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BT Forklift RRE140/160/180/200/250 Repair manual (6070557) - PDF DOWNLOAD
BT Forklift RRE140/160/180/200/250 Repair manual (6070557) - PDF DOWNLOAD
FILE DETAILS:
BT Forklift RRE140/160/180/200/250 Repair manual (6070557) - PDF DOWNLOAD
Language : English
Pages : 816
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Forklift RRE140/160/180/200/250 Repair manual (6070557) - PDF DOWNLOAD
1 - Contents........................................................................................................ 3
2 - General introduction............................................................................................ 19
2.1 How to use the manual....................................................................................... 19
2.2 Warning symbols............................................................................................. 20
2.3 Pictogram................................................................................................... 20
3 - General safety rules............................................................................................ 21
3.1 Safety while working........................................................................................ 21
3.2 Electrical system........................................................................................... 22
3.3 Safe lifting................................................................................................ 23
4 - Descriptions of functions....................................................................................... 25
4.1 Chassis 0000................................................................................................ 25
4.1.1 Operator’s cabin (0500)............................................................................... 25
Versions for cold-store cabs............................................................................ 25
Emergency exit from the cab............................................................................. 26
4.1.2 Cab windows (0530).................................................................................... 27
Electrically heated windows............................................................................. 27
4.1.3 Operator's seat (0620)................................................................................ 28
Adjustment:............................................................................................. 28
Button for seat heater.................................................................................. 28
4.1.4 Cab heating/ventilation (0630)........................................................................ 29
Climate control knobs................................................................................... 29
Ventilation............................................................................................. 29
Temperature............................................................................................. 29
4.1.5 Operator protection (0840)............................................................................ 30
Tilt stops.............................................................................................. 30
Overhead guard.......................................................................................... 32
4.2 Motors 1000................................................................................................. 33
4.2.1 General............................................................................................... 33
4.2.2 Electric pump motor (1710)............................................................................ 33
General................................................................................................. 33
Design.................................................................................................. 33
4.2.3 Electric steering motor (1730)........................................................................ 35
General................................................................................................. 35
Design.................................................................................................. 35
4.2.4 Fan motor/fan (1740).................................................................................. 36
4.2.5 Electric drive motor (1760)........................................................................... 37
General................................................................................................. 37
Design.................................................................................................. 37
4.3 Drive gear - 2000........................................................................................... 38
4.3.1 General............................................................................................... 38
4.3.2 Design................................................................................................ 39
4.4 Brake system 3100........................................................................................... 40
4.4.1 General............................................................................................... 40
Travel brake............................................................................................ 40
Parking brake........................................................................................... 40
Emergency brake......................................................................................... 40
4.4.2 Drive motor brake (travel brake)...................................................................... 41
Accelerator released.................................................................................... 41
Changing the direction of travel........................................................................ 41
4.4.3 Multiple disc brake, support arm (travel brake)....................................................... 42
General................................................................................................. 42
Design.................................................................................................. 42
4.4.4 Disc brake on the drive motor (parking brake)......................................................... 43
General................................................................................................. 43
Design.................................................................................................. 43
4.5 Steering system 4000........................................................................................ 44
4.5.1 General............................................................................................... 44
4.5.2 Design................................................................................................ 44
4.5.3 Sensor................................................................................................ 45
4.6 Operator compartment........................................................................................ 46
4.6.1 Truck control, overview............................................................................... 46
Right-hand control panel, single control................................................................ 46
Right-hand control panel, multi-control................................................................. 46
Emergency off switch.................................................................................... 47
Steering wheel module................................................................................... 47
Pedals.................................................................................................. 48
4.6.2 Single-function controls.............................................................................. 49
4.6.3 Multi-function controls............................................................................... 50
4.6.4 Central Information Display - CID..................................................................... 51
Navigation.............................................................................................. 51
LED symbols............................................................................................. 54
Information symbols..................................................................................... 55
Operator parameter symbols - Overview................................................................... 56
Blocking symbols - Overview............................................................................. 57
Service functions....................................................................................... 59
Calibration functions................................................................................... 61
Automatic calibration of lowering valve................................................................. 62
Configuration functions................................................................................. 64
Other functions......................................................................................... 67
4.6.5 Load Information Display - LID (option)............................................................... 69
LED symbols............................................................................................. 69
Symbols in the display part............................................................................. 70
4.7 sensors and sensors (5800).................................................................................. 71
4.7.1 Inductive sensors..................................................................................... 71
4.7.2 Position sensor....................................................................................... 71
4.7.3 Magnetic sensor....................................................................................... 72
4.8 Operation and connection sequences.......................................................................... 73
4.9 Functions...................................................................................................106
4.9.1 General overview......................................................................................106
Terminology.............................................................................................106
Components..............................................................................................106
4.9.2 MCU - main control unit...............................................................................107
General.................................................................................................107
Downloading software....................................................................................107
System communication....................................................................................107
4.9.3 ACT/ACH transistor regulators.........................................................................108
General.................................................................................................108
