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BT Forklift RRE120M,RRE140M,RRE160M Repair Manual (6111575) – PDF DOWNLOAD
BT Forklift RRE120M,RRE140M,RRE160M Repair Manual (6111575) – PDF DOWNLOAD
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BT Forklift RRE120M,RRE140M,RRE160M Repair Manual (6111575) – PDF DOWNLOAD
Language : English
Pages : 622
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Forklift RRE120M,RRE140M,RRE160M Repair Manual (6111575) – PDF DOWNLOAD
1- Table of contents...........................................................................................0 2- General introduction........................................................................................0 2.1 How to use this manual.................................................................................0 2.2 Warning levels and symbols.............................................................................0 2.3 Pictograms.............................................................................................0 3- General safety rules........................................................................................0 3.1 Work safety............................................................................................0 3.2 Electrical system......................................................................................0 3.3 Safe lifting...........................................................................................0 3.4 Truck modifications....................................................................................0 4- Installation................................................................................................0 4.1 Transporting the truck.................................................................................0 4.2 Transporting the mast..................................................................................0 4.3 Safe lifting...........................................................................................0 5- Technical data 1............................................................................................0 5.1 General tightening torques.............................................................................0 5.1.1 Galvanised, non-oiled screws.....................................................................0 5.1.2 Untreated, oiled screws..........................................................................0 6- Technical data 2............................................................................................0 6.1 General tightening torques.............................................................................0 6.1.1 Galvanised, non-oiled screws.....................................................................0 6.1.2 Untreated, oiled screws..........................................................................0 7- Introduction, maintenance...................................................................................0 7.1 Safety precautions for maintenance work................................................................0 7.2 Cleaning and washing...................................................................................0 7.2.1 Cleaning the exterior............................................................................0 7.2.2 Cleaning the motor compartment...................................................................0 7.2.3 Electric components..............................................................................0 7.3 Safe lifting...........................................................................................0 8- Preventive maintenance......................................................................................0 8.1 Maintenance schedule...................................................................................0 9- Oil and grease specifications...............................................................................0 10- Tools......................................................................................................0 10.1 Super Seal contact....................................................................................0 10.1.1 AMP connectors..................................................................................0 10.1.2 AMP micro timer.................................................................................0 10.1.3 Other tools.....................................................................................0 11- Operator protection – 0840.................................................................................0 11.1 General...............................................................................................0 11.2 Studs.................................................................................................0 11.2.1 Inspection and Adjustment.......................................................................0 11.2.2 Removing the tilt stops.........................................................................0 12- Electric pump motor – 1710.................................................................................0 12.1 General...............................................................................................0 12.2 Disassembled pump motor...............................................................................0 12.2.1 Connection......................................................................................0 12.3 Disassembly and assembly of the pump motor............................................................0 12.3.1 Dismantling.....................................................................................0 12.3.2 Fitting.........................................................................................0 12.4 Replacing the ball bearing............................................................................0 12.4.1 Disassembly (D side)............................................................................0 12.4.2 Fitting.........................................................................................0 12.4.3 Disassembly (N side)............................................................................0 12.4.4 Assembly (N side)...............................................................................0 12.4.5 Carbon brushes and carbon brush- rocker.........................................................0 New carbon brushes should always be ground in......................................................0 Commutator.........................................................................................0 Truing the commutator..............................................................................0 13- Electric steering motor – 1730.............................................................................0 13.1 General...............................................................................................0 13.2 Replacing the steering motor..........................................................................0 13.2.1 Dismantling.....................................................................................0 13.2.2 Fitting.........................................................................................0 13.3 Disassembly and assembly of the carbon brushes........................................................0 14- Electric drive motor – 1760.1..............................................................................0 14.1 General...............................................................................................0 14.2 Disassembled drive motor..............................................................................0 14.3 Disassembly and assembly of the drive motor...........................................................0 14.3.1 Removing the drive motor........................................................................0 Remove the gear wheel..............................................................................0 Disassemble the brake..............................................................................0 14.3.2 Fitting the drive motor.........................................................................0 Fit the brake......................................................................................0 Assemble the gear wheel............................................................................0 14.3.3 Restore the truck...............................................................................0 14.4 Replacing the ball bearing............................................................................0 14.4.1 Dismantling.....................................................................................0 N side.............................................................................................0 D side.............................................................................................0 14.4.2 Fitting.........................................................................................0 N side.............................................................................................0 D side.............................................................................................0 14.5 Installation instructions for the external temperature sensor.........................................0 15- Electric drive motor – 1760.2..............................................................................0 R212, R214, R216...........................................................................................0 15.1 General...............................................................................................0 15.2 Remove and install drive motor........................................................................0 15.2.1 Remove the drive motor from the truck...........................................................0 15.2.2 Remove the brake................................................................................0 15.2.3 Removing the drive motor........................................................................0 15.2.4 Fitting the drive motor.........................................................................0 15.2.5 Replacing the ball bearing......................................................................0 15.2.6 Cleaning........................................................................................0 15.2.7 