Inspect the play between the mast member I
and the mast stabiliser rollers inside the mast
7100.4 Inspect lateral play in the mast stabiliser I
7100.5 Inspect the lifting chains and chain rollers for wear I
7100.6 Inspect correct adjustment of the lifting chains I
7100.7 Inspect the chain pin shafts and split cotters I
1 = The connections are re-tightened for the first time after 500h and
then every 1000 /h.
2 = The attachment bolts are re-tightened after 500h to 45 Nm.
3 = Check for leakage in conjunction with the first oil change
4 = The oil is changed for the first time after 500h/6 month and then
every 3000 h/36 months.
5 = Replace the oil and clean the reservoir the first time after 80 hours/
1 month, and then every 1000 hours/12 months.
6 = If the truck is used in cold stores or other severe conditions, perform
this item every 250 hours.
When points with higher hour intervals are carried out the points with
lower hour intervals should also be carried out unless otherwise speci-
fied above.

789, 791 711956-
Date Order number
2004-04-05 218367-040
5000
7100
6600
4110
5000
5000
3500
1700 3100
0450
5100 6000
2550
5400
3500

Lubrication chart
711956- 789, 791
Order number Date
218367-040 2004-04-05
5.1 Lubrication chart
Table 10: Lubrication chart

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

Lubrication chart
789, 791 711956-
Date Order number
2004-04-05 218367-040

Oil and grease specification – P3
711956- 789, 791
Order number Date
218367-040 2004-04-05
6- Oil and grease specification – P3
Table 11: Oil and grease specification

Lubricant Specification Application area
> - 15°C < - 15°C
A Grease S213366 S213366 Bearings and bushings
Q8 Rubens WB Q8 Rubens WB
B Hydraulic oil ISO-L-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease See table below See table below Chains
F Grease BT 055-70111 BT 055-74320 Mast
G Grease Staburags Staburags Steering bearings
NBU 8EP NBU 8EP
Ambient temperature Viscosity Recommended products ( Similar products

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

Oil and grease specification – P3
789, 791 711956-
Date Order number
2004-04-05 218367-040

Tools – P4
Super Seal connectors
711956- 789, 791
Order number Date
218367-040 2004-04-05
7- Tools – P4
7.1 Super Seal connectors
3
3
Figure Number Application

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

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

3-6 poles (2)
159228 Tools for removing pins/sleeves (3)

Tools – P4
AMP connectors
789, 791 711956-
Date Order number
2004-04-05 218367-040
7.2 AMP connectors

PT = Power Timer (4,8. 5,8. 6,3 mm)
JPT = Junior Power Timer (2,8 mm)
MPT = Micro Power Timer (1,5 mm)

151080 (PT) Tools for removing pins/sleeves
213296 (JPT) Tools for removing pins/sleeves
213298 (MPT) Tools for removing pins/sleeves
1=163787 Tools for fitting sleeves

2=163788
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2

Tools – P4
Molex connectors
711956- 789, 791
Order number Date
218367-040 2004-04-05
7.2.1 AMP Connectors, 040 series

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

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

Tools – P4
Other tools
789, 791 711956-
Date Order number
2004-04-05 218367-040
7.4 Other tools

156263 Service instrument (CAN)
1=163793 Service instrument for pro-

2=163792 gramme changes
08-13022 Driving gear puller

Electric drive motor – 1760
Included components
711956- 789, 791
Order number Date
218367-040 2004-04-05
8- Electric drive motor – 1760
8.1 Included components

16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
Table 12: Included components

Pos. Name Notes
1 Screw M6x25
2 Bearing plate
3 Groove ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20

Included components
789, 791 711956-
Date Order number
2004-04-05 218367-040

Pos. Name Notes
8 Carbon brush
9 Rotor
10 Wedge
11 Plug
12 Armature
13 Cable
14 Cable
15 Bearing plate
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Groove ring
21 Groove ring

Disassembly/assembly of the truck motor
711956- 789, 791
Order number Date
218367-040 2004-04-05
8.2 Disassembly/assembly of the truck

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

Service/repairs
789, 791 711956-
Date Order number
2004-04-05 218367-040
8.3 Service/repairs
8.3.1 Disassembly of the motor

16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
• Loosen the brake disc tappet by first removing the groove ring to-
gether with the washer at the end of the rotor shaft. It is then possible
to remove the tappet by lifting it. It may be necessary to use a suita-
ble tool to free it.
• Us the four plugs that cover the carbon brushes, fold away the car-
bon brush springs and pull out the carbon brushes.
• Disassemble the bearing plate (2) at the end of the commutator to-
gether with the carbon brush bridge (5) and the carbon brushes (8)
by removing the eight screws (1). Then set down the motor, arrest it
properly to the edge of the bearing plate and carefully knock at the
end of the rotor shaft with a rubber mallet.
• Disassemble the drive end of the bearing plate (15) together with the
rotor (9). Be careful not to damage the motor windings when the ro-
tor is remove from the motor cover.

Service/repairs
711956- 789, 791
Order number Date
218367-040 2004-04-05
• Once the motor bearing plates have been disassembled and the ro-
tor has been removed from the motor cover, loosen the gear wheel
at the rotor drive end. This is done by loosening the gear wheel nut
and then pulling out the gear wheel with a puller. Please note that the
gear wheel has been secured to the rotor shaft with Loctite.
• Then loosen the inner groove ring together with the washer below
the ring. Pull out the rotor shaft from the bearing (18).
• Loosen the outer groove ring together with its washer, and remove
the bearing from the bearing plate.
• Remove the bearing plate seal (17) and carefully clean the bearing
plate.
• Install a new seal in the bearing plate.
8.3.2 Motor installation

Install the motor in reverse.
• Carefully check whether the rotor can move freely when rotating and
that the carbon brushes press against the commutator.
• Check the insulation resistance of the motor (between each winding
and the motor cover). On a new motor, the measured value should
be 2 - 3 MOhm. When the motor has become dirty, an insulation re-
sistance down to approx. 1 MOhm is acceptable.
• Install a new O-ring on the bearing plate at the drive shaft end and a
new seal on the bearing plate collar.
8.3.3 Cleaning
Keep the motor as clean as possible since this is a decisive factor for
correct operation. Regularly inspect the motor and motor compartment
for build-up of dust, oil and other contaminants.
If the motor windings and internal compartments are dry, use a vacuum
cleaner with a suitable nozzle to clean the motor. Compressed air can
be used together with a vacuum cleaner for cleaning. If this is the case,
make sure the compressed air is clean and dry.
If deposits have formed on the windings, use a lint-free cloth to remove
them. If required, moisten the cloth with an organic, volatile grease sol-
vent that will not damage the windings. However, do not use too much
cleaning agent as it could penetrate into the motor parts.
If grease deposits are left on the surface, use a suitable solvent to
remove cleaning agent remains.
If the motor components are heavily contaminated, it may be necessary
to use a solvent that is sprayed onto the parts. It is especially important
for the rotor that the cleaning agent is applied in a manner that avoids
contaminants from penetrating into the motor section.
Technical data
789, 791 711956-
Date Order number
2004-04-05 218367-040
One method to clean the rotor is to submerge it in solvent. If this meth-

od is used, be sure to later dry the motor using a heat source. During
the drying process, arrange good ventilation and allow the components
to dry until repeated insulation resistance measurements show similar
and approved values.
8.4 Technical data

Machine type
Type TSL140B-DS41
Power (kW) 1,7
Intermittence S2 60 min.
Minimum carbon brush length (mm) 13
Minimal commutator diameter (mm) 60
Resistance, shunt field winding Ω at 26°C 0,498
Resistance, armature winding Ω at 26°C 0,0161
Insulation resistance between windings >= 1 MOhm
and motor cover
Weight (kg) 17

Drive unit/gear – 2550
Included components
711956- 789, 791
Order number Date
218367-040 2004-04-05
9- Drive unit/gear – 2550
18
2
1 3
4
5
6
10
16 17 7
15 8
9
14
11
12
13
9.1 Included components

Pos. Name Notes
1 Motor gear
wheel
2 Locking nut Tightening torque 70 Nm
Centre punch to lock

Included components
789, 791 711956-
Date Order number
2004-04-05 218367-040

Pos. Name Notes
3 Primary gear
wheel
4 Tapered roller
bearing
5 Shim
6 Shim
7 Tapered roller
bearing
8 Tapered roller
bearing
9 Locking nut Tightening torque 300 Nm
Centre punch to lock
10 Cover
11 Screw Tightening torque 26,6 Nm
Secure using Loctite 242
12 Shim
13 Pinion/crown Gear play 0,09-0,15 mm. Pretighten
wheel the bearing by 2-5/100. The punched
measure in the pinion should be
adjusted using shims.
14 Drive axle
15 Wheel screw Tightening torque 65 Nm
Lock using Loctite 270
16 Jointing ring Fill the jointing ring with grease
Seal using Loctite 574
17 Tapered roller
bearing
18 Cover with gear
ring

Leakage from top cover
711956- 789, 791
Order number Date
218367-040 2004-04-05
9.1.1 Technical data

Truck type SPE125/125L/160/160L
Gear type 2-stage angle gear
Gear ratio 14,20:1
Oil volume, litres 1,75
Oil type Hypoid oil
Viscosity, normal tempera- SAE 80W/90
ture
Viscosity, <-15°C SAE 75W
9.2 Leakage from top cover

Disassembly
• Lift up the truck and properly secure it using trestles.
• Unscrew the drive wheel.
• Using a box wrench, unscrew the M8 nuts which secure the gear unit
to the motor. Hold the gear unit to prevent it from falling down.
• Using a 6 mm Allen key, loosen the M8 screws which secure the
cover.
• Replace the seal.
Assembly is done in reverse.
• Tighten the four M8 screws and the four M8 nuts to a torque of 27
Nm. Secure with Loctite 242.
• Tighten the 5 screws of the drive wheel to a torque of 65 Nm.
9.3 Replacing the drive axle jointing

ring
When replacing the drive axle jointing ring, the gear unit can remain
installed on the truck.
If the drive axle leaks oil, follow the instructions below.

