BT Toyota Electric Forklift RRE140/160/180/200/250 Repair Manual

Description

BT Toyota Electric Forklift RRE140/160/180/200/250 Repair Manual – PDF DOWNLOAD

FILE DETAILS:

BT Toyota Electric Forklift RRE140/160/180/200/250 Repair Manual – PDF DOWNLOAD

Language : English
Pages :932
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Toyota Electric Forklift RRE140/160/180/200/250 Repair Manual – PDF DOWNLOAD

1 – Table of contents0
2 – General introduction0
21 How to use this manual0
22 Warning symbols0
23 Pictograms0
3 – General safety rules0
31 Work safety0
32 Electrical system0
33 Safe lifting0
4 – Descriptions of functions0
41 Chassis 00000
411 Operator’s cabin (0500)0
Versions for cold-store cabs0
Emergency exit from the cab0
412 Cab windows (0530)0
Electrically heated windows0
413 Operator’s seat (0620)0
Adjustment:0
Button for seat heater0
414 Cab heating/ventilation (0630)0
Climate control knobs0
Ventilation0
Temperature0
415 Operator protection (0840)0
Studs0
Protective overhead guard0
42 Motors 10000
421 General0
422 Electric pump motor (1710)0
General0
Construction0
423 Electric steering motor (1730)0
General0
Construction0
424 Fan motor/fan (1740)0
425 Electric drive motor (1760)0
General0
Construction0
43 Drive gear – 20000
431 General0
432 Construction0
44 Brake system 31000
441 General0
Travel brake0
Parking brake0
Emergency brake0
442 Drive motor brake (travel brake)0
Accelerator released0
Changing the direction of travel0
443 Multiple disc brake, support arm (travel brake)0
General0
Construction0
444 Disc brake in support arm wheels (travel brake)0
General0
Construction0
445 Disc brake on the drive motor (parking brake)0
General0
Construction0
45 Steering system 40000
451 General0
452 Construction0
453 Sensor0
Steering reference sensor0
46 Operation area0
461 Truck control, overview0
Right-hand control panel, single control0
Right-hand control panel, multi-control0
Emergency switch off0
Steering wheel module0
Pedals0
462 Single-function control0
463 Multi-function control0
464 Central Information Display – CID0
Navigation0
LED symbols0
Information symbols0
Driver parameter symbols – Overview0
Blocking symbols – Overview0
Service symbols – Overview0
Service functions0
Calibration functions0
Configuration functions0
Other functions0
465 Load Information Display – LID (option)0
LED symbols0
Symbols in the display part0
47 sensors and sensors (5800)0
471 Inductive sensors0
472 Position sensor0
473 Magnetic sensor0
48 Operation and connection sequences0
49 Functions0
491 General overview0
Terminology0
Components0
492 MCU – main control unit0
General0
Downloading software0
System communication0
493 ACT/ACH regulators0
General0
494 Start-up0
495 Shutdown0
496 Driving0
Introduction0
Acceleration and speed reduction0
Reversing0
Brakes0
Travel speed0
497 OTP0
Travel speed reduction – steering angle0
Travel speed reduction – extension of reach carriage0
Speed reduction – main lift range0
Prevention of lifting/lowering the forks0
Reduced extension speed0
498 Steering0
Steering position control0
Steering speed0
Steering reference0
Travel speed limitation0
Compass rose0
499 Hydraulic system0
Definitions0
Controls0
Lift0
Reach movement0
Lift height limitation0
Maximum height limitation0
Auxiliary/Extra functions (option)0
410 Height preselector, description of function0
4101 Using the height preselector0
4102 Symbols0
4103 Travel warning0
4104 Height preselector levels0
4105 Level selection0
4106 Height programming0
4107 Height preselector and TruckCom0
4108 Lift/lowering movement0
4109 Parameter settings braking at height preselector0
411 Hydraulic system 60000
4111 General0
4112 Tank0
4113 Filter0
Return filter0
Dehumidification filter0
4114 Hydraulic pump0
4115 Valve unit0
Main valve block0
Second valve block0
4116 Cylinders0
Main lift cylinders0
Free-lift cylinder0
Cylinders for the reach movement, cabin tilt, sideshift and fork tilt0
4117 Lift and lowering function0
Lifting and lowering of free lift0
Transition from free lift to main lift0
Lifting and lowering of main lift0
Reach movement, in and out0
Simultaneous operation of Mast lift and Reach movement0
4118 Extra functions0
4119 Cabin tilt (RRE Ergo)0
Hydraulic priority system0
Cabin tilt (RRE Ergo) during servicing0
Cabin tilt in the event of hydraulic or electrical power loss0
412 Mast 70000
4121 Mast and reach carriage0
413 Lifting devices0
4131 Fork extensions0
4132 Telescopic forks0
414 Accessories 90000
4141 Radio equipment0
4142 Extra lighting0
4143 Extra warning lights/alarm0
4144 Turn signal lights0
4145 Movement alarm0
4146 Positioning-/TV equipment0
4147 Extra electrical equipment0
4148 Other extra equipment0
Fork spacers0
Load support0
E-bar0
Fire extinguisher0
5 – Parameters0
51 General0
52 Displaying/changing parameters0
53 Operator parameters0
531 Overview0
532 Connection to logged-in operator0
533 Description0
Parameter 1 – Steering0
Parameter 2, 3 – Maximum travel speed0
Parameters 4 and 5 – Acceleration/Deceleration0
Parameter 6 – Cab tilt0
54 General service parameters0
541 Overview0
542 Description0
Parameter 101/104 – Service/Log-out0
Parameter 105/106/114/115/117 (Travel alarms 1 and 2)0
Parameter 107/108 – Battery0
Parameter 109/110/111/112 – Collision sensor0
Parameter 113 (shunt value)0
Parameter 116 (Door on cold store cabs)0