Refit the brake.................................................................................0 15.2.8 Fit the drive motor back in the truck...........................................................0 15.2.9 Restore the truck...............................................................................0 15.3 Replacing the rotational speed sensor.................................................................0 Remove the rotational speed sensor.....................................................................0 Fitting the rotational speed sensor....................................................................0 16- Drive unit/gear – 2550.1...................................................................................0 16.1 General...............................................................................................0 16.2 Components/data for the drive assembly/transmission...................................................0 16.2.1 Component location..............................................................................0 16.2.2 Technical data..................................................................................0 16.2.3 Disassembling the gear..........................................................................0 16.3 Replacing the drive motor/drive gear..................................................................0 16.3.1 Removing the drive motor........................................................................0 Remove the gear wheel..............................................................................0 16.3.2 Removing the drive gear.........................................................................0 16.3.3 Fitting the drive gear..........................................................................0 16.3.4 Installing the drive motor......................................................................0 Fit the gear wheel.................................................................................0 16.3.5 Restore the truck...............................................................................0 16.4 Oil level check/change................................................................................0 16.4.1 Checking/refilling oil..........................................................................0 16.4.2 Oil change......................................................................................0 16.5 Repairs...............................................................................................0 16.5.1 Replacing the drive shaft sealing ring..........................................................0 Removing...........................................................................................0 Fitting............................................................................................0 16.5.2 Leakage from the upper cover....................................................................0 16.5.3 Leakage from the lower cover....................................................................0 16.5.4 Replacing the wheel bolt........................................................................0 17- Drive unit/gear – 2550.2...................................................................................0 R212, R214, R216...........................................................................................0 17.1 General...............................................................................................0 17.2 Components/data for the drive assembly/gear...........................................................0 17.2.1 Component location..............................................................................0 17.2.2 Technical data..................................................................................0 17.3 Replacing the drive motor/drive gear..................................................................0 17.3.1 Remove the drive motor..........................................................................0 17.3.2 Removing the drive gear.........................................................................0 17.3.3 Fitting the drive gear..........................................................................0 17.3.4 Fitting the drive motor.........................................................................0 17.4 Replacing the steering bearing........................................................................0 17.4.1 Removing the steering bearing...................................................................0 17.4.2 Fitting the steering bearing....................................................................0 17.5 Restore the truck.....................................................................................0 17.6 Oil level check/change................................................................................0 17.6.1 Checking/refilling oil..........................................................................0 17.6.2 Oil change......................................................................................0 17.6.3 Leakage from the lower cover....................................................................0 17.7 Replacing the wheel bolt..............................................................................0 17.8 Replacing the gear wheel..............................................................................0 17.8.1 Installing the gear wheel.......................................................................0 17.8.2 Installing the ball bearing.....................................................................0 17.8.3 Fitting the seal................................................................................0 17.8.4 Fitting the gear wheel..........................................................................0 17.9 Installing the bearing on the wheel axle..............................................................0 17.9.1 Determining the required shim thickness to achieve the correct preload..........................0 Calculation of shim required.......................................................................0 17.9.2 Installing the bearing in the cover.............................................................0 18- Service brake system – 3100.1..............................................................................0 18.1 General...............................................................................................0 18.2 Function description..................................................................................0 18.2.1 Releasing the accelerator.......................................................................0 18.2.2 Travel direction selector.......................................................................0 18.2.3 Pressing down the brake pedal...................................................................0 18.2.4 Parking brake...................................................................................0 18.2.5 Emergency brake.................................................................................0 18.3 Electro-mechanical disc brake, drive motor............................................................0 18.4 Dismantling...........................................................................................0 18.5 Inspection............................................................................................0 18.6 Fitting...............................................................................................0 18.7 Maintenance...........................................................................................0 18.7.1 Adjusting clearance.............................................................................0 18.7.2 Wear............................................................................................0 18.7.3 Check of braking force..........................................................................0 19- Service brake system – 3100.2..............................................................................0 R212, R214, R216...........................................................................................0 19.1 General...............................................................................................0 19.2 Function description..................................................................................0 19.2.1 Releasing the accelerator.......................................................................0 19.2.2 Travel direction selector.......................................................................0 19.2.3 Pressing down the brake pedal...................................................................0 19.2.4 Parking brake...................................................................................0 19.2.5 Emergency brake.................................................................................0 19.3 Electro-mechanical disc brake, drive motor............................................................0 19.4 Dismantling...........................................................................................0 19.5 Inspection............................................................................................0 19.6 Fitting...............................................................................................0 19.7 Maintenance...........................................................................................0 19.7.1 Adjusting clearance.............................................................................0 19.7.2 Wear............................................................................................0 19.7.3 Check of braking force..........................................................................0 20- Drive wheel – 3530.........................................................................................0 20.1 General...............................................................................................0 20.2 Dismantling the drive wheel...........................................................................0 20.3 Assembling the drive wheel............................................................................0 21- Fork/support arm wheel – 3550..............................................................................0 21.1 General...............................................................................................0 21.2 Dismantling