4.9.4 Start-up..............................................................................................108
4.9.5 Shutdown..............................................................................................109
4.9.6 Driving...............................................................................................109
Introduction............................................................................................109
Acceleration and speed reduction........................................................................109
Reversing...............................................................................................110
Brake...................................................................................................110
Travel speed............................................................................................111
4.9.7 OTP...................................................................................................112
Travel speed reduction - steering angle.................................................................112
Travel speed reduction - extension of reach carriage....................................................112
Speed reduction - main lift range.......................................................................112
Prevention of lifting/lowering of the forks.............................................................112
Reduced extension speed.................................................................................112
4.9.8 Guide.................................................................................................113
Steering position control...............................................................................113
Steering speed..........................................................................................113
Steering reference......................................................................................114
Travel speed limitation.................................................................................114
Compass rose............................................................................................114
4.9.9 Hydraulic system......................................................................................115
Definitions.............................................................................................115
Controls................................................................................................115
Lift....................................................................................................115
Reach movement..........................................................................................116
Lift height limitation..................................................................................116
Maximum height limitation...............................................................................116
Auxiliary/Extra functions (option)......................................................................117
4.10 Height preselector, description of function................................................................118
4.10.1 Using the height preselector.........................................................................118
4.10.2 Symbols..............................................................................................118
4.10.3 Buzzer...............................................................................................118
4.10.4 Height preselector levels............................................................................119
4.10.5 Level selection......................................................................................119
4.10.6 Height programming...................................................................................120
4.10.7 Height preselector and TruckCom......................................................................121
4.10.8 Lifting/lowering movement............................................................................121
4.10.9 Parameter settings braking at height preselector.....................................................122
4.11 Hydraulic system 6000......................................................................................123
4.11.1 General..............................................................................................123
4.11.2 Tank.................................................................................................123
4.11.3 Filter...............................................................................................123
Return filter...........................................................................................123
Dehumidification filter.................................................................................123
4.11.4 Hydraulic pump.......................................................................................124
4.11.5 Valve unit...........................................................................................124
Main valve block........................................................................................124
Second valve block......................................................................................125
4.11.6 Cylinders............................................................................................126
Main lift cylinders.....................................................................................126
Free-lift cylinder......................................................................................126
Cylinders for the reach movement, cabin tilt, sideshift and fork tilt...................................126
4.11.7 Lift and lowering function...........................................................................127
Lifting and lowering of free lift.......................................................................127
Transition from free lift to main lift..................................................................127
Lifting and lowering of main lift.......................................................................127
Reach movement, in and out..............................................................................127
Simultaneous operation of mast lift and reach movement..................................................128
4.11.8 Extra functions......................................................................................128
4.11.9 Cabin tilt (RRE Ergo)................................................................................128
Hydraulic priority system...............................................................................128
Cabin tilt (RRE Ergo) during servicing..................................................................129
Cabin tilt in the event of hydraulic or electrical power loss...........................................129
4.12 Mast 7000..................................................................................................130
4.12.1 Mast and reach carriage..............................................................................130
4.13 Lifting devices............................................................................................131
4.13.1 Fork extensions......................................................................................131
4.13.2 Telescopic forks.....................................................................................131
4.14 Accessories 9000...........................................................................................133
4.14.1 Radio equipment......................................................................................133
4.14.2 Extra lighting.......................................................................................133
4.14.3 Extra warning lights/alarm...........................................................................134
4.14.4 Turn signal lights...................................................................................134
4.14.5 Movement alarm.......................................................................................135
4.14.6 Positioning/TV equipment.............................................................................136
4.14.7 Extra electrical equipment...........................................................................138
4.14.8 Other extra equipment................................................................................139
Fork spacers............................................................................................139
Load rest...............................................................................................140
E-bar...................................................................................................141
Flashlight..............................................................................................142
5 - Parameters......................................................................................................143
5.1 General.....................................................................................................143
5.2 Displaying/changing parameters..............................................................................143
5.3 Operator parameters.........................................................................................144
5.3.1 Overview..............................................................................................144
5.3.2 Connection to logged-in operator......................................................................145
5.3.3 Description...........................................................................................146
Parameter 1 - Steering..................................................................................146
Parameter 2, 3 - Maximum travel speed...................................................................148
Parameters 4 and 5 - Acceleration/Retardation...........................................................148
Parameter 6 - Cab tilt..................................................................................148
5.4 General service parameters..................................................................................149
5.4.1 Overview..............................................................................................149
5.4.2 Description...........................................................................................149
Parameter 101/104 - Service/Logout......................................................................149
Parameter 105/106/114/115/117 (Travel alarms 1 and 2)...................................................150
Parameter 107/108 - Battery.............................................................................152
Parameter 109/110/111/112 - Collision sensor............................................................156
Parameter 113 (shunt value).............................................................................157
Parameter 116 (Door on cold store cab)..................................................................158