Replacing the drive axle jointing ring
789, 791 711956-
Date Order number
2004-04-05 218367-040
9.3.1 Disassembly
• Unscrew the drive wheel.
• Remove the bottom cover and drain all oil (10).
• Loosen the drive axle nut. Remove the nut and washer (9).
• Carefully knock out the drive axle using a brass mandrel and ham-
mer (14).
• Pull out the bearing from the drive axle using the bearing removal
tool 08-13022 (17).
• Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing puller, then measure the total
thickness of the spacing washers and replace them prior to assem-
bly (12)
• Remove the jointing ring from the drive axle (16).
9.3.2 Assembly
Assembly of the gear unit after replacement of the drive axle jointing
ring is done in reverse compared to disassembly.
Pay special attention to the following during assembly:
• Fill the jointing ring with grease after setting it on the drive axle.
• Ensure that only undamaged spacing washers of equal total thick-
ness as the original spacers are set on the drive axle.
• Press on the bearing on the drive axle, making sure not to damage
the bearing spacing washers.
• During assembly of the drive axle with attached bearing, spacing
washers and jointing ring, make sure the placement of the axle
wedges coincide with the crown wheel wedges and that the bearing
and jointing ring are properly positioned in the gear housing prior to
pressing the axle completely into the opening.
• Place the spacer ring on the drive axle end and then screw on the
axle nut. Always be sure to use a new nut. Tighter the axle nut to a
torque of 300 Nm, and lock it with one centre punch. Lubricate the
drive axle nut prior to setting it on the axle.
• Before installing the bottom cover, replace the seal. Make sure it is
not damaged. Install the cover and tighten the screws to a torque of
26.6 Nm. Lubricate the screws prior to mounting. Fill with oil accord-
ing to the oil filling instructions.
Fit the drive wheel and tighten the screws to a torque of 65 Nm.

Electromagnetic brake – 3370
Main components of the brake
711956- 789, 791
Order number Date
218367-040 2004-04-05
10- Electromagnetic brake – 3370
10.1 Main components of the brake

9 1
8
2
6
4
Table 16: Main components of the brake

Pos. no. Description
1 Magnet coil
2 Electric cable
3 Pressure plate
4 Pressure spring
5 Friction plate
6 Adjusting locking nut
7 Brake disc
8 Mounting bolts
9 Hub

Maintenance
789, 791 711956-
Date Order number
2004-04-05 218367-040
10.2 Maintenance
In normal use, the brake should not require any maintenance. The pre-
ventive maintenance diagram, however, recommends regular inspec-
tion of the brake disc for wear and also to ensure the play between the
magnet coil housing and pressure plate is correct.
10.2.1 Basic adjustment of the play
9,5 Nm
0,3
The specified play between the magnetic coil housing and the pres-
sure plate should be 0.3 mm when applying the brake. The maximum
play prior to adjustment becoming necessary is 0.8 mm.
Adjustment
• Slightly loosen the tightening of the three mounting bolts.
• Turn the locking nuts counter-clockwise and lightly tighten the bolts
while at the same time checking the play in three places using a 0.3
feeler gauge.
• Tighten the mounting bolts to a torque of 9.5 Nm and reverify the
play using the feeler gauge.

Maintenance
711956- 789, 791
Order number Date
218367-040 2004-04-05
10.2.2 Brake disc replacement

Replace the brake disc when its entire thickness has become 8,8 mm.
• Disconnect the electric cables from the brake.
• Loosen and remove the three mounting bolts and the brake coil.
• Replace the brake disc on the hub and inspect the friction plate for
wear. If the surface is uneven, then replace the friction plate.
• Unscrew the locking nuts on the coil at least 6 mm to assure there is
a large play between the coil and the pressure plate when the coil is
later reinstalled.
• Attach the coil to the motor end and adjust the play as described in
the section ”Basic adjustment of the play”.
• Reconnect the electric cables.

Maintenance
789, 791 711956-
Date Order number
2004-04-05 218367-040

Electrical systems – 5000
Electrical equipment overview
711956- 789, 791
Order number Date
218367-040 2004-04-05
11- Electrical systems – 5000

11.1 Electrical equipment overview
A2:S17
A17
KOMPONENT
ÖVERSIKTSBILD
A6
S18:1 S18:2
A2
A2:S20
A2:S19
R14
L1

Electrical equipment overview
T-code Valid from serial number Date Order number
789, 791 711956- 2004-04-05 218367-040
S53 S56
S31
S90
S10
S33
S21
M3
Y59 X1
KOMPONENT
Y58
Y41
ÖVERSIKTSBILD
B4
B5 G1
Y52
X41
Y10 A3
F3
A1
S19
S59
F50
R2 F52
F53
K10
M1
F1
H1
S65

Equipment list and electrical diagram
711956- 789, 791
Order number Date
218367-040 2004-04-05
11.2 Equipment list and electrical

diagram
The following table shows a summary of the major electrical compo-
nents of this truck.
Table 17: Electrical equipment list summary

Sym- Function Description Associated signal Inf.
bol names
Energy and main power isolation
G1 Main electrical power source Traction battery
24 V
X1 Battery connection / isolation Connector
K10 Main contactor Contactor A1:OUT MAIN CON- 7
TACTOR
Equipment protection
F1 Drive motor protection Fuse 125 A
F3 Pump motor protection Fuse 160 A
F 50 Operating circuit protection, A2 Fuse 7,5A A5:INPUT ENABLE B+
F 51 Operating circuit protection A1 Fuse 7,5 A
F 52 Steer servo motor protection Fuse 30 A A5:POWER SUPPLY
24VDC
F 53 Operating circuit protection, A5 Fuse 3 A 3
Control and Signal processing
A1 Traction and peripherals power Transistor regula-
control tor
A2 Control of truck functions Electronic card 1
A3 Lift power and signal control Transistor regula-
tor
A5 Steering servo Electronic card 3, 2
A6 Display of truck functions Display unit 1
A17 PIN log in and data entry Keypad 1

789, 791 711956-
Date Order number
2004-04-05 218367-040

bol names
Braking, Safety & Supervision
S21 Emergency switch-off Switch A1:INP.SUPPLY 24VDC
S10 Tiller arm in drive position Inductive proxi- A1:INP.TILLER ARM IN 7, 10
(Mechanical brake activation) mity switch DRIVE POS
Y1 Mechanical brake Electromechani- A1:OUT.BRAKE A 7
cal brake
A2:S17 Emergency reverse Hall sensor A2:BELLY BUTTON 5
S19 Platform staying down supervi- Inductive proxi- A1:INP.MAN ON PLAT- 7, 3
sion mity switch FORM
S59 Platform not up supervision Inductive proxi- A1:INP.PLATFORM NO 7, 10
mity switch T FOLDED UP
S53 Gates up supervision Inductive proxi- A1:INP GATES UP 7, 10
mity switch
S56 Gates down supervision Inductive proxi- A1:INP GATES DOWN 7, 10
mity switch
S33/1 Supervision -Max. permitted lift Magnetic switch A1:INP LIFT LIMIT 7,9
height for powertrak POWER TRAC 1,<
1.8M
S33/2 Supervision -Max. permitted lift Magnetic switch A3:INP.LIFT LIMIT <1,8 7,9
height with gates up M
H1 Audible warning signal -Horn Horn A1:OUT.SIGNAL HORN 7
S18:1 Horn activation Switch A2:INP.HORN1 7, 4
S18:2 Horn activation Switch A2:INP.HORN2 7, 4

711956- 789, 791
Order number Date
218367-040 2004-04-05

bol names
Traction & traction control
L1 Speed control and travel direc- Hall sensor 6, 7
tion selector (butterfly)
S113 “Turtle” function Switch A2:TURTLE 3
M1 Truck traction Motor
Y58 Powertrak drain-hydraulic control Magnetic valve A1:OUT.POWERTRAK 7
DRAIN VALVE
Y59 Powertrak open-hydraulic control Magnetic valve A1:OUT.POWERTRAK 7
FILL-UP VALVE
B5 Powertrak pressure supervision Pressure sensor A3:INP.PRESSURE PT 7
Steering
R2 Steering angle signal Potentiometer A5:A_IN0 , A_IN1 3
S65 Drive wheel in centre reference Inductive proxim- A5:REF 3
ity switch
M6 Drive wheel steering Motor 3,2
Forks lift
R14 Fork lift/ lower control Hall sensor unit A2:A_IN 7
Y10 Fork lower -hydraulic control Proportional mag- A3:OUT MAGNET 7,8
netic valve VALVE PWM
B4 Load supervision Pressure sensor A3:INP.PRESSURE LIFT 7
M3 Hydraulic pressure Motor

789, 791 711956-
Date Order number
2004-04-05 218367-040

bol names
Support arm lift (SPE125L/160L)
A2:S19 Support arm lift control Hall sensor 5,7,8
A2:S20 Support arm lower control Hall sensor 5,7.8
Y41 Support arm lower -hydraulic con- Magnetic valve A3:OUT.SUPPORT 7,8
trol ARM LOWER VALVE
Y52 Support arm / fork lift selection Magnetic valve A3:OUT. FORK/ 7,8
SUP.ARM VALVE
S31 Support arms at top supervision Inductive proxi- A1:INP.SUPPORT ARM 7,8 10
mity switch AT TOP
S90 Support arms at bottom supervision Inductive proxi- A1:INP.SUPPORT ARM 7,8,10
mity switch AT BOTTOM
Other
R1 Power supply PTC-resistor 15 Ohm
X41 CAN communication (external) Connection point
X9 CAN communication (extra I/O) Connection point
Footnotes to the table above:

1. Situated in the tiller arm handle and communicates via the CAN bus
2. The steering servo controller, servo motor and mechanics are inte-
grated into one single unit.
3. Optional function
4. S18:1 represents the left side button and S18:2 represents the right
side button.
5.These inputs signals are processed directly via Hall effect sensors
mounted on the A2 card and are handled via the CAN bus.
6. Speed control signals from L1 are processed by Hall element sen-
sors mounted on the A2 card. Sensors A2:S1-9 control speed control
signals for driving in fork direction. Sensors A2:S10-18 control speed
control signals for driving in drive wheel direction.
7. Signals to/ from these elements can be checked via the Built-in Test
function. See “11.6.5Built-in Test Function” on page 38
8. Only valid for truck with support arm lift
9. Output is low when sensor is activated.
10. Output is high when sensor is activated.

Order number Date Valid from serial number T-code
218367-040 2004-04-05 711956- 789, 791
11.2.1 Electrical wiring diagram 1 of 8
ELECTRICAL DRAWING SHEET 1

789, 791 711956- 2004-04-05 218367-040

218367-040 2004-04-05 711956- 789, 791

789, 791 711956- 2004-04-05 218367-040

SPE125L/160L
ONLY

SPE125L/160L
ONLY

218367-040 2004-04-05 711956- 789, 791
SPE125L/160L
ONLY

789, 791 711956- 2004-04-05 218367-040

218367-040 2004-04-05 711956- 789, 791
ELECTRICAL DRAWING SHEET

789, 791 711956- 2004-04-05 218367-040

Functional description
711956- 789, 791
Order number Date
218367-040 2004-04-05
11.3 Functional description
means constantly on means flashing.