the wheel.................................................................................0 21.3 Fitting the support arm wheel.........................................................................0 21.4 Dismantling the wheel bearings........................................................................0 21.5 Assembling the wheel bearings.........................................................................0 22- Mechanical steering system – 4100..........................................................................0 22.1 General...............................................................................................0 22.2 Replacing the steering generator......................................................................0 22.2.1 Dismantling.....................................................................................0 22.2.2 Fitting.........................................................................................0 22.2.3 Adjusting the steering system screws............................................................0 23- Steering angle sensor – 4350...............................................................................0 23.1 General...............................................................................................0 23.2 Procedure.............................................................................................0 23.2.1 Adjusting the direction sensor..................................................................0 23.2.2 Adjusting the steering angle sensor.............................................................0 24- Electrical system – 5000.1.................................................................................0 24.1 General...............................................................................................0 24.1.1 Electric panel..................................................................................0 24.2 Symbol list and electric wiring diagram...............................................................0 24.2.1 List of symbols.................................................................................0 24.2.2 Wiring diagram..................................................................................0 24.2.3 Component List..................................................................................0 24.2.4 Figure 1........................................................................................0 24.2.5 Figure 2........................................................................................0 24.2.6 Figure 3........................................................................................0 24.2.7 Figure 4........................................................................................0 24.2.8 Figure 5........................................................................................0 24.2.9 Figure 6........................................................................................0 24.2.10 Figure 7.......................................................................................0 24.2.11 Figure 8.......................................................................................0 24.3 Description of operation..............................................................................0 24.3.1 Key in Position 0...............................................................................0 24.3.2 Key in Position I...............................................................................0 24.3.3 Choice of travel direction......................................................................0 On the operating console...........................................................................0 On the accelerator.................................................................................0 24.3.4 Driving.........................................................................................0 24.3.5 Steering........................................................................................0 24.3.6 Steering wheel indicator........................................................................0 24.3.7 Braking.........................................................................................0 Auto brake.........................................................................................0 Motor braking (electric)...........................................................................0 Foot brake.........................................................................................0 Parking brake......................................................................................0 24.3.8 Fork lifting....................................................................................0 24.3.9 Maximum height..................................................................................0 24.3.10 Maximum height.................................................................................0 24.3.11 Fork lowering..................................................................................0 24.3.12 Mast out/in....................................................................................0 24.3.13 Fork tilt up/down..............................................................................0 24.3.14 Hydraulic function 4...........................................................................0 24.3.15 Hydraulic function 5...........................................................................0 24.3.16 Height indication..............................................................................0 24.3.17 Height pre-selection...........................................................................0 24.3.18 Operator identification........................................................................0 Without pin code...................................................................................0 With pin code......................................................................................0 25- Electrical System – 5000...................................................................................0 R212, R214, R216...........................................................................................0 25.1 Electric panel:.......................................................................................0 25.2 Symbol list and electric wiring diagram...............................................................0 25.2.1 List of symbols.................................................................................0 25.3 General wiring diagram................................................................................0 25.4 Wiring diagram........................................................................................0 25.4.1 Component List..................................................................................0 25.5 Description of the function...........................................................................0 25.5.1 Truck not switched on...........................................................................0 25.5.2 Truck started up................................................................................0 25.5.3 Choice of travel direction......................................................................0 On the operating console...........................................................................0 On the accelerator.................................................................................0 25.5.4 Driving.........................................................................................0 25.5.5 Steering........................................................................................0 25.5.6 Steering wheel indicator........................................................................0 25.5.7 Braking.........................................................................................0 Auto brake.........................................................................................0 Motor braking (electric)...........................................................................0 Foot brake.........................................................................................0 Parking brake......................................................................................0 25.5.8 Fork lifting....................................................................................0 25.5.9 Maximum height..................................................................................0 25.5.10 Maximum height.................................................................................0 25.5.11 Fork lowering..................................................................................0 25.5.12 Mast out/in....................................................................................0 25.5.13 Fork tilt up/down..............................................................................0 25.5.14 Hydraulic function 4...........................................................................0 25.5.15 Hydraulic function 5...........................................................................0 25.5.16 Height indication..............................................................................0 25.5.17 Height pre-selection...........................................................................0 25.5.18 Operator identification........................................................................0 Without pin code...................................................................................0 With pin code......................................................................................0 25.6 Display and programming...............................................................................0 25.6.1 Keyboard and display............................................................................0 25.6.2 Clock, display (C)..............................................................................0 25.6.3 Parameters......................................................................................0 25.6.4 Operator parameters 1-7.........................................................................0 25.6.5 Serial numbers software.........................................................................0 25.6.6 Operating Time..................................................................................0 25.6.7 Error