5.4.3 Service parameters, travel functions..................................................................159
5.4.4 Overview..............................................................................................159
5.4.5 Description...........................................................................................159
Parameter 201 - Deceleration when reversing.............................................................159
Parameter 202/203/204 - Adjusting erroneous, maximum travel speeds......................................160
Parameter 205/206/207 - Adjusting erroneous, maximum travel speeds......................................160
Parameter 208 - Creep speed in travel direction control.................................................161
Parameter 209/210 - Reduced maximum travel speed above a certain lift height............................161
Parameter 211/212 - Reduced maximum travel speed with a certain reach length............................162
Parameter 213 - Permanently reduced maximum travel speed................................................162
Parameter 214 - Adjusting the maximum travel speed in main lift range...................................162
5.5 Service parameters, hydraulics..............................................................................163
5.5.1 Overview..............................................................................................163
5.5.2 Description...........................................................................................166
Parameter 301/302/303/304 - Extra valve function........................................................166
Parameter 305/306/307/308 - Max. oil pressure through valve Q8..........................................168
Parameter 313/314/315/316 - Closing time................................................................169
Parameter 317/318/319/320 - Max. oil flow through valve Q8..............................................169
Parameter 321/322/323/324 - Max. oil flow through valve Q9..............................................170
Parameter 325/326/327/328 - Opening/closing time valve Q8...............................................170
Parameter 329/330/331/332 - Opening/closing time valve Q9...............................................171
Parameter 341/342 - Reducing the lifting/lowering speed.................................................171
Parameter 343 - Reduction of reach speed................................................................172
Parameter 344 - Reduction of fork lowering speed before floor level.....................................172
Parameter 345- Lift/lower sensitivity...................................................................172
Parameter 347/348 - Prevent the lifting/lowering of forks...............................................173
Parameter 349 - Fork weight.............................................................................173
Parameter 350 - Multi-function..........................................................................174
Parameters 358/359/360 - Deactivation of hydraulic functions............................................175
Parameters 361/362/363/364/365 /366 - Function related, maximum lift/lowering speeds....................176
Parameter 367/368 - Fork limit for deactivating the extension of the fork carriage and for sideshift....177
Parameter 369 through 379 - Height preselector..........................................................178
Parameter 380 through 386 - Lift height limitations.....................................................180
Parameters 387 through 393 - Configuration of lift height limitations...................................180
Parameters 395/396/397 - Function-related, maximum lift heights.........................................181
Parameters 398/399 - Operator profile dependent, maximum lift heights...................................182
5.6 Service parameters, CID.....................................................................................183
5.6.1 Overview..............................................................................................183
5.6.2 Description...........................................................................................184
Parameter 503 - Login method............................................................................184
Parameter 504/505/506/507 - Smart Access................................................................184
Parameters 508/509/512/513/514 - CID configuration......................................................189
Parameter 510/511 - Height pre-selector.................................................................191
5.7 Service parameters, General Function Unit GFU...............................................................192
5.8 General factory parameters..................................................................................193
5.8.1 Overview..............................................................................................193
5.8.2 Description...........................................................................................194
Parameter 1001 - Truck type.............................................................................194
Parameter 1002 - (Drive motor)..........................................................................194
Parameter 1003 - Pedal type.............................................................................194
Parameter 1004 - Steering servo.........................................................................195
Parameter 1005 - Pump motor.............................................................................195
Parameter 1006 - Hydraulic pump.........................................................................195
Parameter 1007 - Activation of hydraulic levers.........................................................196
Parameter 1008 - Mast type..............................................................................196
Parameter 1009 - Height indication......................................................................197
Parameter 1010 - Weight indication......................................................................197
5.9 Factory parameters, activation of options...................................................................198
Parameter 1115 (Steering angle).............................................................................200
Parameter 1116 (Extended mast)..............................................................................200
Parameter 1117 (Weight of load and fork height).............................................................201
Parameter 1118 (Main lift range)............................................................................201
5.10 Factory parameters, calibration............................................................................203
6 - Installation....................................................................................................207
6.1 Transporting the truck......................................................................................207
Method 1....................................................................................................207
Method 2....................................................................................................207
6.2 Initial operation...........................................................................................208
6.2.1 Tool..................................................................................................208
6.2.2 Battery...............................................................................................208
Placing the battery.....................................................................................208
Battery parameters......................................................................................209
6.2.3 Mast, fitting.........................................................................................209
6.2.4 Parameters on initial operation.......................................................................209
Load indicator..........................................................................................209
Ergo cabin..............................................................................................210
Cold store cabin........................................................................................210
6.2.5 Parameters for optional equipment.....................................................................211
Height measurement (option).............................................................................211
Travel speed limitation, height-dependent...............................................................211
Travel speed limitation, reach movement dependent.......................................................211
Travel speed limitation, parameter-dependent............................................................212
Collision sensor (BT)...................................................................................212
6.2.6 Test driving..........................................................................................212
7 - Maintenance.....................................................................................................215
7.1 Introduction, maintenance...................................................................................215
7.2 Safety precautions for maintenance work.....................................................................216
7.3 Checks for cracks...........................................................................................218
7.3.1 Visual inspection.....................................................................................218
7.3.2 Crack detection.......................................................................................219
Crack detection with liquid penetrants..................................................................219
Crack detection with magnetic yoke......................................................................219
7.4 Periodic maintenance........................................................................................220
7.4.1 Every 500 B-hours/180 days............................................................................220
7.4.2 Every 1000 B-hours/360 days...........................................................................222
7.4.3 Every 2000 B-hours/720 days...........................................................................227
7.4.4 Every 3000 B-hours/1080 days..........................................................................227
7.4.5 Every 5000 B-hours/1800 days..........................................................................229
7.4.6 Annual status inspection..............................................................................229
7.5 Maintenance instructions....................................................................................230
7.5.1 Cleaning and washing..................................................................................230