55 Service parameters, travel functions0
551 Overview0
552 Description0
Parameter 201 – Retardation when reversing0
Parameters 202/203/204 – Adjusting erroneous, maximum travel speeds0
Parameters 205/206/207 – Adjusting function-related, maximum travel speeds0
Parameter 208 – Creep speed in travel direction control0
Parameter 209/210 – Reduced maximum travel speed above a certain lift height0
Parameter 211/212 – Reduced maximum travel speed with a certain reach length0
Parameter 213 – Permanently reduced maximum travel speed0
Parameter 214 – Adjusting the maximum travel speed in main lift range0
Parameter 215/216/217 – Adjusting OTP speed and starting and finishing angles0
56 Service parameters, hydraulics0
561 Overview0
562 Description0
Parameters 301/302/303/304/333 – Extra valve function0
Parameters 305/306/307/308/334 – Maximum oil pressure through valve Q80
Parameters 313/314/315/316/336 – Closing time0
Parameters 317/318/319/320/337 – Maximum oil flow through valve Q80
Parameters 321/322/323/324/338 – Maximum oil flow through valve Q90
Parameters 325/326/327/328/339 – Opening/closing time for valve Q80
Parameters 329/330/331/332/340 – Opening/closing time for valve Q90
Parameters 333/334 Setting of additional security hydraulic function0
Parameter 341/342 – Reducing the lifting/lowering speed0
Parameter 343 – Reduction of reach speed0
Parameter 344 – Reduction of fork lowering speed before floor level0
Parameter 345- Lift/lower sensitivity0
Parameter 346- Ramping for hydraulic functions Lifting, Lowering and Reach in/out0
Parameter 347/348 – Prevent the lifting/lowering of forks0
Parameter 349 – Fork weight0
Parameter 350 – Multi-function0
Parameters 351/352 Setting of button for additional security hydraulic function0
Parameters 353/354/400 Soft lift0
Parameters 356/357 Active draining0
Parameters 358/359/360 – Deactivation of hydraulic functions0
Parameters 361/362/363/364/365 /366 – Function related, maximum lifting/lowering speeds0
Parameter 367/368 – Fork limit for deactivating the extension of the fork carriage and for sideshift0
Parameter 369 through 379 – Height preselector0
Parameter 380/381 – Lift height limitations0
Parameters 387/388 – Configuring lift height limitations0
Parameters 395/396/397 – Function-related, maximum lift heights0
Parameters 398/399 – Operator profile dependent, maximum lift heights0
57 Service parameters, CID0
571 Overview0
572 Description0
Parameter 503 – Login method0
Parameters 504/505/506/507 – Smart Access0
Parameter 508/509/512/513/514 – CID configuration0
Parameters 510/511 – Height pre-selection0
58 General factory parameters0
581 Overview0
582 Description0
Parameter 1001 – Truck type0
Parameter 1002 – (Drive motor)0
Parameter 1003 – Pedal type0
Parameter 1004 – Steering servo0
Parameter 1005 – Pump motor0
Parameter 1006 – Hydraulic pump0
Parameter 1007 – Activation of hydraulic levers0
Parameter 1008 – Mast type0
Parameter 1009 – Height indication0
Parameter 1010 – Weight indication0
59 Factory parameters, activation of options0
591 Overview0
Parameter 1115 (Steering angle)0
Parameter 1116 (Extended mast)0
Parameter 1117 (Weight of load and fork height)0
Parameter 1118 (Main lift range)0
Parameter 1131 – Adjusting the maximum travel speed in main lift range0
592 Description0
510 Factory parameters, calibration0
6 – Installation0
61 Transporting the truck0
62 Transporting the mast0
63 Transporting the truck0
Method 10
Method 20
64 Commissioning0
641 Tools0
642 Battery0
Placing the battery0
Battery parameters0
643 Mast, fitting0
65 Bleeding the air from the hydraulic system0
651 Parameters on initial operation0
Load indicator0
Ergo cab0
Cold store cabin0
652 Parameters for optional equipment0
Height measurement (option)0
Travel speed limitation, height-dependent0
Travel speed limitation, reach movement dependent0
Travel speed limitation, parameter-dependent0
Collision sensor0
7 – Maintenance0
71 Introduction, maintenance0
72 Safety precautions for maintenance work0
73 Maintenance instructions0
731 Cleaning and washing0
732 High-pressure washers0
733 Degreasing agents0
734 Cleaning the exterior0
735 Cleaning the chain0
736 Cleaning the motor compartment0
737 Electric components0
74 Checks for cracks0
741 Visual inspection0
742 Crack detection0
Crack detection with liquid penetrant0
Crack detection with magnetic yoke0
75 Periodic maintenance0
751 Every 500 operating hours/180 days0
752 Every 1000 operating hours/360 days0
753 Every 2000 operating hours/720 days0
754 Every 3000 operating hours/1080 days0
755 Every 5000 operating hours/1800 days0
756 Annual status inspection0
76 Maintenance instructions0
761 Cleaning and washing0
High-pressure washers0
Degreasing agents0
Cleaning the exterior0
Cleaning the chain0
Cleaning the motor compartment0
Electric components0
8 – Troubleshooting0
81 Abbreviations used in this section0
82 Truck help functions0
821 Error log menu0
Description0
Access0
822 Error information menu0
Description0
Access0
823 Diagnostic screens0
Access0
State 1 – Voltage from the control console levers0
State 2 – Digital signals from the truck control to CID0
State 3 – Voltage from control/sensor to MCU0
State 4 – Digital input signals to MCU0
State 5 – Digital output signals from MCU0
State 6 – PWM output signals from MCU0
State 7 – FCU (not used)0
State 8 – FCU (not used)0