codes.....................................................................................0 25.6.8 Warning codes...................................................................................0 25.7 Parameters............................................................................................0 25.7.1 Parameter 19....................................................................................0 25.7.2 Parameter 21....................................................................................0 25.8 Operating Time........................................................................................0 25.8.1 Installing a new card in the truck..............................................................0 25.9 Warning codes.........................................................................................0 25.10 Error codes..........................................................................................0 25.10.1 Error mode.....................................................................................0 25.10.2 Safety logics..................................................................................0 25.11 Warning code without recording.......................................................................0 25.11.1 Error codes with registration..................................................................0 25.12 Keypad...............................................................................................0 25.12.1 General........................................................................................0 25.12.2 Display........................................................................................0 25.12.3 Description of the keyboard symbols............................................................0 25.12.4 Function.......................................................................................0 25.12.5 Function 0.....................................................................................0 25.12.6 Function 1.....................................................................................0 25.12.7 Function 2.....................................................................................0 25.12.8 Function 3.....................................................................................0 25.12.9 Programming....................................................................................0 25.12.10 LED status....................................................................................0 25.12.11 Operator codes................................................................................0 26- Battery – 5110.............................................................................................0 26.1 Battery dimensions....................................................................................0 26.2 Setting battery parameters with Hawker Evolution gel batteries........................................0 26.2.1 General.........................................................................................0 26.2.2 Battery recommendation..........................................................................0 26.2.3 Battery installation............................................................................0 26.2.4 Parameter setting recommendation for valve-regulated batteries (VRLA)...........................0 Instructions for verifying the parameter setting...................................................0 27- Transistor panel – 5460....................................................................................0 27.1 Frequency converter...................................................................................0 27.1.1 General description.............................................................................0 27.1.2 Connection terminal and terminal pillars........................................................0 27.1.3 Technical data..................................................................................0 27.1.4 Programming.....................................................................................0 28- Power electronic panel – 5660..............................................................................0 28.1 General description...................................................................................0 28.1.1 Connection terminal and terminal pillars........................................................0 28.1.2 Technical data..................................................................................0 28.1.3 Installing a new transistor panel...............................................................0 28.2 Diagnostics and troubleshooting.......................................................................0 28.2.1 Displaying errors codes and error logging.......................................................0 28.2.2 Error codes, troubleshooting....................................................................0 28.2.3 Resetting errors................................................................................0 28.3 Maintenance...........................................................................................0 28.3.1 Safety..........................................................................................0 28.3.2 Cleaning........................................................................................0 29- Logic card 5710............................................................................................0 29.1 General description...................................................................................0 29.2 Connection terminals and voltages on A5...............................................................0 29.2.1 10X.............................................................................................0 29.2.2 20X.............................................................................................0 29.2.3 30X.............................................................................................0 29.2.4 40X.............................................................................................0 29.2.5 50X.............................................................................................0 29.2.6 60X.............................................................................................0 29.2.7 70X.............................................................................................0 29.2.8 80X.............................................................................................0 29.2.9 90X.............................................................................................0 29.3 Adjusting the lowering speed..........................................................................0 29.4 Display...............................................................................................0 29.5 Programming...........................................................................................0 29.5.1 Clock...........................................................................................0 29.5.2 Operator parameters (1–7).......................................................................0 29.6 Warning codes.........................................................................................0 29.7 Error codes...........................................................................................0 29.7.1 Error mode......................................................................................0 29.7.2 Safety logics...................................................................................0 29.7.3 Warning code without recording..................................................................0 29.8 Warning codes with registration.......................................................................0 29.9 Error codes...........................................................................................0 29.9.1 Error codes with registration...................................................................0 29.10 Operating Time.......................................................................................0 29.11 Setting all..........................................................................................0 29.11.1 Parameter 1....................................................................................0 29.11.2 Parameter 2....................................................................................0 29.11.3 Parameter 3....................................................................................0 29.11.4 Parameter 4....................................................................................0 29.11.5 Parameter 5....................................................................................0 29.11.6 Parameter 10...................................................................................0 29.11.7 Parameter 11...................................................................................0 29.11.8 Parameter 12...................................................................................0 29.11.9 Parameters 13 to 14............................................................................0 29.11.10 Parameters 15 and 16..........................................................................0 29.11.11 Parameters 17 and 18..........................................................................0 29.11.12 Parameter 19..................................................................................0 29.11.13 Parameter 20..................................................................................0 29.11.14 Parameter 21..................................................................................0 29.11.15 Parameter 23..................................................................................0 29.11.16 Parameter 24..................................................................................0 29.11.17 Parameter 25..................................................................................0 29.11.18 Parameter 26..................................................................................0 29.11.19 Parameter 27..................................................................................0 29.11.20 Parameter 28..................................................................................0 29.11.21 Parameter 29..................................................................................0 