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

789, 791 711956-
Date Order number
2004-04-05 218367-040
Table 18: Functional description

Event: 1. Battery connected
Action(s) Connect the traction battery [X1, G1]
Influencing Main power fuses ok [F1, F3]

elements Operating circuit fuses ok [F50, F51, F52, F53]
PTC resistor ok [R1]
Resulting 24V (control) supplied directly to [A2], [A5] and via R1 to [A1], [A3], [A5]
conditions Curtis status LED blinks once every 5 seconds.[A1]
Event: 2. Switch on (PIN-code entry)

Prior event(s) 1
Action(s)
Enter valid PIN-code and press [A17]
Influencing Emergency switch-off closed [S21] [INP.SUPPLY +24V] high

elements Tiller arm in drive not activated [S10] [INP.TILLER ARM IN DRIVE POS] low
Resulting
conditions Power lamp lights. Main display shows hour meter reading
and for 4 seconds followed by battery condition as a per-
centage of full charge and [A6]

Mechanical brake remains on [Y1, A1:OUT.BRAKE] high
Main contactor output remains high [A1:OUT.MAIN CONTACTOR] and Main
contactor remains open [K10]

711956- 789, 791
Order number Date
218367-040 2004-04-05

Event: 3. Tiller am lowered for driving
Prior event(s) 2
Action(s) Lower tiller arm handle
Influencing Tiller arm in drive sensor [S10]

elements
Resulting Tiller arm in drive sensor activates [S10] [INP.TILLER ARM IN DRIVE POS.]
conditions high
Brake solenoid control [A1:OUT.BRAKE] remains high
Brake remains on [Y1]
Main contactor output [A1:OUT.MAIN CONTACTOR] goes low
Main contactor closes [K10]
24V (power) supplied to [A1],[A3] & [A5]
Event: 4. Traction, forks first

Prior event(s) 3
Action(s) Move butterfly [L1] in forks drive direction.
Influencing Butterfly Hall sensors [A2:S10-18]

elements Platform staying down sensor [S19]. Platform not up sensor [S59]
Gates up sensor [S53], Gates down sensor [S56]
Fork load supervision sensor [B4]
Parameter settings. See “11.4Speed limitation” on page 23
Resulting [A1:OUT.BRAKE A] goes low

conditions Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises,
mechanical brake releases
Current fed to traction motor field winding (S2 +ve and S1 -ve)
Pulsed current fed to traction motor armature proportional to butterfly deflection

789, 791 711956-
Date Order number
2004-04-05 218367-040

Event: 5. Traction, drive wheel first
Prior event(s) 3
Action(s) Move butterfly [L1] in drive wheel drive direction.
Influencing Butterfly Hall sensors [A2:S1-9]

elements Platform staying down sensor [S19]. Platform not up sensor [S59]
Fork load supervision sensor [B4
See “11.4Speed limitation” on page 23
Resulting [A1:OUT.BRAKE A] goes low

conditions Brake solenoid control [A1:OUT.BRAKE] goes low & brake coil [Y1] energises
Current fed to traction motor field winding (S2 -ve and S1 +ve)
Pulsed current fed to traction motor armature proportional to butterfly deflection

711956- 789, 791
Order number Date
218367-040 2004-04-05

Event: 6. Neutral braking
Prior event(s) 4 or 5
Action(s) Let butterfly [L1] return to neutral position.
Influencing Fork load supervision sensor [B4]

elements Parameter settings
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] converts
conditions the trucks energy of motion into electrical energy thus reducing the truck’s
speed. The excess electrical energy is fed back to the battery helping to
recharge it [G1].
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes
to a complete stand still
Event: 7. Reverse braking

Action(s) Move butterfly [L1] so as to reverse the direction of travel
Influencing Man-on platform switch [S19]

elements Fork load supervision sensor [B4]
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] converts
conditions the trucks energy of motion into electrical energy thus reducing the truck’s
speed. The excess electrical energy is fed back to the battery helping to
recharge it [G1]. The braking effect increases the more the butterfly is
deflected
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck comes
to a complete stand still
Event: 8. Mechanical brake operation

Action(s) Move tiller arm handle to upper or lower position
Influencing Tiller arm in drive sensor goes low [S10]

elements
Resulting The mechanical brake [Y1, A1:OUT.BRAKE A] activates
conditions

789, 791 711956-
Date Order number
2004-04-05 218367-040

Event: 9. Steering
Prior event(s) 3
Action(s) Steer tiller unit handle to left or right
Influencing Steering angle potentiometer [R2]

elements Steering reference switch [S65, A5:INP.REFERENCE SWITCH]
Man on platform switch [S19, A1:INP.DRIVER ON PLATFORM]
Resulting Steer servo motor positions drive wheel according to tiller handle’s deflection
conditions [A5, M6] (See section “11.3.1 Description of steering system” )
Event: 10. Fork lifting

Prior event(s) 2
Action(s) Operate fork lift control [R14] in lifting direction
Influencing Forks lift control [R14]

elements Battery status ok (>20% charge left)
Max permitted lift height with gates up sensor [S33/2]
Support arms at bottom sensor [S90]
Resulting Current fed to lift motor [M3] field winding (S2 -ve and S1 +ve)
conditions Pulsed current fed to lift motor armature proportional to lift control deflection
Pump motor [M3] operates
Event: 11. Fork lowering

Prior event(s) 2
Action(s) Operate fork lift control [R14] in lowering direction
Influencing Forks lift control [R14]

elements
Resulting [A1:OUT.MAGNET VALVE PWM] sends pulsed signal to fork lowering hydrau-
conditions lic valve [Y10]. Valve opens proportionally to signal allowing a variable lower
speed.

711956- 789, 791
Order number Date
218367-040 2004-04-05

Event 12. Support arms lifting (SPE125L/160L)
Prior event(s) 2
Action(s) Operate support arm lift button [A2:S19] i
Influencing Support arm lift button [A2:S19]

elements Battery status ok (>20% charge left)
Support arm at top sensor [S31]
Resulting [A3:OUT.FORK/SUP:ARM VALVE] goes low & valve Y52 operates

conditions A set current is fed to lift motor [M3] field winding (S2 -ve and S1 +ve)
Pulsed current fed to lift motor armature
Pump motor [M3] operates & hydraulic pressure fed to support arm lift circuit
Event 13. Support arms lowering (SPE125L/160L)

Prior event(s) 2
Action(s) Operate support arm lower button [A2:S20] i
Influencing Support arm lower button [A2:S19]

elements Support arm at bottom sensor [S90]
Resulting [A3:OUT.SUPPORT ARM LOWERING VALVE] goes low & valve Y41 operates
conditions support arm lift circuit pressure is drained to tank and support arms lower.
Event 14. Powertrak operation

Prior event(s) 10 / 11 / 12 / 13
Action(s) Lift a load on forks and/or support arms
Influencing Max permitted lift height for Powertrak sensor [S33/2]

elements
Resulting [A1:OUT POWERTRAK FILL-UP VALVE] low & [A1:OUT POWERTRAK
conditions DRAIN] high while fork lift height <1,8 m
Lift pressure applied to Powertrak cylinder.
Fork lift height goes over 1.8m and [S33/2] [A3:INP LIFT LIMIT, <1,8M] goes
low
[A1:OUT POWERTRAK DRAIN VALVE] then goes low and valve [Y58] opens
thus draining pressure from Powertrak cylinder

789, 791 711956-
Date Order number
2004-04-05 218367-040
11.3.1 Description of steering system

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

Speed limitation
711956- 789, 791
Order number Date
218367-040 2004-04-05
11.4 Speed limitation

The truck’s maximum speed is limited by a combination of, fork lift
height, fork load and operator’s driving position. Driver parameter set-
tings also affect maximum speed. See “11.8.6Summary of driver
parameters” on page 47 for more information. The table below summa-
rises the speed limitations and assumes that all relevant driver param-
eters are set to 100%. Note that the speeds given are nominal.
Table 19: Summary of speed limitations

Load Fork lift Driver position or mode Max.
(kg) height speed
(mm) (km/h)
<800 <1800 Platform down, gates up (transportation mode) 8
Platform down, gates down 6
Platform up, gates down (pedestrian mode) 6
Platform up, gates up 0
<800 >1800 Platform down, gates up 0
>800 <1800 Platform down, gates up (transportation mode) 8 - 7a
>800 >1800 Platform down, gates up (transportation mode) 0
- - Turtle mode is controlled by parameter # 7
- - Snail speed mode ≈ 1,6
- - Error / Warning code mode ≈ 2,5
a.Max. speed determined by actual load and will ramp between 8 & 7 km/h

Hour meter and battery condition
789, 791 711956-
Date Order number
2004-04-05 218367-040
11.5 Hour meter and battery condition

At switch on, the hour meter is displayed and the hour meter symbol
lights for 4 seconds. Fig. 1
The display will then change to show the battery’s remaining capacity
Fig. 1
expressed as a percentage of full charge and the battery symbol lights.
Fig. 2
The truck’s control system stores 5 different elapsed time values in
units of hours. The time value normally shown depends on the setting
of service parameter #20. (See “# 20 - Hour meter selection” on
page 53). However, any of these time values can be temporarily dis-
played on the hour meter. To choose which value to display carry out
the following procedure:
Fig. 2
• Ensure the battery is connected.
• Ensure the truck is switched off. Press on the keypad.

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

• Hold S18 depressed until “H” is displayed, then release S18. Fig. 3
Hour meter symbol lights.

Fig. 3
The different hour meter modes are displayed by repeatedly operating
speed control L1. The actual time value will be displayed momentarily
after the mode is selected.

Hour meter and battery condition
711956- 789, 791
Order number Date
218367-040 2004-04-05
Table 20: Hour meter modes

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

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

(Parameter #25 controls the initial value) See “# 25 - Service interval”
on page 55 for more information.