State 9 – GFU (not used)0
State 10 – GFU (not used)0
State 11 – Temperature signals0
State 12 – Voltage levels0
State 13 – Travel information0
State 14 – Steering information0
State 15 – Lift/lowering information0
Stage 16 – Reach movement information0
Stage 17 – Hydraulic information0
State 18 – VNA (not used)0
State 19 – Pressure sensor for free and main lifts0
83 Initial troubleshooting0
84 Troubleshooting using blocking symbol0
85 Troubleshooting using error codes0
851 CID, warnings and errors0
852 MCU and other warnings and errors0
853 Drive system error0
854 Hydraulic system error0
855 Steering system, warnings and errors0
856 External systems0
86 Troubleshooting without indications0
861 Mechanical brake (3000)0
862 Steering (4000)0
863 Telescopic forks0
864 Log on was normal, but one or several functions cannot be used0
9 – Frame/Chassis 00000
91 General0
92 Motor hood (0340)0
921 Opening the motor compartment0
RRE 140-RRE 2500
Replacing the motor cover0
Adjusting the motor cover0
Method0
93 Battery compartment components (0390)0
931 Adjusting the battery tray0
932 Adjusting the battery tray from serial number 6229952-0
94 Operator’s cabin (0500)0
941 Tilting the cab RRE 140 – 250 Ergo0
942 Ergoled0
Disassembly0
95 Assembly0
951 Cab windows (0530)0
Fitting a window0
952 Cab door (0550)0
Disassembly of the door lock0
Method0
96 Cab heating/ventilation C06300
961 Replacing the air filter on the cold store cab0
962 Replacement of wiring harness with potentiometer0
963 Replacing the air outlet0
964 Climate control knobs0
Disassembly of the lock device0
Method0
97 Operator’s compartment (0600)0
971 Adjusting the seat:0
Seat heater button (Option)0
972 Replacing the seat assembly0
Method0
973 Replacing the seat assembly, Basic0
Removing the operator’s seat (Basic)0
Fitting the operator’s seat (Basic)0
974 Replacing the seat switch0
Method0
975 Replacing the back rest0
Method0
976 Replacing the chair seat0
Method0
977 Replacing the seat heater switch0
Method0
978 Installing the safety belt/armrest (Option)0
Method0
979 Cab heating/ventilation (0630)0
Replacing the air filter on the cold store cabin:0
Removing the fan and heater0
Replacing the potentiometers0
9710 Internal fittings (0680)0
9711 Disassembly/assembly of floor plate, B version 06800
98 Operator controls (mechanical) C06400
981 Replacing pedals0
Method0
99 Overhead guard/roof C08100
991 Overview0
992 Removing the overhead guard0
Method0
993 Fastening the overhead guard0
Method0
994 Removing the roof cassette0
Method0
995 Fastening the roof cassette0
Method0
910 Finger/foot guards C08200
9101 Replacing a figure guard0
Method0
911 Operator protection C08400
9111 Replacing the fender0
Method0
912 Safety equipment (0800)0
9121 Checking the overhead guard (0810)0
9122 Adjusting the support lugs (0840)0
10 – Motors 10000
101 Motor sensors0
1011 Temperature sensor0
Retrofitting of external temperature sensor0
1012 Replacing the rotational speed sensor0
102 Pump motor (1710)0
1021 General0
Disassembled pump motor0
1022 Replacing the bearing on the pump motor0
Dismantling the pump motor0
Assembling the pump motor0
103 Steering motor and steering unit (1730)0
1031 General0
1032 Layout of the flange holes0
1033 Removing the steering motor from the truck0
1034 Mounting a steering motor in the truck0
104 Fan motor/fan (1740)0
1041 General0
1042 Replacing the frequency converter cooling fan0
Standard truck:0
Ergotruck0
1043 Replacing the motor compartment cooling fan0
105 Drive motor (1760)0
1051 General0
Disassembled drive motor0
1052 Removing the drive motor from the truck0
1053 Dismantling the drive motor0
1054 Cleaning0
1055 Assembling the drive motor0
1056 Mounting the drive motor in the truck0
11 – Drive gear 20000
111 General0
112 Repair- and serviceability0
113 Measures0
1131 Checking the oil level0
1132 Oil change0
Oil refill table0
1133 Leakage from the bottom cover0
1134 Replacing the drive gear0
Special tools0
Exposing the drive gear0
Removing a drive motor from the truck0
Removing a steering motor from the truck0
Removing the drive gear from the truck0
Fit the drive gear back in the truck0
Placing the steering motor in the truck0
Placing the drive motor in the truck0
Concluding work0
12 – Brake and wheel 30000
121 Travel brake system (3100)0
1211 Removing the support arm’s multiple disc brake0
1212 Dismantling the multiple disc brake0
Inspection0
Adjusting clearance0
Assembling the multiple disc brake0
1213 Installing the multiple disc brake in the truck0
122 Single disk brake support arm0
1221 Removing the brake disc from the wheel0
1222 Fitting the brake disc in the wheel0
1223 Install the support arm electro- magnetic brake0
1224 Removing the brake, RRE160R0
1225 Removing the brake disc from the hub, RRE160R0
1226 Fitting a new brake disc on the hub, RRE160R0
1227 Fitting the brake in the support arm, RRE160R0
1228 Checking the wheel brake’s brake force0
123 Parking brake (3300)0
1231 General0
1232 Emergency release of the parking brake0
1233 Check of braking force0
Up to and including serial number 63083940
From and including serial number 63083950
1234 Removing the parking brake from the truck0
Disassembly and inspection of wear0
Method0
Adjusting the air gap0
Method0
1235 Installing the parking brake in the truck0
124 Drive wheel (3530)0
1241 General0