High-pressure washers...................................................................................230
Degreasing agents.......................................................................................230
Cleaning the truck exterior.............................................................................230
Cleaning the chain......................................................................................231
Cleaning the motor compartment..........................................................................231
Electrical components...................................................................................231
8 - Troubleshooting.................................................................................................233
8.1 Abbreviations used in this section..........................................................................233
8.2 Truck help functions........................................................................................233
8.2.1 Error log menu........................................................................................233
Description.............................................................................................233
Access..................................................................................................233
8.2.2 Error information menu................................................................................234
Description.............................................................................................234
Access..................................................................................................234
8.2.3 Diagnostic screens....................................................................................234
Access..................................................................................................234
State 1 - Voltage from the control console levers.......................................................235
State 2 - Digital signals from the truck control to CID.................................................236
State 3 - Voltage from control/sensor to MCU............................................................237
State 4 - Digital input signals to MCU..................................................................238
State 5 - Digital output signals from MCU...............................................................240
State 6 - PWM output signals from MCU...................................................................241
State 7 - FCU (not used)................................................................................241
State 8 - FCU (not used)................................................................................241
State 9 - GFU (not used)................................................................................241
State 10 - GFU (not used)...............................................................................241
State 11 - Temperature signals..........................................................................242
State 12 - Voltage levels...............................................................................242
State 13 - Travel information...........................................................................243
State 14 - Steering information.........................................................................244
State 15 - Lift/lowering information....................................................................245
Stage 16 - Reach movement information...................................................................246
Stage 17 - Hydraulic information........................................................................247
State 18 - VNA (not used)...............................................................................248
State 19 - Pressure sensor for free and main lifts......................................................248
8.3 Initial troubleshooting.....................................................................................249
8.4 Troubleshooting using catch symbol..........................................................................250
8.5 Troubleshooting using error codes...........................................................................258
8.5.1 CID, warnings and errors..............................................................................260
8.5.2 MCU and other warnings and errors.....................................................................264
8.5.3 Drive system error....................................................................................274
8.5.4 Hydraulic system error................................................................................287
8.5.5 Steering system, warnings and errors..................................................................320
8.5.6 GFU, warnings and errors..............................................................................327
8.6 Troubleshooting without indications.........................................................................329
8.6.1 Mechanical brake (3000)...............................................................................329
8.6.2 Steering (4000).......................................................................................329
8.6.3 Telescopic forks......................................................................................330
8.6.4 Log on was normal, but one or several functions cannot be used........................................331
9 - Frame/Chassis 0000..............................................................................................333
9.1 General.....................................................................................................333
9.2 Motor hood (0340)...........................................................................................333
9.2.1 Opening the motor compartment.........................................................................333
RRE 140-RRE 250.........................................................................................333
To open the motor compartment:..........................................................................333
To close the motor compartment:.........................................................................333
Replacing the motor hood................................................................................334
Adjustment of motor hood................................................................................334
9.3 Battery compartment components (0390).......................................................................336
9.3.1 Adjusting the battery bed.............................................................................336
9.4 Operator's cab (0500).......................................................................................337
9.4.1 Cab tilting RRE 140 - 250 Ergo........................................................................337
9.3.1 Cab windows (0530)....................................................................................338
Fitting a window........................................................................................338
9.3.2 Cab door (0550).......................................................................................340
Disassembly of the door lock............................................................................340
Tools required..........................................................................................341
Method..................................................................................................341
Disassembly of the lock device..........................................................................342
9.4 Operator compartment (0600).................................................................................344
9.4.1 Operator's seat (0620)................................................................................344
Disassembling the entire seat...........................................................................344
Replacing the seat switch...............................................................................345
Replacing the back rest.................................................................................346
Replacing the chair seat................................................................................347
Replacing the seat heater switch........................................................................347
9.4.2 Cab heating/ventilation (0630)........................................................................348
Replacing the air filter on the cold store cabin:.......................................................348
Removing the fan and heater.............................................................................349
Replacing the potentiometers............................................................................353
9.4.3 Internal fittings (0680)..............................................................................355
9.4.4 Disassembling/assembling the floor plate, B version 0680..............................................356
9.5 Safety equipment (0800).....................................................................................358
9.5.1 Checking the overhead guard (0810)....................................................................358
9.5.2 Adjusting the tilt stops (0840).......................................................................359
10 - Motors 1000....................................................................................................361
10.1 Motor sensors..............................................................................................361
10.1.1 Temperature sensor...................................................................................361
Retrofitting an external temperature sensor.............................................................362
10.1.2 Replacing the motor speed sensor.....................................................................362
10.2 Pump motor (1710)..........................................................................................363
10.2.1 General..............................................................................................363
The pump motor dismantled...............................................................................363
10.2.2 Replacing the bearing on the pump motor..............................................................364
Dismantling the pump motor..............................................................................364
Reassembling the pump motor.............................................................................366
10.3 Steering motor and steering unit (1730)....................................................................367
10.3.1 General..............................................................................................367
10.3.2 Layout of the flange holes...........................................................................367
10.3.3 Removing the steering motor from the truck...........................................................368