29.11.22 Parameter 38..................................................................................0 29.11.23 Parameter 39..................................................................................0 29.11.24 Parameters 40 to 42...........................................................................0 29.11.25 Miscellaneous parameters......................................................................0 29.11.26 Installing a new card in the truck............................................................0 30- Hydraulics – 6000..........................................................................................0 30.1 General...............................................................................................0 30.2 Symbols...............................................................................................0 30.2.1 Hydraulics diagram 1 (3)........................................................................0 30.2.2 Hydraulics diagram 2 (3)........................................................................0 30.2.3 Hydraulics diagram 3 (3)........................................................................0 30.3 List of symbols.......................................................................................0 30.3.1 Component placement 1 (2).......................................................................0 30.3.2 Component placement 2 (2).......................................................................0 30.4 Adjusting fork lowering...............................................................................0 30.5 Adjusting the maximum lifting capacity................................................................0 31- Hydraulic pump – 6140......................................................................................0 31.1 General...............................................................................................0 31.2 Replacing the hydraulic pump..........................................................................0 31.2.1 Dismantling.....................................................................................0 31.2.2 Mounting........................................................................................0 32- Hydraulic couplings – 6230.................................................................................0 32.1 General...............................................................................................0 32.2 Tightening torques for hydraulic connections..........................................................0 32.2.1 Tapered coupling with O-ring....................................................................0 32.2.2 Tredo seal......................................................................................0 32.2.3 Pipe coupling...................................................................................0 32.2.4 Coupling set in aluminium.......................................................................0 32.2.5 Coupling set in steel...........................................................................0 Pressure class L...................................................................................0 33- Mast-mounted hose reel – 6370..............................................................................0 33.1 General...............................................................................................0 33.2 Fitting...............................................................................................0 33.3 Checks after fitting..................................................................................0 34- Hydraulic cylinder – 6600..................................................................................0 34.1 General...............................................................................................0 34.2 Duplex mast...........................................................................................0 34.2.1 Dismantling the lift cylinders from the mast....................................................0 34.2.2 Dismantling the cylinder........................................................................0 34.2.3 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder.......0 34.2.4 Assembling the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder....0 34.2.5 Dismantling and assembling the lower brake valve................................................0 34.2.6 Assembling the cylinder.........................................................................0 34.2.7 Assembling cylinder in the mast.................................................................0 34.3 Triplex mast:.........................................................................................0 34.3.1 Dismantling the free lift cylinder from the mast................................................0 34.3.2 Dismantling the mast lift cylinders from the mast...............................................0 34.4 Cylinder seals........................................................................................0 34.5 Replacing wear parts in the cylinder..................................................................0 34.5.1 Securing........................................................................................0 34.5.2 Dismantling the cylinder........................................................................0 34.5.3 Replacing the lower support ring................................................................0 34.5.4 Replacing the O-ring on the top sleeve..........................................................0 34.5.5 Replacing the internal wear parts in the top sleeve.............................................0 34.5.6 Assembling the cylinder.........................................................................0 34.5.7 Assembling the free lift cylinder in the mast...................................................0 34.5.8 Assembling the mast lift cylinder...............................................................0 35- Main lift cylinder – 6610..................................................................................0 35.1 General...............................................................................................0 35.2 Tools.................................................................................................0 35.3 Dismantling the lift cylinders from the mast..........................................................0 35.4 Dismantling the cylinder..............................................................................0 35.4.1 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder.......0 35.4.2 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder...........0 35.4.3 Dismantling and assembling the hose rupture valve...............................................0 35.5 Assembling the cylinder...............................................................................0 35.5.1 Assembling cylinder in the mast.................................................................0 36- Free lift cylinder – 6620..................................................................................0 36.1 General...............................................................................................0 36.2 Tools.................................................................................................0 36.3 Dismantling...........................................................................................0 36.3.1 Dismantling the cylinder........................................................................0 36.4 Dismantle the rod seal and support ring...............................................................0 36.4.1 Assembling the rod seal and support ring........................................................0 36.5 Dismantling the piston................................................................................0 36.5.1 Fitting the piston in the free lift cylinder....................................................0 36.6 Dismantling and assembling the hose rupture valve.....................................................0 36.7 Assembling the cylinder...............................................................................0 36.8 Fitting...............................................................................................0 37- Reach cylinder – 6650......................................................................................0 37.1 General...............................................................................................0 37.2 Assembling and dismantling the reach cylinder.........................................................0 37.2.1 Dismantling the cylinder........................................................................0 37.2.2 Removing the piston rod.........................................................................0 37.2.3 Removing the top sleeve seals...................................................................0 37.2.4 Fitting the top sleeve..........................................................................0 37.2.5 Fitting the piston seal.........................................................................0 37.2.6 Mounting the piston rod.........................................................................0 37.2.7 Assembling the cylinder.........................................................................0 37.3 Fitting...............................................................................................0 38- Tilt cylinder – 6660.1.....................................................................................0 38.1 General...............................................................................................0 38.2 Assembling and dismantling the tilt cylinder..........................................................0 38.2.1 Dismantling the cylinder........................................................................0 38.2.2 Removing the piston rod.........................................................................0 38.2.3 Removing the piston seals.......................................................................0 38.2.4 Removing the top sleeve seals...................................................................0 38.2.5 Assembling the top sleeve.......................................................................0 38.2.6 Fitting the piston seal.........................................................................0 