Diagnostic and troubleshooting
789, 791 711956-
Date Order number
2004-04-05 218367-040
11.6 Diagnostic and troubleshooting
means constantly on means flashing.
11.6.1 Fault codes

The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 4.
Fig. 4
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C50 to C99 will limit the truck’s maximum speed to creep-
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C19 to C43 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely. i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.
11.6.2 Fault code history

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


• Hold S18 depressed until “E” is displayed, then release S18. Fig. 5
Fig. 5

711956- 789, 791
Order number Date
218367-040 2004-04-05
Fault symbol lights.
The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control L1.
11.6.3 List of fault codes

NOTE!
The text “Restart the truck!” in the following tables always means
switching the truck off completely by removing the battery connector
[X1], reconnecting and then switching the truck on again.
Table 21: List of fault codes

Code Description Possible cause / Hint or Solution
C19 Default parameter warning Parameter area is probably corrupt. Default values have been
down loaded / Driver specific parameter settings must be re-
entered again if this code is displayed.
C20 Butterfly warning Problem with butterfly sensor [L1].
Butterfly may have been activated during start up or faulty sen-
sor(s).[A2] / Check action of butterfly
C21 Lift/Lower control warning Lift / Lower control for the forks may have been activated dur-
ing start up or faulty sensor / Check action of Lift / Lower con-
trol
C28 Emergency switch warning Emergency switch activated [S21]
No voltage supply to Traction transistor regulator [A1].
Harness problem. / Check emergency switch is not depressed.
Check wiring.
C29 Service time warning Next service is due / Check service counter. It may not be reset
after latest service See “# 25 - Service interval” on page 55 for
setting of parameter #25.
C30 Max.fork load exceeded The load on the forks has exceeded the truck’s classified lift
capacity. / Ensure the load to be lifted does not exceed the
classified lift capacity
Ensure the mast sections and lifting chains move freely
Check pressure sensor o/p [B1:INP.PRESSURE LIFT]
voltage ≈ 0,5V with no load & lowered forks / support arms
Perform a Max. load calibration See “# 36 - Calibrate” on
page 55

789, 791 711956-
Date Order number
2004-04-05 218367-040

C35 Steer servo -Internal tem- The internal temperature of the steer servo[A5] has exceeded
perature warning +68° C / Steering may be too intensive
C41 Battery undervoltage war- Traction transistor regulator[A1] has detected battery voltage
ning -traction transistor re- < 17V
gulator Battery parameter not correctly adjusted. See “# 21 - Battery
size” on page 54 for setting of parameter #21
Battery due for charging
C42 Battery overvoltage war- Traction transistor regulator[A1] has detected battery
ning -traction transistor voltage > 33V /
regulator Can be caused by fully-charged battery and energy return feed
to the battery during heavy reverse braking
C43 Traction transistor regula- Driving may be too intensive
tor thermal cutback Defective Traction transistor regulator [A1]
C47 Battery under voltage Pump transistor regulator[A3] has detected battery voltage < 17V /
warning -pump transistor Battery parameter not correctly adjusted. See “# 21 - Battery
regulator size” on page 54 for setting of parameter #21
Battery due for charging
C48 Battery overvoltage -pump Pump transistor regulator[A3] has detected battery
transistor regulato voltage > 33V
C49 Pump transistor regulator - Lifting may be too intensive
thermal cutback Defective pump transistor regulator [A3]
C60 Pressure sensor error, Lift Voltage at i/p [B4:INP.PRESSURE LIFT] outside range
system +0,3V to +7,7V
/ Check pressure sensor [B4] wiring and function
Defective pressure sensor [B4]
C61 Pressure sensor error - Voltage at i/p [B5:INP.PRESSURE PT] outside range
powertrak +0,3V to +7,7V
/ Check pressure sensor [B5] wiring and function
Defective pressure sensor [B5]
C62 Powertrak error Unexpected pressure level in Powertrak system /
Check wiring & connections to Powertrak related components
[Y58], [Y59], [B4] & [B5]
Mechanical failure in powertrak valves
C63 Powertrak valve output Valve defective [Y59] or fault in o/p from traction transistor re-
error gulator [A1:OUT.POWERTRAK FILL UP VALVE]
C64 Powertrak valve output Valve defective [Y58] or fault in o/p from traction transistor re-
error gulator [A1:OUT.POWERTRAK DRAIN VALVE]

711956- 789, 791
Order number Date
218367-040 2004-04-05

C 70 Pump motor field circuit open Shunt field open [M3], harness broken, pump transistor regulator
defective [A3]./ Check wiring and connections to shunt field [M3]
C 71 M minus error - Pump tran- Problem with switch transistor in armature circuit inside Pump
sistor regulator [A3] transistor regulator [A3]
Defective Pump transistor regulator [A3].
C 72 Current sensor error - Armature current sensor fault in pump transistor regulator [A3]
Pump transistor regulator Defective pump transistor regulator [A3]
[A3]
C73 CAN timeout error -Pump Pump transistor regulator [A3] reports unexpected loss of data
transistor regulator [A3] flow from tiller head [A2]./ Check CAN bus signal cables and
connections.[A3, A2]
Restart the truck
C74 Data not received - Pump Data from [A3] not received by [A2]
transistor regulator [A3] Broken CAN wire
/ Check CAN bus signal cables and connections.[A3, A2]
Restart the truck
C75 Transmission to Pump Data from [A2] not received by [A3]
transistor controller[A3] Broken CAN wire
failed Defective Pump transistor regulator [A3]
/Check CAN bus signal cables and connections.[A3, A2]
Restart the truck
C76 Pump transistor regulator Incorrect type of pump transistor regulator is fitted / Check cor-
[A3] incompatible with the rect transistor regulator type is fitted
type of truck
C77 Lift potentiometer [R14] Analogue potentiometer control not detected.
connection error / Check wiring & connections between potentiometer [R14] &
[A2]
C80 Steer servo - Reference Steer servo reference current < 0,1A
sensor current error Supply fault to home reference sensor [S65]
Defective home reference sensor [S65] / Check wiring to sen-
sor
C81 Steer servo - Reference Sensor supply from
sensor supply error Defective home reference sensor [S65] /
Check supply voltage is 12V between wires 95-97 / Check Wi-
ring to sensor
Check condition of [F50]
C82 Steer servo - drive current Steer servo drive current is exceeding 80% of maximum.
warning Steering activity may be too intensive
See also code E132

789, 791 711956-
Date Order number
2004-04-05 218367-040

E90 Extra I/0 (0) CAN commu- Data from extra I/0 box (0) not received by [A2] / Check CAN
nication error bus cables and connections. [A2] Restart the truck
E91 Extra I/0 (1) CAN commu- Data from extra I/0 box (1) not received by [A2] / Check CAN
nication error bus cables and connections. [A2] Restart the truck
E92 Configuration error Extra Faulty configuration of option in extra I/0 box (0) / Check allo-
I/0 (0) cation of outputs in I/0 extension box (0).
E93 Configuration error Extra Faulty configuration of option in extra I/0 box (1) / Check allo-
I/0 (1) cation of outputs in I/0 extension box (1).
E100 Steer servo - configuration Presence of steer servo and parameter #38 setting do not
error match/ Ensure parameter #38 is set correctly
E101 Traction transistor regula- Incorrect type of traction transistor regulator is fitted / Check
tor [A1] incompatible with correct transistor regulator type is fitted
the type of truck
E104 Brake switch transistor out- Defective Traction transistor regulator [A1] / Check cables and
put in Traction transistor magnetic coil to the brake [Y1]
regulator [A1] shorted
E106 Digital output fault or field Attempting to drive more current than specified from outputs.
current limit OR problem regulating field current.
Internal Traction transistor regulator fault. [A1]
E107 Main contactor not acti- Problem with main contactor tips or cabling (open circuit).
vated [K10] Contactor control wire not connected.
Contactor drive output in controller faulty (off) / Check main
contactor tips. Check control wires to main contactor.
Check contactor drive output goes low. [A1]
E108 Main contactor tips welded Main contactor tips welded.
or open circuit in coil.[K10] Contactor drive output in controller faulty (on) / Check main
contactor tips Check contactor drive output goes high. [A1]
E110 Fault in armature current Possible defect in the transistor regulator [A1].
reading Can be caused by excessive moisture inside regulator. /
Restart the truck
E112 Steer servo- wheel posi- Error when comparing actual wheel position (reference sensor
tion error signal) with steer servo’s calculated position.
/ Check reference sensor[S65] functions correctly
Check steer servo pinion is not loose and in contact with drive
unit’s gear ring
Restart the truck

711956- 789, 791
Order number Date
218367-040 2004-04-05

E113 Unspecified steer servo Control system has detected a fault condition but is unable to
fault ascertain the exact cause. / Restart the truck
E114 Steer servo phase error Loss of motor phase to steer servo motor. / Check internal
[A5, M6] motor cable connections in steer servo[A5, M6]
E115 Steer servo initialisation Faulty Servo [A5]
error [A5] Internal logical fault
Wrong parameters / Restart the truck
E116 Steer servo checksum Can occur after new firmware has been loaded into truck /
error [A5] Restart the truck
E117 Steer servo communica- Shall not occur under normal conditions./ Contact support
tion error organisation
E118 Command mode error Shall not occur under normal conditions./ Contact support
organisation
E119 Steer servo error during Home position (steering straight) not achieved within preset
homing operation (Time time.
out) Home reference sensor [S65] not adjusted correctly
Faulty reference sensor / Check reference sensor gap is
adjusted correctly, check wiring to sensor
E120 Steer servo- potentiometer Comparison of voltages between IN_0 & IN_1 is out of range. /
error Check potentiometer inputs
E121 Steer servo error -steering Restart the truck
angle value check Check that sum of voltages between wire nos.
92-94 and 93-94 ≈ 5V
Re calibrate steering (See “# 36 - Calibrate” on page 55)
E122 Steer servo -reference sup- Defective steer servo [A5] / Check voltage between wire nos.
ply out of range 91-94 = 4,5 to 5,5 V
E123 Steer servo - Hall sensor Intermittent contacts inside steer servo
fault Defective steer servo [A5] / Check internal connections from
Hall sensors to main circuit board in steer servo [A5]
E124 Steer servo - overvoltage May occur when performing heavy reverse braking on newly
[A5] charged battery (Voltage exceeded 39V) / Restart the truck
E125 Steer servo - internal short Defective steer servo [A5,M6] /
circuit [A5, M6] Check wiring for short-circuit
Restart the truck
E126 Steer servo - current offset Defective steer servo [A5,M6] / Restart the truck
error [A5, M6]

789, 791 711956-
Date Order number
2004-04-05 218367-040

E127 Steer servo - temperature Steer servo internal temperature outside range -40 to +85º C
error[A5, M6] Steering activity may be too intensive
Defective steer servo [A5,M6] / Restart the truck (See also
code C35)
E128 Not applicable in this truck -
E129 Steer servo - supply under- Battery charge too low
voltage Intermittent connection in servo supply circuit [A5]
Steer servo fuse [F52] faulty or blown. / Check condition of
Fuse [F52]
Charge battery
E130 Steer servo - analogue Faulty steer angle potentiometer [R2]
steer signal input fault Intermittent connection in potentiometer circuit [R2,A5] / Check
wiring to potentiometer [R2]
Move tiller handle in all directions to ensure no wiring problems
exist.
steer signal input 0 fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN0] / Check 0,4 to 4.8V between wires 94-93,
check wiring to potentiometer [R2]
exist.
E132 Steer servo - current limit Output current to steer motor exceeding 80% of maximum for
reached longer than 5 seconds.
Steered portion of drive unit not moving freely./ Check for free
movement of drive wheel on floor. Check steering drive train is
free of dirt or other foreign objects.(See also code C82)
steer signal input 1 fault Intermittent connection in potentiometer circuit
[R2,A5:INP.A_IN1] / Check 0,4 to 4.8V between wires 94-92 ,
check wiring to potentiometer [R2]
exist.
E134 Steer servo - analogue Faulty steer angle potentiometer [R2] or wiring short circuit
steer signal input short cir- between [A5:INP.A_IN1 and INP.A_IN0] / Check wiring to
cuit potentiometer [R2],
exist.