10.3.4 Fitting the steering motor in the truck..............................................................368
10.4 Fan motor/fan (1740).......................................................................................369
10.4.1 General..............................................................................................369
10.4.2 Replacing the frequency converter cooling fan........................................................369
Standard truck..........................................................................................369
Ergo truck..............................................................................................369
10.4.3 Replacing the motor compartment cooling fan..........................................................371
10.5 Drive motor (1760).........................................................................................372
10.5.1 General..............................................................................................372
The drive motor dismantled..............................................................................372
10.5.2 Removing the drive motor from the truck..............................................................373
10.5.3 Dismantling the drive motor..........................................................................375
10.5.4 Cleaning.............................................................................................377
10.5.5 Assembling the drive motor...........................................................................378
10.5.6 Fitting the drive motor in the truck.................................................................380
11 - Drive gear 2000................................................................................................383
11.1 General....................................................................................................383
11.2 Repair- and serviceability.................................................................................383
11.3 Measures...................................................................................................384
11.3.1 Checking the oil level...............................................................................384
11.3.2 Oil change...........................................................................................385
Oil refill table........................................................................................385
11.3.3 Leakage from the bottom cap..........................................................................386
11.3.4 Replacing the drive gear.............................................................................387
Special tools...........................................................................................387
Exposing the drive gear.................................................................................387
Removing a drive motor from the truck...................................................................387
Removing a steering motor from the truck................................................................387
Removing the drive gear from the truck..................................................................388
Fit the drive gear back in the truck....................................................................390
Placing the steering motor in the truck.................................................................391
Placing the drive motor in the truck....................................................................391
Concluding work.........................................................................................391
12 - Brake and wheel 3000...........................................................................................393
12.1 Travel brake system (3100).................................................................................393
12.1.1 Removing the support arm's multiple disc brake.......................................................393
12.1.2 Dismantling the multiple disc brake..................................................................393
Inspection..............................................................................................394
Adjusting play..........................................................................................394
Assembling the multiple disc brake......................................................................395
12.1.3 Installing the multiple disc brake in the truck......................................................395
12.1.4 Checking the wheel brake's brake force...............................................................396
12.2 Parking brake (3300).......................................................................................397
12.2.1 General..............................................................................................397
12.2.2 Emergency release of the parking brake...............................................................398
12.2.3 Checking the brake force.............................................................................398
12.2.4 Removing the parking brake from the truck............................................................399
Dismantling and checking for wear.......................................................................400
Adjusting the air gap...................................................................................402
12.2.5 Installing the parking brake in the truck............................................................404
12.3 Drive wheel (3530).........................................................................................405
12.3.1 General..............................................................................................405
12.3.2 Removing the drive wheel from the truck..............................................................405
12.3.3 Installing the drive wheel on the truck..............................................................405
12.4 Wheel bolt (3530)..........................................................................................406
General.....................................................................................................406
12.4.1 Replacing wheel bolts................................................................................406
12.5 Support arm wheel (3550)...................................................................................407
12.5.1 Removing the support arm wheel from the truck........................................................407
12.5.2 Replacing a wheel bearing - braked wheel (A).........................................................408
12.5.3 Replacing a wheel bearing - unbraked wheel (B).......................................................409
12.5.4 Fitting the support arm wheel to the truck...........................................................410
12.5.5 Wheel wear and tear..................................................................................411
13 - Steering system 4000...........................................................................................413
13.1 Electric steering wheel (4310).............................................................................413
13.1.1 General..............................................................................................413
13.1.2 Replacing the pulse transducer on the steering wheel module..........................................413
13.1.3 Removing the operating console from the truck........................................................414
13.1.4 Replacing the wiring harness in the operating console................................................416
13.1.5 Fitting the operating console in the truck...........................................................418
13.2 Steering reference sensor (4350)...........................................................................419
General.....................................................................................................419
13.2.1 Replacing the reference transducer [B17].............................................................419
13.3 Steering bearings (4380)...................................................................................420
13.3.1 Removing a steering bearing from the drive gear......................................................420
13.3.2 Fitting a steering bearing on the drive gear.........................................................420
14 - Electrical system 5000.........................................................................................423
14.1 Battery (5110).............................................................................................423
14.1.1 Battery recommendation...............................................................................423
Exide gel batteries (e.g. Sonnenschein).................................................................423
Hawker Evolution gel batteries..........................................................................423
14.1.2 Battery installation.................................................................................424
Replacement/installation of battery.....................................................................424
Procedure without battery changing table................................................................425
Procedure with battery changing table...................................................................425
14.2 LID (5200).................................................................................................426
14.2.1 Replacing the LID....................................................................................426
14.2.2 Replacing the LID cold store cab.....................................................................427
14.3 Replacing pedals (5300)....................................................................................428
14.3.1 Accelerator and brake pedal..........................................................................428
14.3.2 Safety pedal.........................................................................................428
14.4 Control console (5510).....................................................................................429
14.4.1 General..............................................................................................429
14.4.2 Replacement/installation of a control................................................................429
14.4.3 Replacing the multi-function control.................................................................430
Replacing the multi-function control's buttons..........................................................430
14.4.4 Removing the control console from the truck..........................................................431
14.4.5 Replacing the access card's circuit board............................................................432
14.4.6 Dismantling the control console......................................................................434
Installing an extra push button.........................................................................436