38.2.7 Mounting the piston rod.........................................................................0 38.2.8 Assembling the cylinder.........................................................................0 38.3 Fitting...............................................................................................0 39- Tilt cylinder – 6660.2.....................................................................................0 39.1 General...............................................................................................0 39.2 Mast with valve on the fork carriage..................................................................0 39.2.1 Disassembly of the fork carriage................................................................0 39.2.2 Dismantling the cylinder........................................................................0 39.2.3 Dismantling the piston rod seal.................................................................0 39.2.4 Dismantling the piston..........................................................................0 39.2.5 Fitting the piston..............................................................................0 39.2.6 Fitting the piston rod seal.....................................................................0 39.2.7 Assembling the cylinder.........................................................................0 39.2.8 Fitting the fork carriage.......................................................................0 39.3 Mast without valve on the fork carriage...............................................................0 39.3.1 Disassembly of the fork carriage................................................................0 39.3.2 Dismantling the cylinder........................................................................0 39.3.3 Dismantling the piston rod seal.................................................................0 39.3.4 Dismantling the piston..........................................................................0 39.3.5 Fitting the piston..............................................................................0 39.3.6 Fitting the piston rod seal.....................................................................0 39.3.7 Assembling the cylinder.........................................................................0 39.3.8 Fitting the fork carriage.......................................................................0 40- Main mast/mast – 7100.1....................................................................................0 40.1 General...............................................................................................0 40.2 Tool list.............................................................................................0 40.3 Transporting the truck................................................................................0 40.4 Assembling the mast...................................................................................0 40.5 Disassembling the mast................................................................................0 40.5.1 Chains, cylinders and hoses.....................................................................0 40.5.2 Dismantling the runner..........................................................................0 40.5.3 Inner guide.....................................................................................0 40.6 Assembling Duplex mast................................................................................0 40.6.1 Assembly – shimming of lateral play.............................................................0 40.6.2 Inner guide.....................................................................................0 40.6.3 Chains, cylinders and hoses.....................................................................0 40.6.4 Fork carriage:..................................................................................0 40.6.5 Docking the mast in the truck...................................................................0 40.7 Assembling the Triplex mast...........................................................................0 40.7.1 Assembly-shimming the side play.................................................................0 40.7.2 Inner guide.....................................................................................0 40.7.3 Chains, cylinders and hoses.....................................................................0 40.7.4 Fork carriage:..................................................................................0 40.8 Problem with mast rollers.............................................................................0 40.9 Adjusting the fork-to-floor distance..................................................................0 41- Main mast/mast – 7100.2....................................................................................0 41.1 General...............................................................................................0 41.2 Tool list.............................................................................................0 41.3 Transporting the truck................................................................................0 41.4 Assembling the mast...................................................................................0 41.5 Disassembling the mast................................................................................0 41.6 Adjusting the play....................................................................................0 41.6.1 Adjusting the mast play.........................................................................0 Lateral play.......................................................................................0 41.6.2 Radial play.....................................................................................0 41.7 Fitting...............................................................................................0 41.8 Problem with mast rollers.............................................................................0 41.9 Adjusting the fork-to-floor distance..................................................................0 42- Main lift chain system – 7120..............................................................................0 42.1 General...............................................................................................0 42.2 Checking the chain setting............................................................................0 42.3 Checking the chain....................................................................................0 42.3.1 Noise...........................................................................................0 42.3.2 Surface rust....................................................................................0 42.3.3 Rusty links.....................................................................................0 42.3.4 Stiff links.....................................................................................0 42.3.5 Bolt rotation...................................................................................0 42.3.6 Loose bolts.....................................................................................0 42.3.7 Outline wear....................................................................................0 42.3.8 Stretching......................................................................................0 42.3.9 Damage..........................................................................................0 42.3.10 Damaged plates.................................................................................0 42.3.11 Damaged bolts..................................................................................0 42.3.12 Dirty chain....................................................................................0 42.4 Cleaning..............................................................................................0 42.5 Adjustment............................................................................................0 42.6 Lubrication...........................................................................................0 43- Lifting devices – 7400.....................................................................................0 43.1 General...............................................................................................0 43.1.1 Inspection intervals............................................................................0 43.1.2 Inspection......................................................................................0 43.1.3 Surface cracks..................................................................................0 43.1.4 Difference in height between the fork tips......................................................0 43.1.5 Position lock...................................................................................0 43.1.6 Marking legibility..............................................................................0 43.1.7 Fork blade and shaft............................................................................0 43.1.8 Mounting fixtures on the fork...................................................................0 43.1.9 Repairs and testing.............................................................................0 Repairs............................................................................................0 Testing the yield point............................................................................0 Fork...............................................................................................0 Fork extension.....................................................................................0 43.2 Checking the fork carriage wear strip (Applies to T-codes 657, 658, 793, 794).........................0 43.3 Fork spread unit (Applies to T-codes 657, 658, 793, 794)..............................................0 43.3.1 Servicing the fork spread unit..................................................................0 Replacing bearings.................................................................................0 44- Battery charger – 8340.....................................................................................0 44.1 General...............................................................................................0 44.2 