1242 Removing the drive wheel from the truck0
1243 Installing the drive wheel on the truck0
125 Wheel studs (3530)0
General0
1251 Wheel stud replacement0
126 Support arm wheel (3550)0
1261 Removing the support arm wheel from the truck0
1262 Removing the support arm wheel, RRE160R0
1263 Replacing wheel bearings, RRE160R0
1264 Fitting a support arm wheel to the truck, RRE160R0
1265 Replacing a wheel bearing – braked wheel (A)0
Version with disc brake0
1266 Replacing a wheel bearing – unbraked wheel (B)0
1267 Fitting a support arm wheel to the truck0
1268 Support arm wheel, (280mm wheel with 1050mm support arm width)0
General0
1269 Dismantling the wheel0
12610 Fitting the support arm wheel0
12611 Dismantling the wheel bearings0
12612 Assembling the wheel bearings0
12613 Wheel wear0
13 – Steering system 40000
131 Electric steering wheel (4310)0
1311 General0
1312 Replacing the steering wheel0
1313 Replacing the steering wheel knob0
1314 Replacing the pulse transducer on the steering wheel module0
1315 Removing the steering console from the truck0
1316 Replacing the wiring harness in the steering console0
1317 Fit the steering console in the truck0
132 Steering reference sensor (4350)0
General0
1321 Replacing the reference sensor [B17]0
133 Steering bearings (4380)0
1331 Steering bearing0
Replacing the steering bearing0
Method0
14 – Electrical system 50000
141 Battery (5110)0
1411 Battery recommendation0
Exide gel batteries (eg Sonnenschein)0
Hawker Evolution gel batteries0
Lithium-ion batteries (Li-ion)0
1412 Battery installation0
Replacement/installation of battery0
Procedure without battery changing table0
Procedure with battery changing table0
1413 Replacing/installing the lithium-ion battery0
Battery replacement0
1414 Installation of electrolyte mixing, fixed battery0
1415 Installation of electrolyte mixing, battery replacement0
142 LID (5200)0
1421 Replacing the LID0
1422 Replacing the LID cold store cab0
143 Replacing pedals (5300)0
1431 Accelerator and brake pedal0
1432 Safety pedal0
144 Control console (5510)0
1441 General0
1442 Replacement/installation of a control0
1443 Replacing the multi-function control0
Replacing the multi-function control’s buttons0
1444 Removing the control console from the truck0
1445 Replacing the access card’s circuit board0
1446 Dismantling the control console0
Installing an extra push button0
Replacing the travel direction selector with signal button0
Replacing the display0
1447 Assembling the control console0
1448 Placing the control console in the truck0
145 Magnetic sensor (5850)0
General0
1451 Replacing the magnetic sensor [B47]0
1452 Reference magnet0
146 Parameter settings0
1461 Configuration menu0
Calendar/hour counter menu0
Parameter menu (PAR)0
Setting driver parameters0
147 PIN menu0
1471 Activate PIN block menu0
1472 Menu for programming a PIN (P)0
148 Calibrations0
1481 Calibrating the hydraulic function control0
1482 Height measurement/reach movement length calibration0
Calibrating height measurement (option)0
1483 Valve calibration0
Lift valve calibration0
Lowering valve calibration with height indication0
Lowering calibration without height indication0
Reach movement valve calibration0
Calibration of the Ergo cabin0
1484 Weight calibration0
Calibrating the weight indicator0
149 Replacing the wiring harness0
1410 main computer unit MCU (A5)0
14101 Installing a new card in the truck0
14102 Power supply0
14103 Battery negative0
14104 Internal status monitoring0
14105 Resetting the battery indicator0
15 – Hydraulic system 60000
151 Hydraulic hygiene0
1511 Washing0
1512 Packaging0
1513 Handling0
1514 Storage0
1515 Work procedures0
152 Hydraulic unit (6100)0
1521 Hydraulic tank, emptying0
1522 Hydraulic system, bleeding0
1523 Filter0
Overview0
Filter replacement (for air and oil)0
Method0
1524 Removing the pump motor from the truck0
1525 Replacing the hydraulic pump or the O- Ring0
1526 Fitting the pump motor in the truck0
153 Main valve (6210)0
1531 Emergency lowering of the forks0
1532 Replacing the main valve block0
1533 Replacing the lifting/lowering valves0
Overview0
Method0
1534 Adjusting the maximum opening pressure0
154 Hydraulic connections (6230)0
1541 Tightening torques for hydraulic connections0
Tapered coupling with O-ring0
Tredo seal0
Pipe coupling0
1542 Quick change connectors0
Overview0
Assembly0
Disassembly0
155 Hydraulic system, mast (6300)0
1551 Mast-mounted hose reel (6370)0
General0
1552 Fitting the hose reel0
Spring preloading (turns)0
1553 Checks after fitting0
156 Main lift cylinder 66100
General0
1561 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
1562 Removing the air cylinder from the mast0
1563 Replacing the hose rupture valve0
1564 Dismantling the cylinder0
Method0
1565 Dismantling the piston0
Method0
1566 Dismantling the cylinder head0
Method0
1567 Fitting the cylinder head seals0
Method0
1568 Fitting the piston seals0
Method0
1569 Assembling the cylinder0
Method0
15610 Assembling a mast cylinder0
157 Free lift cylinder (6620)0
General0
1571 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
1572 Removing the free lift cylinder from the truck0
1573 Replacing the hose rupture valve, free lift cylinder0
1574 Dismantling the cylinder0
Method0
1575 Dismantling the piston0
Method0
1576 Dismantling the cylinder head0
Method0
1577 Fitting the cylinder head seals0
Method0