711956- 789, 791
Order number Date
218367-040 2004-04-05

E135 Steer servo - offset value Voltage difference between [A5:INP.A_IN1 and INP.A_IN0] is
error too great
Requires re calibration / Re calibrate steering (parameter #36)
See “# 36 - Calibrate” on page 55
E136 Steer servo - steer angle Calibrated neutral position value is out of range.
potentiometer error Defective potentiometer [R2] / Ensure potentiometer is fitted
correctly.
Re calibrate steering (parameter #36). See “# 36 - Calibrate”
on page 55
E137 Steer servo - checksum Faulty wiring / Check CAN bus signal cables and connec-
error on received data tions.[A5, A2]
Restart the truck
E138 CAN data not received Data from traction transistor regulator not received by [A2]
Faulty wiring / Check CAN bus signal cables and connec-
tions.[A1, A2]
Restart the truck
E139 Steer servo - data trans- Faulty wiring / Check CAN bus signal cables and connec-
mission to servo failed tions.[A5, A2]
Restart the truck
E140 Checksum error Faulty internal micro controller [A2], faulty software
E141 Software problem Faulty internal micro controller [A2], faulty software / New soft-
ware may need loading via CAN
E150 Data not received - Trac- Traction transistor regulator [A1] does not answer, bad connec-
tion transistor controller tions or faulty Traction transistor regulator [A1].
E151 Transmission to traction Broken CAN-wire.
transistor regulator failed Traction transistor regulator [A1] defective
E157 Bus off error CAN-bus problem, wiring harness or hardware problem.[A2] /
Check CAN wiring
E159 Over-run error CAN-bus problem, wiring harness or hardware problem.[A2] /
Check CAN wiring
E160 Error -safety switch against Error in Hall sensor for safety switch against collision “belly
collision button”/
Check switch is not activated.
E200 Drive motor field circuit Shunt field open [M1], harness broken, Traction transistor reg-
open ulator defective [A1]. / Check wiring and connections to shunt
field [M1]

789, 791 711956-
Date Order number
2004-04-05 218367-040

E201 M minus error Problem with switch transistor in armature circuit inside Trac-
tion transistor regulator [A1]
Defective Traction transistor regulator [A1].
E202 Current sensor error - trac- Armature current sensor fault in Traction transistor regulator
tion transistor regulator [A1].
[A1] Defective Traction transistor regulator [A1].
E214 CAN-timeout error - trac- Traction transistor regulator reports unexpected loss of data
tion transistor regulator flow from tiller head [A2]./ Check CAN bus signal cables and
[A1] connections

711956- 789, 791
Order number Date
218367-040 2004-04-05
11.6.4 Transistor regulator troubleshooting

and error codes
STATUS
MODEL VOLTAGE
SERIAL CURRENT
General
Curtis 1243 is a regulator [A1] & [A3] for controlling shunt motors. Vary-
ing the voltage applied through the armature primarily controls the
speed. The voltage is varied through use of pulse-width modulation
(PWM). This involves varying the “on” time of the MOS-FET transistors
regulating the armature current.
Switching of the rotational direction is achieved by switching the pola-
rity on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
STATUS
MODEL VOLTAGE
tor bridge for the armature winding.
SERIAL CURRENT
Transistor regulator errors

The table below depicts the error codes that may be shown by the
STATUS LED or read using the hand-held terminal.
Table 22: Transistor regulator error code

STATUS LED Hand-held Explanation Possible cause
terminal dis-
play
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator
LED on - Defective regulator Defective regulator
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in motor
SHUNT FAULT shunt defective controller.

789, 791 711956-
Date Order number
2004-04-05 218367-040
Table 22: Transistor regulator error code

STATUS LED Hand-held Explanation Possible cause
terminal dis-
play
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in arma-
B- ture circuit inside motor controller
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current for Attempt to drive more current than
SHORT contactor feeding specified from outputs.
or shorted field Problem to regulate field current.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shunt field open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <17 volts
VOLTAGE 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor regu-
lator
4. Operation under extreme conditions

711956- 789, 791
Order number Date
218367-040 2004-04-05
Resetting errors
To reset an error turn S17 to off and then on again.
Error Reset when

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

789, 791 711956-
Date Order number
2004-04-05 218367-040
11.6.5 Built-in Test Function

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

NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!
Table 23: Built-in test modes

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

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

See Table 26:
Inputs / outputs traction transistor -

regulator & pump transistor regula-
tor. See Table 24: & Table 25:
Battery voltage V
Armature current to traction motor A

[M1]
Field current to traction motor [M1] A

711956- 789, 791
Order number Date
218367-040 2004-04-05
Table 23: Built-in test modes

Flashing sym- Displayed data Unit
bol
Armature PWM to traction motor %
[M1]
Armature current to pump motor A

[M3]
Field current to pump motor [M3] A
Armature PWM to pump motor [M3] %
Signal from pressure sensor [B4] bar

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

(Hydraulic pressure in powertrak
circuit)
Maximum lift pressure setting. bar

789, 791 711956-
Date Order number
2004-04-05 218367-040
Digital inputs/outputs test mode

In the digital inputs/outputs mode, the operation of both inputs and out-
puts can be checked by checking the individual segments of the main
display as given in the following tables.
Table 24: Transistor regulator inputs

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

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

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

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

A3:INP.SUPPORT ARM AT TOP
(SPE125L/160L)
Support arms at bottom switch [S90], input
A3:INP.SUPPORT ARM AT BOTTOM
(SPE125L/160L)
Forks < 1800mm [S33/2] magnetic switch , input
A3:LIFT LIMIT <1,8M
Powertrak lift limit [S33/1] magnetic switch, input

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

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

711956- 789, 791
Order number Date
218367-040 2004-04-05
Table 25: Transistor regulator outputs

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

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

TACTOR
Powertrak fill up valve [Y59], output

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

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

A3.OUT.FORK SUP.ARM VALVE
(SPE125L/160L)
Support arm lower valve [Y41], output
A3.SUPPORT ARM LOWERING VALVE
(SPE125L/160L)

789, 791 711956-
Date Order number
2004-04-05 218367-040
Table 26: Main control card signals [A2]

Function Segment
Support arms up [A2:S19] (SPE125L/160L)
Support arms down [A2:S20] (SPE125L/160L)
Signal horn [S18]
Option switch -lefthand left
Option switch -lefthand middle
Option switch -lefthand inner
Option switch -righthand inner
Option switch -righthand middle
Option switch -righthand outer

711956- 789, 791
Order number Date
218367-040 2004-04-05
11.6.6 Display test mode

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


Fig. 6
• Hold S18 depressed until “d” is displayed, then release S18. Fig. 6
All number segments on the display and symbol lamps should flash
sequentially. Fig. 7
Fig. 7

Part numbers
789, 791 711956-
Date Order number
2004-04-05 218367-040
11.7 Part numbers

To select part number display mode carry out the following procedure:


• Hold S18 depressed until “Pn” is displayed, then release S18. Fig. 8
Fig. 8 The display will now show the part numbers for the control program, the
hardware part number and hardware serial number.
The part numbers are displayed by repeatedly operating speed control
L1. The display will first show the starting portion of the number then the
ending portion.
Table 27: Part numbers

Display Meaning
Software (Control program) part number
Hardware part number
Hardware serial number

Parameters
711956- 789, 791
Order number Date
218367-040 2004-04-05
11.8 Parameters
11.8.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Driver parameters and Service parameters.
• Driver parameters (2 to 7) - These parameters are used to tailor the
driving characteristics of a truck for a specific driver or operation. Up
to 10 sets of driver parameters can be stored. Driver parameters can
be adjusted directly without the requirement for a suitable CAN serv-
ice key.1
• Service parameters (10 to 39) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as driver parameters. Service pa-
rameters can ONLY be adjusted when a suitable CAN service key is
plugged into the truck.2
11.8.2 Viewing parameters -CAN key not

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


• Hold S18 depressed until “P” is displayed, then release S18. Fig. 9
Parameters symbol lights.

Fig. 9
The different parameters are now displayed by repeatedly operating
speed control L1. Driver parameters can be both viewed and changed.1
1.Driver parameters can only be set without a CAN key if parameter #39 is
set to value 3. See “# 39 - Access code” on page 59
2.Service parameters can be viewed without a CAN key being plugged in but
they cannot be adjusted.

Parameters
789, 791 711956-
Date Order number
2004-04-05 218367-040
11.8.3 Viewing parameters -CAN key

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

• Press and hold horn button S18 for at least 1 second and then press
on the keypad.
• Hold S18 depressed until “P” is displayed, then release S18. Fig. 10

Fig. 10
Operating speed control L1 in the forward direction causes the display
to show the first set of driver parameters. Continued operation of speed
control L1 in the forward direction will then cause display to show the
next set of driver parameters (for driver no.2) and so on, up to the last
driver (Driver no. 10). See Fig. 11
Driver parameter no.

Parameter set no. After the ten sets of driver parameters have been displayed, the trucks
Fig. 11 service parameters will be displayed when operating the speed control
L1 in the forward direction
The truck’s service parameters can be displayed first by operating
speed control L1 in the backward direction. This will cause parameter
#40 to be displayed and then parameter #39 etc.1
11.8.4 Setting Driver parameters

To change the value of a particular driver parameter carry out the fol-
lowing:
• Switch on the truck and log in with the appropriate PIN-code. This is
important if the truck has more than one set of Driver parameters ac-
tive. Any changes made will only be in effect when that particular
“driver” is logged in.
• Select the required parameter using [L1].
• Press Horn button S18.
Parameter symbol flashes. .
1.Certain parameters numbers displayed are not active in this truck model.

Parameters
711956- 789, 791
Order number Date
218367-040 2004-04-05
• Set parameter value by repeatedly operating speed control L1 up or

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

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
For detailed descriptions and effects of these parameters.see the sec-
tion “11.8.6Summary of driver parameters” on page 47
11.8.5 Setting Service parameters

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

key pad. Once the CAN service key is plugged in, the procedure is the
same as setting Driver parameters.
For detailed descriptions and effects of these parameters see the sec-
tion “11.8.8Summary of service parameters” on page 50.
NOTE!
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necessary know how.
11.8.6 Summary of driver parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in sections
“11.8.2Viewing parameters -CAN key not connected” on page 45 and
“11.8.6Summary of driver parameters” on page 47
See also section “11.4Speed limitation” on page 23 for information
regarding the maximum speeds of the truck.