Replacing the travel direction selector with signal button..............................................436
Replacing the display...................................................................................437
14.4.7 Assembling the control console.......................................................................437
14.4.8 Fitting the control console in the truck.............................................................438
14.5 Magnetic sensor (5850).....................................................................................440
General.....................................................................................................440
14.5.1 Replacing the magnetic sensor [B47]..................................................................440
14.5.2 Reference magnet.....................................................................................441
14.6 Parameter settings.........................................................................................442
14.6.1 Configuration menu...................................................................................442
Calendar/hour counter menu..............................................................................442
Parameter menu (PAR)....................................................................................442
Setting operator parameters.............................................................................443
14.7 PIN menu...................................................................................................444
14.7.1 Menu for activating a PIN block......................................................................445
14.7.2 Menu for programming a PIN (P).......................................................................445
14.8 Calibrations...............................................................................................446
14.8.1 Calibrating the hydraulic function control...........................................................446
14.8.2 Height measurement/reach movement length calibration.................................................447
Calibrating height measurement (option).................................................................448
14.8.3 Valve calibration....................................................................................451
Lift valve calibration..................................................................................451
Lowering valve calibration with height indication.......................................................453
Lowering calibration without height indication..........................................................455
Reach movement valve calibration........................................................................457
Calibration of the Ergo cab.............................................................................460
14.8.4 Weight calibration...................................................................................461
Calibrating the weight indicator........................................................................461
14.9 Replacing the wiring harness...............................................................................463
14.10 main computer unit MCU (A5)...............................................................................464
14.10.1 Installing a new card in the truck..................................................................464
14.10.2 Voltage supply......................................................................................465
14.10.3 Battery negative....................................................................................465
14.10.4 Internal status monitoring..........................................................................465
14.10.5 Resetting the battery indicator.....................................................................465
15 - Hydraulic system 6000..........................................................................................467
15.1 Hydraulic hygiene..........................................................................................467
15.1.1 Washing..............................................................................................467
15.1.2 Packaging............................................................................................467
15.1.3 Handling.............................................................................................467
15.1.4 Storage..............................................................................................468
15.1.5 Work procedures......................................................................................468
15.2 Hydraulic unit (6100)......................................................................................469
15.2.1 Hydraulic tank, emptying.............................................................................470
15.2.2 Hydraulic system, bleeding...........................................................................471
15.2.3 Filter...............................................................................................472
Overview................................................................................................472
Filter replacement (air and oil)........................................................................473
15.2.4 Remove the pump motor from the truck.................................................................475
15.2.5 Replacing the hydraulic pump.........................................................................476
15.2.6 Fitting the pump motor in the truck..................................................................477
15.3 Main valve (6210)..........................................................................................478
15.3.1 Emergency lowering of forks..........................................................................478
15.3.2 Replacing the main valve block.......................................................................480
15.3.3 Replacing the lifting/lowering valves................................................................482
Overview................................................................................................482
Method..................................................................................................483
15.3.4 Adjusting the maximum opening pressure...............................................................486
15.4 Hydraulic connections (6230)...............................................................................488
15.4.1 Tightening torques for hydraulic connections.........................................................488
Tapered coupling with O-ring............................................................................488
Tredo sealing...........................................................................................489
Pipe coupling...........................................................................................490
15.4.2 Quick change connector...............................................................................492
15.5 Hydraulic system, mast (6300)..............................................................................494
15.5.1 Mast-mounted hose reel (6370)........................................................................494
General.................................................................................................494
15.5.2 Fitting the hose reel................................................................................494
Spring preloading (turns)...............................................................................494
15.5.3 Checks after fitting.................................................................................495
15.6 Main lift cylinder 6610....................................................................................496
General.....................................................................................................496
15.6.1 Overview.............................................................................................497
Cylinder nomenclature...................................................................................497
Nomenclature for cylinder head..........................................................................498
Nomenclature for piston.................................................................................498
15.6.2 Removing the air cylinder from the mast..............................................................499
15.6.3 Replacing the hose rupture valve.....................................................................500
15.6.4 Dismantling the cylinder.............................................................................502
15.6.5 Dismantling the piston...............................................................................504
Method..................................................................................................504
15.6.6 Dismantling the cylinder head........................................................................504
15.6.7 Fitting the cylinder head seals......................................................................506
15.6.8 Fitting the piston seals.............................................................................508
15.6.9 Assembling the cylinder..............................................................................510
15.6.10 Assembling cylinder in the mast.....................................................................512
15.7 Free lift cylinder (6620)..................................................................................514
General.....................................................................................................514
15.7.1 Overview.............................................................................................515
Cylinder nomenclature...................................................................................515
Nomenclature for cylinder head..........................................................................516
Nomenclature for piston.................................................................................516
15.7.2 Removing the free lift cylinder from the truck.......................................................517
15.7.3 Replacing the hose rupture valve, free lift cylinder.................................................517
15.7.4 Dismantling the cylinder.............................................................................518
Tools required..........................................................................................519
Method..................................................................................................519
15.7.5 Dismantling the piston...............................................................................519
Method..................................................................................................519
15.7.6 Dismantling the cylinder head........................................................................520