1578 Fitting the piston seals0
Method0
1579 Assembling the cylinder0
Method0
15710 Assembling the free lift cylinder in the mast0
158 Reach cylinder (6650)0
1581 General0
1582 Removing the reach cylinder from the truck0
1583 Fitting the reach cylinder in the truck0
159 Fork tilt cylinder (6660)0
1591 General0
1592 Dismantling the tilting cylinder0
Mast with valve on the fork carriage0
Method0
1593 Removing a tilt cylinder from truck number 6395129-0
Mast with valve on the fork carriage0
Mast without valve on the fork carriage:0
Method0
1594 Mounting the tilting cylinder0
Mast with valve on the fork carriage0
Method0
Mast without valve on the fork carriage:0
Method0
1595 Mounting a tilt cylinder, from truck number 6395129-0
Mast with valve on the fork carriage0
1510 Cab tilt cylinder (6660)0
15101 General0
15102 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
15103 Dismantling the cylinder0
Method0
15104 Removing the piston rod0
Method0
15105 Dismantling the cylinder head0
Method0
15106 Fitting the cylinder head seals0
Method0
15107 Mounting the piston rod0
Method0
15108 Assembling the cylinder0
Method0
1511 Sideshift cylinder (6670)0
15111 General0
15112 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
15113 Dismantling the cylinder from the truck0
Method0
15114 Dismantling the cylinder0
Method0
15115 Removing the piston rod0
Method0
15116 Dismantling the cylinder head0
Method0
15117 Fitting the cylinder head seals0
Method0
15118 Mounting the piston rod0
Method0
15119 Assembling the cylinder0
Method0
151110 Refitting the cylinder in the truck0
16 – Mast/Lift system 70000
161 General0
162 Checking the chain0
1621 Noise0
1622 Surface rust0
1623 Rusty links0
1624 Stiff links0
1625 Bolt rotation0
1626 Loose bolts0
1627 Outline wear0
1628 Stretching0
1629 Damage0
16210 Damaged plates0
16211 Damaged bolts0
16212 Dirty chain0
163 Lubricating the chain0
164 Adjustment0
165 Main mast 16-25 t (7100)0
1651 Replacing the full mast0
1652 Remove the mast from the truck0
1653 Adjusting mast clearance0
General0
Preparations0
Adjusting lateral clearance0
Adjustment of radial clearance0
Adjusting the damper parts0
Adjusting the damper plate0
Refitting the mast0
1654 Replacing the mast damper plates0
1655 Replacing the free lift chain0
Removing the free lift chain0
Fitting the free lift chain0
Checking the chain bolt angle0
1656 Assembly of frame on truck0
166 Main lift chain system (7120)0
1661 Main lift chain system, adjusting the fork- to-floor distance0
167 Reach carriage (7190)0
Overview:0
1671 Adjusting the radial clearance in the reach carriage0
1672 Adjusting the axial clearance in the reach carriage0
168 Lifting devices (7400)0
1681 Forks0
General0
Inspection0
Inspection intervals0
Surface cracks0
Difference in height between the fork tips0
Position lock0
Readability of the markings0
Fork blades and back of fork carriage0
Mounting fixtures on the fork0
1682 Forks, repairs and testing0
Repairs0
Testing the yield point0
Fork0
169 Fork carriage0
1691 Checking the fork carriage’s wear strip0
1692 Lubricating the fork carriage0
1610 Fork spread unit0
16101 Servicing the fork spread unit0
Replacing the bearing0
Roller replacement0
1611 Fork extensions with adjustable fork length0
1612 Manual shuttle forks0
16121 Assembly0
16122 Maintenance0
1613 Hydraulic shuttle forks0
16131 Shuttle forks with separate flow dividers0
Fitting instructions0
Initial operation of shuttle forks with separate flow dividers0
16132 Shuttle forks with integrated flow dividers0
Fitting instructions0
Initial operation of shuttle forks with integrated flow dividers0
16133 Maintenance of shuttle forks0
16134 Wear0
16135 Wear plate welding information0
16136 Dismantling shuttle forks0
16137 Shuttle fork assembly0
17 – Peripherals – 80000
171 Introduction0
18 – Optional equipment – 90000
181 Smart Access 2 (SA2)0
1811 Replacing SA 20
Removing SA 20
Mounting the SA 20
182 Pre-Op Check0
1821 Replacing the Pre-Op Check0
Removing the Pre-Op Check0
Mounting the Pre-Op Check0
19 – Appendix “Destruction instructions”0
191 General0
192 Marking of plastics0
1921 General marking of products and packaging0
1922 Marking according to Standard0
Abbreviations0
Marking examples0
193 Pressure vessels0
1931 Gas struts0
194 Sorting categories0
20 – Wiring diagram0
201 Components0
202 Component location0
Figure 1 (Fork carriage)0
Figure 2 (Chassis wiring harness)0
Figure 3 (Chassis wiring harness)0
Figure 4 (Support leg brake)0
Figure 5 (Pedals)0
Figure 6 (Motor wiring harness)0
Figure 7 (Reach carriage wiring harness)0
Figure 8 (Level/position meter)0
Figure 9 (seat)0
Figure 10 (DC/DC)0
Figure 11 (Driver position wiring harness)0
Figure 12 (Extra hydraulic function(s))0
Figure 13 (Travel alarm)0
Figure 14 (Roof wiring harness)0
Figure 15 (Roof)0
Figure 16 (Sound system)0
Figure 17 (Forks camera)0
Figure 18 (Battery harness)0
Figure 19 (Fuse box)0
Figure 20 (LID)0
Figure 21 (Mast wiring harness)0
Figure 22 (Fork carriage wiring harness)0
Figure 23 (Reach carriage wiring harness options)0
Figure 24 (Working light wiring harness)0
Figure 25 (Extra outlet DC)0
Figure 26 (TWIS)0
Figure 27 (Shock Switch / Impact Manager)0
Figure 28 (Heated windows CC)0
Figure 29 (Cabling driver position CC)0
Figure 30 (Heater CC)0
Figure 31 (Cab heater wiring harness CC)0
Figure 32 (Safety switch for door CC)0