Parameters
789, 791 711956-
Date Order number
2004-04-05 218367-040
Table 28: Summary of driver parameters

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

range S
10: 100:
S= maximum speed
03 Maximum acceleration % 10 100 5 80
A
10: 100:
A= maximum acceleration
04 Neutral braking effect % 5 100 5 70
F
5: 100:
F= neutral brake force
06 Maximum speed -low % 10 100 5 100
range S
10: 100:
S= maximum speed
07 Maximum speed- “Tur- % 10 100 5 60
tle” S
10: 100:
S= maximum speed

Parameters
711956- 789, 791
Order number Date
218367-040 2004-04-05
11.8.7 Description of driver parameters

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

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

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

Allows for adjustment of the maximum speed of the truck in the “Turtle”
mode.

Parameters
789, 791 711956-
Date Order number
2004-04-05 218367-040
11.8.8 Summary of service parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in sections
“11.8.3Viewing parameters -CAN key connected” on page 46 and
“11.8.8Summary of service parameters” on page 50
l The CAN service key must be connected to the external CAN connec-
tor [X41] before adjusting any Service parameters
Table 29: Summary of service parameters

Parameter
10 PIN-code - 0 9999 1 1 Assignment of up to 10

PIN-codes (10 different
drivers)
14 Creep speed % -10 10 1 0
S
-10: +10:
S= Speed at first sensor

15 Non-configurable See Service Manual“11.8.10“Option” Parameters” on page 59
options 0 to 9
16 Configurable option #1 See“11.8.10“Option” Parameters” on page 59
17 Configurable option #2
20 Hour meter selection - 1 5 1 2 Select which hour meter is
normally displayed
21 Battery size - 1 20 1 5 Battery size selection
22 Maximum fork lower- - 64 255 1 180
ing speed L
1: 255:
L= max. lowering speed

Parameters
711956- 789, 791
Order number Date
218367-040 2004-04-05
Table 29: Summary of service parameters

Parameter
23 Fork lower stop ramp - 1 20 1 5

T
1: 20:
T= Stop ramp time

25 Service interval h 0 2000 50 100 Setting of service interval-
timer.
35 Log off min. 0 20 1 20 Time interval to automatic
log off
36 Calibrate - 0 4 1 0 Calibrate fork lift OR steer
servo
37 Steering offset 1/10° -300 300 1 0 Trim steering
-300:30° to left
300:30° to right
38 Steer servo activated - 0 1 1 0 Activates steer servo,
when fitted
39 Access code - 1 4 1 3 State which level of authori-
zation the driver has to the
driver parameters

Parameters
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Date Order number
2004-04-05 218367-040
11.8.9 Description of service parameters

# 10 - PIN code
The parameter stores the truck’s active PIN-codes. The truck can store
up to ten PIN-codes. Each PIN-code has a set of parameters associat-
ed with it, called driver Parameters. Entering a particular PIN-code at
start-up will make the selected PIN-code’s driver parameters active.
This allows up to ten operators to individually adjust the characteristics
of the truck.
On delivery the truck has one default PIN-code stored which is “1“.
To enter a new PIN-code:

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

The new PIN-code has now been entered.
To remove an existing PIN-code:

• Operate L1 repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this
driver.
• Repeat the step above until the PIN-code to be removed is dis-
played.
1.Operating L1 lightly will step the value in increments of 1.

Operating L1 fully will step the value in increments of 100
Valid values are 1 to 9999

Parameters
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• Operate L1 to set the PIN-code value to “0”(zero).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in
Table 18, “Functional description,” on page 16(Event 2 -Switch on (PIN
code entry)
Parameter #10 cannot be displayed without the CAN service key.
# 14 - Creep speed
This parameter allows adjustment of the initial speed when the first Hall
sensor is activated in the speed control [L1].
#15 - Non-configurable options

See “11.8.10“Option” Parameters” on page 59l
#16 - Configurable option #1

See “11.8.10“Option” Parameters” on page 59



# 20 - Hour meter selection

This parameter determines which hour meter mode to display during
normal use.

Parameters
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Table 30: Hour meter parameter selection

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

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

(Parameter #25 controls the initial value)
See “# 25 - Service interval” on page 55 for more information
# 21 - Battery size
This parameter matches the discharge indication to the characteristics
of the battery fitted.
To adjust the disconnection point of the battery discharge indicator,
measure according to:
• Acid concentration when fully charged battery. To check quality of
battery. Shall be between 1,27-1,29.
• When you get lift cut-out (80% discharged of battery capacity) you
shall have close to 1,15 not less.
The acid concentration can vary depending on battery brand.

Parameters
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Table 31: Battery size parameter

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

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

This parameter adjusts the time interval between releasing the fork low-
er control and fork lower valve completely closing. Decreasing the
parameter value will shorten the time interval resulting in a “harder” fork
stop. Increasing the parameter value will make the fork stop more “gen-
tle”
# 25 - Service interval
This parameter determines the time value in hours to the next service
from 0 to 2000 hours in steps of 50 hours. Whenever this value is
changed the timer is reset and will start counting activity time up to the
set value. On reaching the set value caution code 29 (C29) will be
shown on the display.
# 35 - Log off
This parameter determines the time interval before the truck automati-
cally logs off when truck has been idle. A value of “0”(zero) disables the
function.
# 36 - Calibrate
This parameter is used to perform calibration of fork lift start point, auto-
matic calibration of maximum load, manual calibration of maximum
load and steering servo:

Parameters
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- Value 0 : No calibration value active (default value)

- Value 2 : Valve startpoint for fork lower
To optimize the fork lowering function it is necessary to “trim” the control
signal for the proportional lowering valve. The point when the valve just
starts to open is called the valve start point.
To calibrate the valve start point perform following procedure:
• Select parameter #36 and set its value to 2.
• Switch off the truck by pressing on the keypad.
Press on the keypad. The display shows

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

plete
- Value 3 : Automatic calibration of maximum load
• Press on the keypad. The display shows

• With truck’s rated load + 100 kg on the forks, lift the forks above the
initial lift height.

Parameters
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• Press and hold depressed the horn button [S18].

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

plete
- Value 4 : Manual calibration of maximum load
SAFETY NOTE!
Under no circumstances shall the maximum load setting be increased
above the truck’s rated load capacity + 100 kg.
The maximum load can be set manually in this mode without the
requirement of a test load on the forks. It is necessary, therefore to
establish the correct value to be entered. See Table 32: below
• Press on the keypad. The display shows the present value

stored.
• Press the horn button [S18]
• Set parameter value by repeatedly operating speed control [L1] up
or down. See Table 32:
• Press the horn button [S18] to store the new value. The display will
show .

Parameters
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Table 32: Man. max.load calibration values

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

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

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

Parameters
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• Press on the keypad. Steering calibration is now complete
# 37 - Steering offset
This parameter can be used to “trim” the actual steering position of the
drive wheel in relation to the position of the steering tiller. It should only
be adjusted after having performed a steering calibration (parameter
#36)
A situation which may require that this parameter be adjusted is if the
truck tends to drift away from a straight ahead course when driving over
longer distances Many factors can contribute to this. It is therefore
advisable to make adjustments to this parameter on a trial and error
basis.
Whenever this parameter is adjusted, it is necessary to restart the
truck. (Disconnect and reconnect battery)
# 38 - Steer servo activated

If the truck is equipped with steer servo it must be activated by setting
this parameter.
Value 0 - Steer servo not activated (default)
Value 1 - Steer servo activated
# 39 - Access code
This parameter determines whether the operator has access to the
Driver parameters:
• Value 1 - Key switch -Driver parameters accessible (without CAN
service key)
• Value 2 - Key switch -Driver parameters not accessible (without CAN
service key)
• Value 3 - Driver parameters accessible (without CAN service key) -
default.
• Value 4 - Driver parameters not accessible (without CAN service
key)
11.8.10 “Option” Parameters

WARNING!
Do not attempt to make any adjustments to these parameters unless
you have sufficient knowledge of the truck’s options/ modified func-
tions. This manual only covers the truck’s standard equipment. Spe-
cially modified trucks may require that you have access to special
service information. Improper adjustment of the option service pa-
rameters may result in a malfunction.

Parameters
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General
Parameters #15 to #19 are reserved in the truck’s control system for
extra truck options and/or special product modifications. Normally,
these parameters are configured by the manufacturer when the truck is
modified or customized. It is advisable to up-load the parameter set-
tings from trucks which are modified. In the event the main control
card[A2] is changed, the original parameter settings can be transferred
to the new card thus ensuring the special option functions correctly.
Parameter #15 Non-configurable options

Up to 16 so called sub-parameters are stored and accessed via param-
eter #15.These options are either switched ON or switched OFF and
require no other adjustments. They are therefore called non-configura-
ble options.
Setting Non-configurable options

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

The first sub-parameter will be displayed
Continued operation of the speed control L1 will display the next sub-
parameter. Note also that only relevant sub-parameters will be dis-
played.
After 1 second the value of the sub-parameter will be displayed

• Set sub-parameter value by repeatedly operating speed control L1

up or down. See Table 33: for details.

The non-configurable option shall now be activated.

Parameters
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• Ensure the option operates correctly before returning the truck for
normal use.
P
Table 33: Parameter #15 Non-configurable options

Option name Value Note
Sub-parameter No.
Default setting
Function OFF
Function ON
0 Snail function 1 0 0
1 Turtle function 1 0 0
2 to 9 N/A at present - - -

Parameters
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Parameter #16 to #19 Configurable options

Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a
maximum of 4 preprogrammed functions to be activated and config-
ured to suit a specific special option or customization. See “Table
34:Configurable option list” on page 64. They are therefore called con-
figurable options.
• Each parameter can be designated to hold a particular option.
• Each designated option has up to 4 arguments associated with it.
• Each argument holds a value which configures that option.
Parameter no. (range 16-19)

Argument: #0 holds option designator
Argument value (range 0 - 63)
0= no option is activated for this parameter
1 to 63 = Preprogrammed option no. See separate table)
16 - 0 - 1
OPTION ASSIGNATION
Argument: #1, #2, #3 & #4 hold configurable values for the option
Argument value (range depends on argument)
Value depends on option and argument selected
See separate table
16 - 1- 1
OPTION CONFIGURATION
Fig. 12Configurable option layout
Setting Configurable options

To activate a configurable option it must first be assigned to one of the
parameters #16 to #19. This is achieved by setting argument #0 to the
pre-programmed option no. Once it is assigned, the option’s arguments
must be configured. This is achieved by setting a value for arguments
#1, #2, #3 and #4.
• Ensure the truck is in parameter mode.
• Select parameter #16, #17, #18 or #19 using [L1].