Method..................................................................................................520
15.7.7 Fitting the cylinder head seals......................................................................521
Method..................................................................................................521
15.7.8 Fitting the piston seals.............................................................................522
Method..................................................................................................523
15.7.9 Assembling the cylinder..............................................................................524
15.7.10 Assembling the free lift cylinder in the mast.......................................................526
15.8 Reach cylinder (6650)......................................................................................527
15.8.1 General..............................................................................................527
15.8.2 Removing the reach cylinder from the truck...........................................................527
15.8.3 Fitting the reach cylinder in the truck..............................................................528
15.9 Fork tilt cylinder (6660)..................................................................................529
15.9.1 General..............................................................................................529
15.9.2 Remove the tilt cylinder from the truck..............................................................530
Mast with valve on the fork carriage:...................................................................530
Mast without valve on the fork carriage:................................................................532
15.9.3 Fit the tilt cylinder in the truck...................................................................534
Mast without valve on the fork carriage:................................................................536
15.10 Cab tilt cylinder (6660)..................................................................................538
15.10.1 General.............................................................................................538
15.10.2 Overview............................................................................................538
Cylinder nomenclature...................................................................................538
Nomenclature for cylinder head..........................................................................539
Nomenclature for piston.................................................................................539
15.10.3 Dismantling the cylinder............................................................................540
15.10.4 Dismantling the piston rod..........................................................................542
15.10.5 Dismantling the cylinder head.......................................................................544
15.10.6 Fitting the cylinder head seals.....................................................................546
15.10.7 Mounting the piston rod.............................................................................548
15.10.8 Assembling the cylinder.............................................................................550
15.11 Sideshift cylinder (6670).................................................................................552
15.11.1 General.............................................................................................552
15.11.2 Overview............................................................................................553
Cylinder nomenclature...................................................................................553
Nomenclature for cylinder head..........................................................................554
Nomenclature for piston.................................................................................554
15.11.3 Dismantling the cylinder from the truck.............................................................555
15.11.4 Dismantling the cylinder............................................................................556
15.11.5 Dismantling the piston rod..........................................................................558
15.11.6 Dismantling the cylinder head.......................................................................560
15.11.7 Fitting the cylinder head seals.....................................................................562
15.11.8 Mounting the piston rod.............................................................................564
15.11.9 Assembling the cylinder.............................................................................566
15.11.10 Refitting the cylinder in the truck................................................................567
16 - Mast/Lift system 7000..........................................................................................569
16.1 Main mast 1.6-2.5 t (7100).................................................................................569
16.1.1 Replacing the full mast..............................................................................569
16.1.2 Removing the mast from the truck.....................................................................570
16.1.3 Adjusting mast play..................................................................................573
General.................................................................................................573
Preparations............................................................................................573
Adjusting lateral play..................................................................................576
Adjustment of radial play...............................................................................577
Adjusting the damper parts..............................................................................577
Adjusting the damper plate..............................................................................578
Refitting the mast......................................................................................578
16.1.4 Replacing the mast damper plates.....................................................................579
16.1.5 Placing the mast on the truck........................................................................580
16.2 Main lift chain system (7120)..............................................................................584
16.2.1 General..............................................................................................584
16.2.2 Checking the chain...................................................................................584
Noise...................................................................................................584
Surface rust............................................................................................584
Rusty links.............................................................................................584
Stiff links.............................................................................................585
Bolt rotation...........................................................................................585
Loose bolts.............................................................................................585
Outline wear............................................................................................586
Stretching..............................................................................................587
Damage..................................................................................................587
Damaged plates..........................................................................................588
Damaged bolts...........................................................................................588
Dirty chain.............................................................................................588
16.2.3 Lubricating the chain................................................................................588
16.2.4 Main lift chain system, adjusting the fork-to-floor distance.........................................589
16.3 Reach carriage (7190)......................................................................................590
16.3.1 Adjusting radial play in the reach carriage..........................................................590
16.3.2 Adjusting axial play in the reach carriage...........................................................592
16.4 Lifting devices (7400).....................................................................................593
16.4.1 Forks................................................................................................593
General.................................................................................................593
Inspection..............................................................................................593
Inspection intervals....................................................................................593
Surface cracks..........................................................................................593
Difference in height between the fork tips..............................................................594
Position lock...........................................................................................594
Readability of the markings.............................................................................594
Fork blades and back of fork carriage...................................................................594
Mounting fixtures on the fork...........................................................................594
16.4.2 Forks, repairs and testing...........................................................................595
Repairs.................................................................................................595
Testing the yield point.................................................................................595
Fork....................................................................................................595
16.5 Fork carriage..............................................................................................596
16.5.1 Checking the fork carriage’s wear strip..............................................................596
16.5.2 Lubricating the fork carriage........................................................................597
16.6 Fork spread unit...........................................................................................598
16.6.1 Servicing the fork spread unit.......................................................................598
Replacing bearings......................................................................................599
Roller replacement......................................................................................599
16.7 Fork extensions with adjustable fork length................................................................600