Figure 33 (Cab tilt wiring harness)0
Figure 34 (Control panel)0
Figure 35 (Control panel)0
Figure 36 (Steering arm)0
Figure 37 (MCU)0
Figure 38 (Control motor)0
Figure 39 (Main valve block)0
Figure 40 (Li-ion wiring harness)0
203 Cable connections and terminal posts0
2031 ACT/ACH transistor regulators0
2032 Connections to CID0
2033 Connections on the MCU0
204 Fuse box A90
205 Overview0
206 Details up to and including serial no 62068000
207 Detailed diagram cold-store cab0
21 – Hydraulics schematics0
211 Main valve unit0
2111 RRE Std0
2112 RRE Ergo0
212 Hydraulic diagrams0
2121 Schematics designations0
2122 List of symbols0
2123 Wiring diagrams RRE/RRE Ergo0
22 – Tools0
221 AMP connectors0
222 MQS connectors0
223 CPC contacts0
224 Other tools0
23 – Appendix “Service data and grease specifications”0
231 General tightening torques0
2311 Galvanised, non-oiled screws0
2312 Untreated, oiled screws0
232 Lubricants specification0
24 – Technical data0
Mast, maximum weight and maximum height01 – Table of contents0
2 – General introduction0
21 How to use this manual0
22 Warning symbols0
23 Pictograms0
3 – General safety rules0
31 Work safety0
32 Electrical system0
33 Safe lifting0
4 – Descriptions of functions0
41 Chassis 00000
411 Operator’s cabin (0500)0
Versions for cold-store cabs0
Emergency exit from the cab0
412 Cab windows (0530)0
Electrically heated windows0
413 Operator’s seat (0620)0
Adjustment:0
Button for seat heater0
414 Cab heating/ventilation (0630)0
Climate control knobs0
Ventilation0
Temperature0
415 Operator protection (0840)0
Studs0
Protective overhead guard0
42 Motors 10000
421 General0
422 Electric pump motor (1710)0
General0
Construction0
423 Electric steering motor (1730)0
General0
Construction0
424 Fan motor/fan (1740)0
425 Electric drive motor (1760)0
General0
Construction0
43 Drive gear – 20000
431 General0
432 Construction0
44 Brake system 31000
441 General0
Travel brake0
Parking brake0
Emergency brake0
442 Drive motor brake (travel brake)0
Accelerator released0
Changing the direction of travel0
443 Multiple disc brake, support arm (travel brake)0
General0
Construction0
444 Disc brake in support arm wheels (travel brake)0
General0
Construction0
445 Disc brake on the drive motor (parking brake)0
General0
Construction0
45 Steering system 40000
451 General0
452 Construction0
453 Sensor0
Steering reference sensor0
46 Operation area0
461 Truck control, overview0
Right-hand control panel, single control0
Right-hand control panel, multi-control0
Emergency switch off0
Steering wheel module0
Pedals0
462 Single-function control0
463 Multi-function control0
464 Central Information Display – CID0
Navigation0
LED symbols0
Information symbols0
Driver parameter symbols – Overview0
Blocking symbols – Overview0
Service symbols – Overview0
Service functions0
Calibration functions0
Configuration functions0
Other functions0
465 Load Information Display – LID (option)0
LED symbols0
Symbols in the display part0
47 sensors and sensors (5800)0
471 Inductive sensors0
472 Position sensor0
473 Magnetic sensor0
48 Operation and connection sequences0
49 Functions0
491 General overview0
Terminology0
Components0
492 MCU – main control unit0
General0
Downloading software0
System communication0
493 ACT/ACH regulators0
General0
494 Start-up0
495 Shutdown0
496 Driving0
Introduction0
Acceleration and speed reduction0
Reversing0
Brakes0
Travel speed0
497 OTP0
Travel speed reduction – steering angle0
Travel speed reduction – extension of reach carriage0
Speed reduction – main lift range0
Prevention of lifting/lowering the forks0
Reduced extension speed0
498 Steering0
Steering position control0
Steering speed0
Steering reference0
Travel speed limitation0
Compass rose0
499 Hydraulic system0
Definitions0
Controls0
Lift0
Reach movement0
Lift height limitation0
Maximum height limitation0
Auxiliary/Extra functions (option)0
410 Height preselector, description of function0
4101 Using the height preselector0
4102 Symbols0
4103 Travel warning0
4104 Height preselector levels0
4105 Level selection0
4106 Height programming0
4107 Height preselector and TruckCom0
4108 Lift/lowering movement0
4109 Parameter settings braking at height preselector0
411 Hydraulic system 60000
4111 General0
4112 Tank0
4113 Filter0
Return filter0
Dehumidification filter0
4114 Hydraulic pump0
4115 Valve unit0
Main valve block0
Second valve block0
4116 Cylinders0
Main lift cylinders0
Free-lift cylinder0
Cylinders for the reach movement, cabin tilt, sideshift and fork tilt0
4117 Lift and lowering function0
Lifting and lowering of free lift0
Transition from free lift to main lift0
Lifting and lowering of main lift0
Reach movement, in and out0
Simultaneous operation of Mast lift and Reach movement0
4118 Extra functions0
4119 Cabin tilt (RRE Ergo)0
Hydraulic priority system0
Cabin tilt (RRE Ergo) during servicing0
Cabin tilt in the event of hydraulic or electrical power loss0
412 Mast 70000
4121 Mast and reach carriage0
413 Lifting devices0
4131 Fork extensions0
4132 Telescopic forks0
414 Accessories 90000
4141 Radio equipment0
4142 Extra lighting0
4143 Extra warning lights/alarm0
4144 Turn signal lights0
4145 Movement alarm0
4146 Positioning-/TV equipment0
4147 Extra electrical equipment0
4148 Other extra equipment0
Fork spacers0
Load support0
E-bar0
Fire extinguisher0
5 – Parameters0
51 General0