Parameters
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Argument #0 will be displayed
After 1 second the argument value will be displayed. A value of “0” indi-
cates no option is assigned to this parameter, in which case continued
operation of the speed control L1 will display the next parameter
• Set argument #0 value by repeatedly operating speed control L1 up

or down. Refer to Table 34:
• Select argument #1 by operating speed control L1.

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

or down. Refer to option list Table 34:
Adjust arguments #2, #3 and #4 using the same method as above.

The special option shall now be activated.
• Ensure the special option operates correctly before returning the
truck for normal use.

Parameters
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Table 34: Configurable option list

Argument #1 Argument #2 Argument #3 Argument #4
Argument #0 = 1: Option button controls Spider output
0:Spider 0 0:Digital out 1 1-6:option button 1-6 Type of function:
1:Spider 1 1:Digital out 2 0:momentary
2: Digital out 3 1:toggling
3: Digital out 4
Argument #0 = 2:Reduced drive speed controlled by Spider digital input
0:Spider 0 0-7:Digital in 1-8 0-12:reduced speed 0:high speed
1:Spider 1 40-100% range
(i.e. 40+5*arg3 e.g. 1:low speed range
4: 40+5*4=60%) 2: both ranges
Argument #0 = 3:Activate Spider output at certain machine movements
0:Spider 0 0:Digital out 1 To select activating Output mode:
1:Spider 1 1:Digital out 2 movement, see Table 0: steady on
2: Digital out 3 35: 1: flashing 1Hz
3: Digital out 4 2: flashing 2Hz
Argument #0 = 4:Pull main contactor controlled by Spider digital input
0:Spider 0 0-7:Digital in 1-8 0-30:Hold time 0-30 Not used
1:Spider 1 minutes
Argument #0 = 5: Lift/Lower controlled by Spider digital inputs
0:Spider 0 0: Lift, digital in 1 0: Lower inhibit disa- 0: Fork lift/lower
1:Spider 1 Lower, digital in 2 bled 1: Support arm
Lower inhibit, in 3 1: Lower inhibit ena- lift/lower
1: Lift, digital in 2 bled
Lower, digital in 3
Lower inhibit, in 4
2: Lift digital in 3
Lower digital in 4
Lower inhibit in 5
Lower digital in 5
Lower inhibit in 6
Lower digital in 6
Lower inhibit in 7
Lower digital in 7
Lower inhibit in 8

Parameters
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Table 34: Configurable option list

Argument #1 Argument #2 Argument #3 Argument #4
Argument #0 = 6:Lift height restriction with override
0:Spider 0 0-7: Restriction 1-6: Override, Not used
1:Spider 1 switch at option switch 1-6
digital in 1-8
Table 35: Option 3 - Movement selection

Selected movement Argument #3
- 0
Driving forward 1
Driving backward 2
Driving forward or backward 3
Lifting forks 4
Lifting forks or driving for- 5
ward
Lifting forks or driving back- 6
ward
Lifting forks or driving for- 7
ward or backward
Lowering forks 8
Lowering forks or driving for- 9
ward
Lowering forks or driving 10
backward
ward or backward
Lifting forks or lowering forks 12
or driving forward
or driving backward

Parameters
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Table 35: Option 3 - Movement selection

Selected movement Argument #3
or driving forward or driving
backward
All other movements (AOM) 16
Driving forward or AOM 17
Driving backward or AOM 18
Driving forward or backward or 19
AOM
Lifting forks or AOM 20

Lifting forks or driving forward 21
or AOM
Lifting forks or driving backward 22

or AOM
Lifting forks or driving forward 23

or backward or AOM
Lowering forks or AOM 24

ward or AOM
Lowering forks or driving back- 26

ward or AOM

ward or backward or AOM
Lifting forks or lowering forks or 28

AOM

driving forward or AOM

driving backward or AOM

driving forward or driving back-
ward or AOM

Technical specifications – Curtis 1243
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Order number Date
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11.9 Technical specifications – Curtis

1243
Table 36: Technical specification -Curtis 1243

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

Technical specifications – Curtis 1243
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Date Order number
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Hydraulic system – 6000
Hydraulic diagram
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12- Hydraulic system – 6000
12.1 Hydraulic diagram
12.1.1 SPE125L/160L

Hydraulic diagram
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Date Order number
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12.1.2 SPE125/160

Hydraulic diagram
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12.1.3 Main components

1+2
12
11
3
10
Table 37: Main components

Pos. no. Name Remarks
1 Motor Pump motor
2 Pump
3 Pressure sensor B4 Fork lifting/support arm lifting
4 Pressure sensor B5 PowerTrak
5 Overflow valve Max. 200 bar
6 Air bleeder Oil replenishment
7 Brake valve for lowering
action
8 Proportional valve Y10 Fork lowering
9 Lowering valve Y41 Support arm lowering
(SPE125L/160L)
10 Switching valve Y52 Forks/Support arms
(SPE125L/160L)
11 PowerTrak valve Y58 Draining of PowerTrak cylinder
12 PowerTrak valve Y59 Replenishment of PowerTrak
cylinder

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

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

Hydraulic diagram
711956- 789, 791
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Working pressure
The working pressure shows the classified weight.
• SPE125: 110 bar
• SPE160: 110 bar
• SPE125L:110 bar.
• SPE160L:110 bar.
Overflow valve
The overflow valve opens at the following pressure:
• SPE125/125L: 200 bar.
• SPE160/160L: 200 bar.
Pressure sensor
The pressure sensor is used to adjust the speed and is affected by the
load.
Load < 800 kg. Travel speed = 8.0 km/h
Load >800 kg. Travel speed = 7.0 km/h (Declines linearly to 7.0 km/h at
maximum load)

Hydraulic diagram
789, 791 711956-
Date Order number
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Main lift chain system – 7120
General
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13- Main lift chain system – 7120
13.1 General
Applies to all machines with a mast.
13.2 Checking the chain setting

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

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.
13.3.1 Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.
13.3.2 Surface rust

Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced
13.3.3 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.

Chain inspection
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13.3.4 Stiff links

If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.
13.3.5 Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
The chain should be replaced
.
13.3.6 Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.

Chain inspection
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13.3.7 Outline wear
H2 H3
P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

Chain inspection
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13.3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.
Table 38: Stretching

Type of Nominal Minimum Pitch P Nominal chain Maximum permitted
chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.

Chain inspection
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13.3.9 Damage
The chain should be replaced if damaged in any way.
13.3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
13.3.11 Damaged bolts

It can be difficult to discover whether a bolt has broken. It can appear as
bolt rotation and/or that the outer disc is loose.

Cleaning
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13.3.12 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.
13.4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.
13.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.

Lubrication
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The lubricate must comply with the viscosity demands at respective

temperatures as set out in the table below. The following lubricants are
recommended:
Table 39: Recommended Product

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
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

Lubrication
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Date Order number
2004-04-05 218367-040

Control/computer equipment – 8700
General
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Order number Date
218367-040 2004-04-05
14- Control/computer equipment –

8700
TruckCom 3.4 User Manual -for trucks using the
“PowerDrive” platform.
This Manual is valid for version 3.4 of TruckCom p/n 182145-007.
14.1 General
TruckCom is a communication program which communicates with
trucks equipped with CAN (Controller Area Network) communication.
It enables the following tasks to be performed:
• downloading truck control software.
• viewing and adjusting driver / truck parameters and hour meters. Ad-
ditionally, the truck’s parameter set (including hour meter values)
can be saved to file and reloaded later.
• viewing diagnostic data for various digital inputs / outputs and ana-
logue data including voltages, currents and certain temperatures.
The program is a Windows program running under Windows® 95/98,
Windows® XP/2000 and Windows® NT.
14.2 Connection
A CAN interface of the CPC-PP type is needed to connect it to the
truck, with attendant cable. The interface is connected to the printer
port on a PC, and the cable is connected between the interface and
truck’s CAN connection.
The CAN interface is supplied with power from the truck electronics and
is protected from any high voltages in the truck if a fault should occur.

Layout
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Date Order number
2004-04-05 218367-040
14.3 Layout
14.3.1 Main program screen

Information
Menu bar window
Tool
buttons
Nodes
Icons
Status bar
Fig. 13Main TruckCom program screen

A main window opens when the program is started, consisting of menu
bar, tool buttons, workspace, log window and status window.
14.3.2 Nodes
Devices which are connected to and communicate via the CAN inter-
face are called nodes. The nodes detected on the bus are shown in the
node window. The current node status and input component/informa-
tion is shown with different icons.
Fig. 14A typical node window dis-

play

Layout
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Order number Date
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14.3.3 Icons
Icon Description
Node OK is shown when contact is made with a
node and no errors have been reported.
Node not connected is shown when there is no

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

reported by a node. Click on node to obtain more
information.
Program version is shown when information is
available on which software is installed. Click to
obtain more information.
Information is shown when a node has information
on, for example, error codes.
Truck report
See “14.7Truck report function” on page 8
Parameters is shown when a node has information

on a parameter.
Diagnostics
Exit

Connection function
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Date Order number
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14.3.4 Tool buttons and menu bar

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

units from PC Download report
Parameters Diagnostics Information Exit

Fig. 15Tool button bar
14.3.5 Information window

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

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

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

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

Disconnection function
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Order number Date
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14.5 Disconnection function

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

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

Select Open.. to open the file to be downloaded into a node. The file
name, file type and version number are shown in the window for file
information. If it is file for a controller, indicate which type of controller is
to receive the file. Start downloading by selecting Start... and by restart-
ing the truck by turning the key off and on twice.
Restart must be made within 20 seconds from when the Start button
has been activated.
Close the download window when the download is ready, and then dis-
connect the PC from the network. A new connection can now be made
to verify the new program.
Downloading program function
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Date Order number
2004-04-05 218367-040
14.6.2 Normal downloading (truck with

keypad)
To open the file to be downloaded to a node, select Open… The file
name, file type and version number are displayed in the "File informa-
tion" dialog box. If the file is intended for a controller, be sure to indicate
which type of controller should receive the file. Start downloading by
depressing and then releasing the red key on the keypad.
The truck must be restarted within 20 seconds from the time the Start
key has been actuated.
When downloading has been completed, close the download dialog
box and then disconnect the PC from the network. It is now possible to
reconnect to verify the new application.
14.6.3 Emergency downloading (truck with

keypad)
• Disconnect the battery connector.
• Select OK in the dialog box.
• Keep the red key on the keypad depressed while reconnecting the
battery connector.
• Release the red key to commence downloading.