16.8 Manual telescopic forks....................................................................................602
16.8.1 Installation.........................................................................................602
16.8.2 Maintenance..........................................................................................603
16.9 Hydraulic telescopic forks.................................................................................604
16.9.1 Telescopic forks with separate flow dividers.........................................................605
Fitting instructions....................................................................................606
Initial operation of telescopic forks with separate flow dividers.......................................606
16.9.2 Telescopic forks with integrated flow dividers.......................................................607
Fitting instructions....................................................................................608
Initial operation of telescopic forks with integrated flow dividers.....................................608
16.9.3 Maintenance of telescopic forks......................................................................609
16.9.4 Dismantling telescopic forks.........................................................................610
16.9.5 Assembling telescopic forks..........................................................................611
17 - Peripherals - 8000.............................................................................................613
17.1 Introduction...............................................................................................613
18 - Extra equipment - 9000.........................................................................................615
18.1 Introduction...............................................................................................615
19 - Appendix “Destruction instructions”............................................................................617
19.1 General....................................................................................................617
19.2 Marking of plastics........................................................................................617
19.2.1 General marking of products and packaging material...................................................617
19.2.2 Marking according to our standard....................................................................618
Abbreviations...........................................................................................618
Marking examples........................................................................................618
19.3 Pressure vessels...........................................................................................619
19.3.1 Gas dampers..........................................................................................619
19.4 Sorting categories.........................................................................................620
20 - Wiring diagram.................................................................................................623
20.1 Components.................................................................................................623
20.2 Component location.........................................................................................633
Figure 1 (Fork carriage)....................................................................................633
Figure 2 (Chassis wiring harness)...........................................................................634
Figure 3 (Chassis wiring harness)...........................................................................635
Figure 4 (Support leg brake)................................................................................636
Figure 5 (Pedals)...........................................................................................636
Figure 6 (Motor wiring harness).............................................................................637
Figure 7 (Reach carriage wiring harness)....................................................................638
Figure 8 (Level/position meter).............................................................................639
Figure 9 (seat).............................................................................................640
Figure 10 (DC/DC)...........................................................................................641
Figure 11 (Driver position wiring harness)..................................................................642
Figure 12 (Extra hydraulic function(s)).....................................................................643
Figure 13 (Travel alarm)....................................................................................644
Figure 14 (Roof wiring harness).............................................................................645
Figure 15 (Roof)............................................................................................646
Figure 16 (Sound system)....................................................................................647
Figure 17 (Forks camera)....................................................................................648
Figure 18 (Battery harness).................................................................................649
Figure 19 (Fuse box)........................................................................................650
Figure 20 (LID).............................................................................................651
Figure 21 (Mast wiring harness).............................................................................652
Figure 22 (Fork carriage wiring harness)....................................................................653
Figure 23 (Reach carriage wiring harness options)...........................................................654
Figure 24 (Working light wiring harness)....................................................................655
Figure 24 (Extra outlet DC).................................................................................656
Figure 25 (T.W.I.S.)........................................................................................656
Figure 26 (Shock Switch / Impact Manager)...................................................................657
Figure 27 (Heated windows CC)...............................................................................658
Figure 28 (Cabling driver position CC)......................................................................659
Figure 29 (Heater CC).......................................................................................660
Figure 30 (Cab heater wiring harness CC)....................................................................661
Figure 31 (Safety switch for door CC).......................................................................662
Figure 32 (Cab tilt wiring harness).........................................................................662
Figure 33 (Control panel)...................................................................................663
Figure 34 (Control panel)...................................................................................664
Figure 35 (Steering arm)....................................................................................665
Figure 36 (MCU).............................................................................................666
Figure 37 (Control motor)...................................................................................667
Figure 38 (Main valve block)................................................................................668
20.3 Cable connections and pole bolts...........................................................................670
20.3.1 ACT/ACH transistor regulators........................................................................670
20.3.2 Connections to CID...................................................................................672
20.3.3 Connections on the MCU...............................................................................674
20.4 Fuse box A9................................................................................................676
20.5 Overview...................................................................................................677
20.6 Details up to and including serial no. 6206800.............................................................682
20.7 Detailed diagram cold-store cab............................................................................707
20.8 Details up to and including serial no. 6206800.............................................................732
20.9 Details cold store cab starting with 6206800...............................................................758
21 - Hydraulics schematics..........................................................................................785
21.1 Main valve unit............................................................................................785
21.1.1 RRE Std..............................................................................................785
21.1.2 RRE Ergo.............................................................................................786
21.2 Hydraulics schematics......................................................................................787
21.2.1 Schematics designations..............................................................................787
21.2.2 List of symbols......................................................................................788
21.2.3 Wiring diagrams RRE/RRE Ergo.........................................................................789
22 - Tools..........................................................................................................795
22.1 AMP connectors.............................................................................................795
22.2 MQS contacts...............................................................................................796
22.3 CPC contacts...............................................................................................798
22.4 Miscellaneous tools........................................................................................799
23 - Appendix “Service data and grease specifications”..............................................................803
23.1 General tightening torques.................................................................................803
23.1.1 Galvanised non-oiled bolts...........................................................................803
23.1.2 Untreated oiled bolts................................................................................804
23.2 Oil and grease specification...............................................................................805
24 - Technical data.................................................................................................807
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