52 Displaying/changing parameters0
53 Operator parameters0
531 Overview0
532 Connection to logged-in operator0
533 Description0
Parameter 1 – Steering0
Parameter 2, 3 – Maximum travel speed0
Parameters 4 and 5 – Acceleration/Deceleration0
Parameter 6 – Cab tilt0
54 General service parameters0
541 Overview0
542 Description0
Parameter 101/104 – Service/Log-out0
Parameter 105/106/114/115/117 (Travel alarms 1 and 2)0
Parameter 107/108 – Battery0
Parameter 109/110/111/112 – Collision sensor0
Parameter 113 (shunt value)0
Parameter 116 (Door on cold store cabs)0
55 Service parameters, travel functions0
551 Overview0
552 Description0
Parameter 201 – Retardation when reversing0
Parameters 202/203/204 – Adjusting erroneous, maximum travel speeds0
Parameters 205/206/207 – Adjusting function-related, maximum travel speeds0
Parameter 208 – Creep speed in travel direction control0
Parameter 209/210 – Reduced maximum travel speed above a certain lift height0
Parameter 211/212 – Reduced maximum travel speed with a certain reach length0
Parameter 213 – Permanently reduced maximum travel speed0
Parameter 214 – Adjusting the maximum travel speed in main lift range0
Parameter 215/216/217 – Adjusting OTP speed and starting and finishing angles0
56 Service parameters, hydraulics0
561 Overview0
562 Description0
Parameters 301/302/303/304/333 – Extra valve function0
Parameters 305/306/307/308/334 – Maximum oil pressure through valve Q80
Parameters 313/314/315/316/336 – Closing time0
Parameters 317/318/319/320/337 – Maximum oil flow through valve Q80
Parameters 321/322/323/324/338 – Maximum oil flow through valve Q90
Parameters 325/326/327/328/339 – Opening/closing time for valve Q80
Parameters 329/330/331/332/340 – Opening/closing time for valve Q90
Parameters 333/334 Setting of additional security hydraulic function0
Parameter 341/342 – Reducing the lifting/lowering speed0
Parameter 343 – Reduction of reach speed0
Parameter 344 – Reduction of fork lowering speed before floor level0
Parameter 345- Lift/lower sensitivity0
Parameter 346- Ramping for hydraulic functions Lifting, Lowering and Reach in/out0
Parameter 347/348 – Prevent the lifting/lowering of forks0
Parameter 349 – Fork weight0
Parameter 350 – Multi-function0
Parameters 351/352 Setting of button for additional security hydraulic function0
Parameters 353/354/400 Soft lift0
Parameters 356/357 Active draining0
Parameters 358/359/360 – Deactivation of hydraulic functions0
Parameters 361/362/363/364/365 /366 – Function related, maximum lifting/lowering speeds0
Parameter 367/368 – Fork limit for deactivating the extension of the fork carriage and for sideshift0
Parameter 369 through 379 – Height preselector0
Parameter 380/381 – Lift height limitations0
Parameters 387/388 – Configuring lift height limitations0
Parameters 395/396/397 – Function-related, maximum lift heights0
Parameters 398/399 – Operator profile dependent, maximum lift heights0
57 Service parameters, CID0
571 Overview0
572 Description0
Parameter 503 – Login method0
Parameters 504/505/506/507 – Smart Access0
Parameter 508/509/512/513/514 – CID configuration0
Parameters 510/511 – Height pre-selection0
58 General factory parameters0
581 Overview0
582 Description0
Parameter 1001 – Truck type0
Parameter 1002 – (Drive motor)0
Parameter 1003 – Pedal type0
Parameter 1004 – Steering servo0
Parameter 1005 – Pump motor0
Parameter 1006 – Hydraulic pump0
Parameter 1007 – Activation of hydraulic levers0
Parameter 1008 – Mast type0
Parameter 1009 – Height indication0
Parameter 1010 – Weight indication0
59 Factory parameters, activation of options0
591 Overview0
Parameter 1115 (Steering angle)0
Parameter 1116 (Extended mast)0
Parameter 1117 (Weight of load and fork height)0
Parameter 1118 (Main lift range)0
Parameter 1131 – Adjusting the maximum travel speed in main lift range0
592 Description0
510 Factory parameters, calibration0
6 – Installation0
61 Transporting the truck0
62 Transporting the mast0
63 Transporting the truck0
Method 10
Method 20
64 Commissioning0
641 Tools0
642 Battery0
Placing the battery0
Battery parameters0
643 Mast, fitting0
65 Bleeding the air from the hydraulic system0
651 Parameters on initial operation0
Load indicator0
Ergo cab0
Cold store cabin0
652 Parameters for optional equipment0
Height measurement (option)0
Travel speed limitation, height-dependent0
Travel speed limitation, reach movement dependent0
Travel speed limitation, parameter-dependent0
Collision sensor0
7 – Maintenance0
71 Introduction, maintenance0
72 Safety precautions for maintenance work0
73 Maintenance instructions0
731 Cleaning and washing0
732 High-pressure washers0
733 Degreasing agents0
734 Cleaning the exterior0
735 Cleaning the chain0
736 Cleaning the motor compartment0
737 Electric components0
74 Checks for cracks0
741 Visual inspection0
742 Crack detection0
Crack detection with liquid penetrant0
Crack detection with magnetic yoke0
75 Periodic maintenance0
751 Every 500 operating hours/180 days0
752 Every 1000 operating hours/360 days0
753 Every 2000 operating hours/720 days0
754 Every 3000 operating hours/1080 days0
755 Every 5000 operating hours/1800 days0
756 Annual status inspection0
76 Maintenance instructions0
761 Cleaning and washing0
High-pressure washers0
Degreasing agents0
Cleaning the exterior0
Cleaning the chain0
Cleaning the motor compartment0