Installation..........................................................................................0 44.3 Function description..................................................................................0 44.3.1 Display functions...............................................................................0 44.3.2 Charging process................................................................................0 44.3.3 Shutdown conditions.............................................................................0 44.3.4 Delayed power on and charging...................................................................0 44.3.5 Extra charging..................................................................................0 44.3.6 Equalising charging.............................................................................0 44.3.7 Current and voltage characteristics.............................................................0 44.3.8 Safety shutdowns................................................................................0 44.3.9 Display and keyboard............................................................................0 Reading of analogue measurement values.............................................................0 Error indication and error messages................................................................0 Reading statistics from the previous charge........................................................0 Reading of long term statistics....................................................................0 Storing parameters.................................................................................0 Reading parameters.................................................................................0 Battery specific parameters........................................................................0 Charger specific parameters........................................................................0 Mains voltage codes................................................................................0 Other functions....................................................................................0 Changing parameters................................................................................0 44.3.10 Acid circulation...............................................................................0 General............................................................................................0 BTM with acid circulation..........................................................................0 Pump type APE, VPM.................................................................................0 Pump type API......................................................................................0 44.4 Service and Maintenance...............................................................................0 44.4.1 Basic programming, code 30......................................................................0 44.4.2 Resetting the statistics, code 31...............................................................0 44.4.3 Calibrating the measurement value...............................................................0 Calibrating the battery voltage measurement value code 20..........................................0 Calibrating the current’s zero value and temperatures, code 21.....................................0 Calibrating the charging current, code 25..........................................................0 Calibrating the mains voltage display, code 26.....................................................0 44.4.4 Calibrating and programming API.................................................................0 Calibrating zero pressure..........................................................................0 Calibrating the pressure...........................................................................0 Programming the alarm limits.......................................................................0 Programming the API function.......................................................................0 44.4.5 Adjusting the charging characteristics..........................................................0 44.4.6 Troubleshooting.................................................................................0 Error message, analysis and action.................................................................0 Errors without indication..........................................................................0 44.4.7 Trouble shooting acid circulation...............................................................0 44.4.8 Service measures................................................................................0 Switching to the timer charger.....................................................................0 Replacing the display card.........................................................................0 Replacing the computer board.......................................................................0 Replacing the mother board.........................................................................0 Replacing the diodes...............................................................................0 44.4.9 Preventive maintenance..........................................................................0 45- Extra Lighting– 9360.......................................................................................0 46- Extra warning light/alarm – 9370...........................................................................0 46.1 General...............................................................................................0 47- Positioning/TV equipment – 9390............................................................................0 47.1 General...............................................................................................0 47.2 Height indication.....................................................................................0 47.3 Function..............................................................................................0 47.4 Display...............................................................................................0 47.5 Height pre-selection..................................................................................0 47.6 Function..............................................................................................0 47.7 Display...............................................................................................0 47.7.1 Description of the display symbols..............................................................0 47.8 Assembly of height pre-set............................................................................0 47.9 Programming...........................................................................................0 47.9.1 Programming a level.............................................................................0 Collect level......................................................................................0 Leave level........................................................................................0 47.9.2 Deleting programmed levels......................................................................0 47.10 Automatic driving....................................................................................0 47.10.1 Collect load...................................................................................0 47.10.2 Deposit load...................................................................................0 47.10.3 Checking.......................................................................................0 47.11 Parameters...........................................................................................0 47.11.1 Parameter 1....................................................................................0 47.11.2 Parameter 2....................................................................................0 47.11.3 Parameter 3....................................................................................0 47.11.4 Parameter 4....................................................................................0 47.11.5 Parameter 5....................................................................................0 47.11.6 Parameter 7....................................................................................0 47.11.7 Parameter 8....................................................................................0 47.11.8 Parameter 9....................................................................................0 47.12 Programming parameters...............................................................................0 47.13 Error codes..........................................................................................0 48- Truck log system, code lock – 9420.1.......................................................................0 48.1 General...............................................................................................0 TLS - Truck Log System.................................................................................0 48.2 EV 1 and S 16 keyboard version........................................................................0 48.2.1 Logging in with a code (5 digits)...............................................................0 48.2.2 Logout..........................................................................................0 48.2.3 Log-in with fault reporting (5+1 digit).........................................................0 Only applies to S 16...............................................................................0 Logging in.........................................................................................0 48.2.4 Log-in with extra code (5+3 digits).............................................................0 Only applies to S 16...............................................................................0 48.2.5 Log-in with extra code and fault reporting (5+3+1 digits).......................................0 Only applies to S 16...............................................................................0 48.2.6 Changing the three-digit personal code..........................................................0 Only applies to S 16...............................................................................0 48.3 EV 1 and S 16 