Downloading program function
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Order number Date
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14.6.4 Downloading in old versions of logic

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

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

Truck report function
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Date Order number
2004-04-05 218367-040
14.7 Truck report function

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

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

Parameters function
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Order number Date
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14.8 Parameters function

To change the truck parameters, select the Parameter function. This
can be done with the menu <Tools | Change parameters > or with the
tool button [Parameters].
NOTE!
The truck must in Normal mode (i.e. not Parameter mode) when con-
necting TruckCom. Otherwise TruckCom will report “Unable to deter-
mine truck brand”
The parameter numbers follow the description in the respective truck
Service Manuals.
Fig. 16, Fig. 17 and Fig. 18 show the OL 20 / OL 25 truck
Fig. 16Driver tab

Parameters function
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Date Order number
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Fig. 17Truck tab
Fig. 18Time tab

Diagnostics function
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Order number Date
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14.9 Diagnostics function

To access diagnostics, select the Diagnostic function. This can be done
with the menu <Tools | Diagnostic...> or with the tool button [Diagnos-
tic].
NOTE!
If the value “---” is shown in a field, or a “read status LED” is red, the
communication has been interrupted for some reason and error data
will not be able to be shown.
NOTE!
The tab information displayed in diagnostics mode depends on the
type of truck connected.
14.9.1 Representation of signal colours

The screen dumps shown in the following section have been modified
to improve legibility in black & white print.
BLACK
GREEN
RED

789, 791 711956-
Date Order number
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14.9.2 “Tiller arm” tab
Clicking on the tiller arm tab will display a dialog showing the following:
• Speed lever -the status of the speed control and travel direction se-
lector. The status of each individual hall element is displayed.
• Buttons -the status of the control buttons is displayed. “Sxx” refers to
the switch designations as given in the circuit diagram.
• Option -the status of the optional function buttons
• Battery -The measured battery voltage
• R14 / R15 -Not used at present

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Order number Date
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14.9.3 “Drive Controller” tab
Clicking on the Drive Controller tab will display a dialog showing the fol-
lowing:
• Status of digital inputs and outputs of the transistor regulator. pin refers
to the motor controller pin designations as given in the circuit diagram.
• Field PWM - The effective drive output supplied to the field circuit as
a percentage.
• Armature PWM -The effective drive output supplied to the armature
circuit as a percentage
• Field current - The current flowing in the field circuit in Amperes.
• Armature current -The current flowing in the Armature circuit in Am-
peres
• Raw throttle data - The received speed control signal as a percentage.
• Temperature - The temperature of the output stage of the transistor
controller in degrees Celcius
• Inp pin 10 -The input voltage from the pressure sensor
“digital o” indicates the digital status of the input.
• Inp pin 11-The input voltage from the man-on platform sensor.
“digital o” indicates the digital status of the input
789, 791 711956-
Date Order number
2004-04-05 218367-040
14.9.4 “EPS” tab (only OL 20 / 25)
Clicking on the “EPS” tab will display a dialog showing the following:
“Status”
• “Operational” - Indicates the status of the servo’s control system
• “Power stage enabled” - Indicates status of the servo’s power stage
output.
• “I2T integral” - indicates the status of the overload protection monitor
• “Warning” - indicates whether a warning condition is present in the
steer servo
• “Sleep mode” - whether the servo is in standby (longer period of in-
activity)
• “Error” -indicates whether an error condition is present in the steer
servo
• “Reference switch reached” - indicates status of drive wheel in cen-
tre reference switch
• “Reference position found” - indicates whether a successful steeing
in centre has been performed.

711956- 789, 791
Order number Date
218367-040 2004-04-05
“Actual values”
• “Temperature power stage” -the temperature of the output stage of
the steering servo in degrees Celcius
• “DC bus voltage” - supply voltage to steering servo
• “Voltage analog input 1”- the measured d.c. input signal (0) from the
steering potentiometer
• “Voltage analog input 2” - the measured d.c. input signal (1) from the
steering potentiometer
• “Current” - the measured current supplied to the steer servo motor in
Ampere
• “I2T” - the amount of current limitation (overload protection) being

applied as a percentage.
• “Actual velocity” -The measured rotational speed of the steer servo
motor shaft in r.p.m.

Other menu functions
789, 791 711956-
Date Order number
2004-04-05 218367-040
14.10 Other menu functions
14.10.1 Save to file

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

A set of parameters can be downloaded from the PC to the truck. Select
<File | Load from file | Parameters >. The parameters in the file will be
copied to the nodes connected to the bus. If only the hour meter set-
tings are needed, select <File | Load from file | Hour meters >.
14.10.3 Reset CAN adapter

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

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

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

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

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

Specifications
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Order number Date
218367-040 2004-04-05
14.10.8 Adjusting the hour meter on older

cards
To adjust the hour meter on trucks with older cards, select
< Tools | Adjust Hour meters >. The time in the PC will then be down-
loaded to the truck.
14.10.9 Help
About TruckCom
To see program information, select <Help | About TruckCom... > or tool
button [About].
14.10.10 Exit
To exit the program, select <File | Exit > or the tool button [Exit].
14.11 Specifications
Table 40: Can interface specification

Description Value Unit
Power consumption 40-120 mA
Supply voltage 11-28 V
Transfer rate 125 kbit/s
Storage temperature -20-80 0C
Operating temperature 0-60 0

C

Installation
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Date Order number
2004-04-05 218367-040
14.12 Installation
Note
The program must be installed from the hard disk.
Note
The software application in the computer can be damaged, which is why
the PC installation should be performed by someone with the required
knowledge. BT does not accept any responsibility for any errors that oc-
cur during the installation.
Note
All references to PC operating system actions, menus and commands
are based on the English language version of Windows®.
14.12.1 Installation on a PC with Windows® 95/98

If a previous version of the TruckCom application has been installed on the
PC, it will be necessary to edit the System.ini file.
Start the Msconfig.exe application by selecting the Start button, selecting
Run and then typing msconfig.
Click on System.ini and open the folder (386Enh).
Unmark the option at Device=C:\Windows\Cpcppvd.vxd.
Save the change and close the application.
Now continue with installation
The software application is supplied on a CD or via a network. Start
installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found.
Then follow the on-screen instructions.
14.12.2 Installation on a PC with Windows XP/2000

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

Installation
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Order number Date
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• Mark the Enum folder which can be found under

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the
Registry Editor.
Select the Edit option, then Find and type PortName to search for the
correct folder.
NOTE!
The location of the folder differs between different computers (some
may be .. \Enum\Root\.., while others could be ...\Enum\ACPI\... etc.).
Thus be sure to search for the correct folder.
When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in

the PortName data field and that the folder name is Device Parameters.
Right-click with the mouse in the right box to enter a new value of the
DWORD type and with the name
EnableConnectInterruptIoctl.

Installation
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Date Order number
2004-04-05 218367-040
Change the value in data field 1 by right-clicking on the name and

selecting Modify.

Installation
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Order number Date
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EnableConnectInterruptIoctl
The Device Parameters folder should look like the one in the picture.
The Registry change is now complete. Close the Registry Editor.

Changes in Windows® Control Panel
Select the Start button. Choose Settings, then Control Panel and dou-
ble-click on System, then select Hardware.
Click on Device Manager and open Ports (Com & LPT).

Installation
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Date Order number
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Installation
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Order number Date
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Double-click on the LPT port to be changed, and select the Port Set-
tings tab. Check the "Use any Interrupt assigned to the port" option and
click on OK.


Installation
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Date Order number
2004-04-05 218367-040
14.12.3 Installation on a PC with Windows NT

14.12.4 In case of communication problems

with CAN
Make sure the computer settings for the printer port in the BIOS Setup
are as follows:
Port address: 0378
IRQ: 7
Mode: Output only
For detailed information on how to change the Setup settings, refer to
the User's Guide supplied with the computer.
14.12.5 To uninstall
To uninstall TruckCom under Windows®, select the Start button, Set-
tings, Control Panel, Add/Remove Programs. To uninstall you must
then select the TruckCom Program and click Change/Remove.

Installation
711956- 789, 791
Order number Date
218367-040 2004-04-05

© BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com

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What is the intended purpose and application of the truck?

What is the intended purpose and application of the truck?

What are the main components of the truck?

What are the main components of the truck?

Service Manual en

Order number: 218367-040

© BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

Presentation of the truck – M2 2-1

Intended application of the truck ................... 2

Truck dimensions ......................................... 4

Addition and information plate ...................... 6

Capacity plate for double pallet handling ...... 7

Main components ......................................... 8

Warning and information plates ................... 10

Technical data – M4 3-1

General tightening torques ........................... 5

Installation and maintenance

© BT Europe AB Service Manual SPE125/160/125L/160LApproved by: L-G Andersson 1- 1

Maintenance schedule – P2 5-1

Lubrication chart ........................................... 7

Oil and grease specification – P3 6-1

Super Seal connectors ................................. 1

AMP connectors ........................................... 2

Other tools .................................................... 4

Electric drive motor – 1760 8-1

Disassembly/assembly of the truck motor..... 3

Drive unit/gear – 2550 9-1

Replacing the drive axle jointing ring ............ 3

1- 2 © BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

Electromagnetic brake – 3370 10-1

Main components of the brake...................... 1

Electrical systems – 5000 11-1

Electrical equipment overview ...................... 1

Equipment list and electrical diagram ........... 3

Hour meter and battery condition................. 24

Diagnostic and troubleshooting ................... 26

© BT Europe AB Service Manual SPE125/160/125L/160LApproved by: L-G Andersson 1- 3

11.8.7 Description of driver parameters ...................... 49

Hydraulic system – 6000 12-1

Main lift chain system – 7120 13-1

Checking the chain setting............................ 1

Chain inspection ........................................... 1

1- 4 © BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

Control/computer equipment – 8700 14-1

Disconnection function ................................. 5

Downloading program function ..................... 5

Parameters function ..................................... 9

Diagnostics function .................................... 11

© BT Europe AB Service Manual SPE125/160/125L/160LApproved by: L-G Andersson 1- 5

1- 6 © BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

2- Presentation of the truck – M2

© BT Europe AB Service Manual SPE125/160/125L/160LApproved by: L-G Andersson 2- 1

2.1 Intended application of the truck

2.2 Forbidden application of the truck

2- 2 © BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson

2.3 Truck data

Table 1: Truck data

© BT Europe AB Service Manual SPE125/160/125L/160LApproved by: L-G Andersson 2- 3

2.4 Truck dimensions

2- 4 © BT Europe AB Service Manual SPE125/160/125L/160L Approved by: L-G Andersson