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BT Forklift RRE140/160/180/200/250 Repair manual (6070557) – PDF
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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
S.S 06/24