code card version.......................................................................0 48.3.1 Logging in......................................................................................0 48.3.2 Logout..........................................................................................0 48.3.3 Wiring diagram..................................................................................0 48.4 Collision sensor......................................................................................0 Only applies to S 16...................................................................................0 48.4.1 Wiring diagram..................................................................................0 48.5 Troubleshooting.......................................................................................0 48.5.1 EV 1............................................................................................0 48.5.2 S 16............................................................................................0 48.6 Truck log system, code lock – 9420.2..................................................................0 R212, R214, R216.......................................................................................0 48.6.1 General.........................................................................................0 48.6.2 SD 16...........................................................................................0 48.6.3 Logging in with a code (5 digits)...............................................................0 48.6.4 Logout..........................................................................................0 48.6.5 Components......................................................................................0 If the truck does not start:.......................................................................0 48.7 I/O module............................................................................................0 49- Extra equipment – 9500.....................................................................................0 49.1 Dry powder extinguisher...............................................................................0 In the event of fire, the powder extinguisher should be employed as follows:...........................0 49.1.1 Regular checks of the powder extinguisher – truck driver........................................0 49.1.2 Inspection of powder extinguisher in service inspection of the truck............................0 50- Disposal instructions......................................................................................0 50.1 General...............................................................................................0 50.2 Procedure.............................................................................................0 50.3 Abbreviations.........................................................................................0 50.4 Sorting...............................................................................................0 50.5 Frame/chassis (0300)..................................................................................0 50.5.1 Dismantling.....................................................................................0 50.5.2 Material handling...............................................................................0 50.6 Seat, cushions (0620).................................................................................0 50.6.1 Dismantling.....................................................................................0 50.6.2 Material handling...............................................................................0 50.7 Operator controls (0640)..............................................................................0 50.7.1 Dismantling.....................................................................................0 50.7.2 Material handling...............................................................................0 50.8 Internal fittings (0680)..............................................................................0 50.8.1 Dismantling.....................................................................................0 50.8.2 Material handling...............................................................................0 50.9 Rollover guard/overhead guard (0810)..................................................................0 50.9.1 Dismantling.....................................................................................0 50.9.2 Material handling...............................................................................0 50.10 Finger guards (0820).................................................................................0 50.10.1 Dismantling....................................................................................0 50.10.2 Material handling..............................................................................0 50.11 Electric motors (1700)...............................................................................0 50.11.1 Dismantling....................................................................................0 50.11.2 Material handling..............................................................................0 50.12 Electric fan motor (1740)............................................................................0 50.12.1 Dismantling....................................................................................0 50.12.2 Material handling..............................................................................0 50.13 Drive unit, final gear (2500)........................................................................0 50.13.1 Dismantling....................................................................................0 50.13.2 Material handling..............................................................................0 50.14 Wheels (3500)........................................................................................0 50.14.1 Dismantling....................................................................................0 50.14.2 Material handling..............................................................................0 50.15 Electric steering system (4300)......................................................................0 50.15.1 Dismantling....................................................................................0 50.15.2 Material handling..............................................................................0 50.16 General electronic equipment (5100)..................................................................0 50.16.1 Dismantling....................................................................................0 50.16.2 Material handling..............................................................................0 50.17 Power system, drive function (5400)..................................................................0 50.17.1 Dismantling....................................................................................0 50.17.2 Material handling..............................................................................0 50.18 Control system, working function (5500)..............................................................0 50.18.1 Dismantling....................................................................................0 50.18.2 Material handling..............................................................................0 50.19 Steering/protective electronics (5700)...............................................................0 50.19.1 Dismantling....................................................................................0 50.19.2 Material handling..............................................................................0 50.20 Hydraulic unit (6100)................................................................................0 50.20.1 Dismantling....................................................................................0 50.20.2 Material handling..............................................................................0 50.21 Hydraulic system, fitted on the chassis (6200).......................................................0 50.21.1 Dismantling....................................................................................0 50.21.2 Material handling..............................................................................0 50.22 Hydraulic system, mast mounted (6300)................................................................0 50.22.1 Dismantling....................................................................................0 50.22.2 Material handling..............................................................................0 50.23 Hydraulic cylinders (6600)...........................................................................0 50.23.1 Dismantling....................................................................................0 50.23.2 Material handling..............................................................................0 50.24 Main mast and mast (7100)............................................................................0 50.24.1 Dismantling....................................................................................0 50.24.2 Material handling..............................................................................0 50.25 Lift fork (7410).....................................................................................0 50.25.1 Dismantling....................................................................................0 50.25.2 Material handling..............................................................................0 50.26 Optional electric equipment (9300)...................................................................0 50.26.1 Dismantling....................................................................................0 50.26.2 Material handling..............................................................................0 50.27 Optional electric equipment (9400)...................................................................0 50.27.1 Dismantling....................................................................................0 50.27.2 Material handling..............................................................................0
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