Electric components0
8 – Troubleshooting0
81 Abbreviations used in this section0
82 Truck help functions0
821 Error log menu0
Description0
Access0
822 Error information menu0
Description0
Access0
823 Diagnostic screens0
Access0
State 1 – Voltage from the control console levers0
State 2 – Digital signals from the truck control to CID0
State 3 – Voltage from control/sensor to MCU0
State 4 – Digital input signals to MCU0
State 5 – Digital output signals from MCU0
State 6 – PWM output signals from MCU0
State 7 – FCU (not used)0
State 8 – FCU (not used)0
State 9 – GFU (not used)0
State 10 – GFU (not used)0
State 11 – Temperature signals0
State 12 – Voltage levels0
State 13 – Travel information0
State 14 – Steering information0
State 15 – Lift/lowering information0
Stage 16 – Reach movement information0
Stage 17 – Hydraulic information0
State 18 – VNA (not used)0
State 19 – Pressure sensor for free and main lifts0
83 Initial troubleshooting0
84 Troubleshooting using blocking symbol0
85 Troubleshooting using error codes0
851 CID, warnings and errors0
852 MCU and other warnings and errors0
853 Drive system error0
854 Hydraulic system error0
855 Steering system, warnings and errors0
856 External systems0
86 Troubleshooting without indications0
861 Mechanical brake (3000)0
862 Steering (4000)0
863 Telescopic forks0
864 Log on was normal, but one or several functions cannot be used0
9 – Frame/Chassis 00000
91 General0
92 Motor hood (0340)0
921 Opening the motor compartment0
RRE 140-RRE 2500
Replacing the motor cover0
Adjusting the motor cover0
Method0
93 Battery compartment components (0390)0
931 Adjusting the battery tray0
932 Adjusting the battery tray from serial number 6229952-0
94 Operator’s cabin (0500)0
941 Tilting the cab RRE 140 – 250 Ergo0
942 Ergoled0
Disassembly0
95 Assembly0
951 Cab windows (0530)0
Fitting a window0
952 Cab door (0550)0
Disassembly of the door lock0
Method0
96 Cab heating/ventilation C06300
961 Replacing the air filter on the cold store cab0
962 Replacement of wiring harness with potentiometer0
963 Replacing the air outlet0
964 Climate control knobs0
Disassembly of the lock device0
Method0
97 Operator’s compartment (0600)0
971 Adjusting the seat:0
Seat heater button (Option)0
972 Replacing the seat assembly0
Method0
973 Replacing the seat assembly, Basic0
Removing the operator’s seat (Basic)0
Fitting the operator’s seat (Basic)0
974 Replacing the seat switch0
Method0
975 Replacing the back rest0
Method0
976 Replacing the chair seat0
Method0
977 Replacing the seat heater switch0
Method0
978 Installing the safety belt/armrest (Option)0
Method0
979 Cab heating/ventilation (0630)0
Replacing the air filter on the cold store cabin:0
Removing the fan and heater0
Replacing the potentiometers0
9710 Internal fittings (0680)0
9711 Disassembly/assembly of floor plate, B version 06800
98 Operator controls (mechanical) C06400
981 Replacing pedals0
Method0
99 Overhead guard/roof C08100
991 Overview0
992 Removing the overhead guard0
Method0
993 Fastening the overhead guard0
Method0
994 Removing the roof cassette0
Method0
995 Fastening the roof cassette0
Method0
910 Finger/foot guards C08200
9101 Replacing a figure guard0
Method0
911 Operator protection C08400
9111 Replacing the fender0
Method0
912 Safety equipment (0800)0
9121 Checking the overhead guard (0810)0
9122 Adjusting the support lugs (0840)0
10 – Motors 10000
101 Motor sensors0
1011 Temperature sensor0
Retrofitting of external temperature sensor0
1012 Replacing the rotational speed sensor0
102 Pump motor (1710)0
1021 General0
Disassembled pump motor0
1022 Replacing the bearing on the pump motor0
Dismantling the pump motor0
Assembling the pump motor0
103 Steering motor and steering unit (1730)0
1031 General0
1032 Layout of the flange holes0
1033 Removing the steering motor from the truck0
1034 Mounting a steering motor in the truck0
104 Fan motor/fan (1740)0
1041 General0
1042 Replacing the frequency converter cooling fan0
Standard truck:0
Ergotruck0
1043 Replacing the motor compartment cooling fan0
105 Drive motor (1760)0
1051 General0
Disassembled drive motor0
1052 Removing the drive motor from the truck0
1053 Dismantling the drive motor0
1054 Cleaning0
1055 Assembling the drive motor0
1056 Mounting the drive motor in the truck0
11 – Drive gear 20000
111 General0
112 Repair- and serviceability0
113 Measures0
1131 Checking the oil level0
1132 Oil change0
Oil refill table0
1133 Leakage from the bottom cover0
1134 Replacing the drive gear0
Special tools0
Exposing the drive gear0
Removing a drive motor from the truck0
Removing a steering motor from the truck0
Removing the drive gear from the truck0
Fit the drive gear back in the truck0
Placing the steering motor in the truck0
Placing the drive motor in the truck0
Concluding work0
12 – Brake and wheel 30000
121 Travel brake system (3100)0
1211 Removing the support arm’s multiple disc brake0
1212 Dismantling the multiple disc brake0
Inspection0
Adjusting clearance0
Assembling the multiple disc brake0
1213 Installing the multiple disc brake in the truck0
122 Single disk brake support arm0
1221 Removing the brake disc from the wheel0
1222 Fitting the brake disc in the wheel0
1223 Install the support arm electro- magnetic brake0
1224 Removing the brake, RRE160R0
1225 Removing the brake disc from the hub, RRE160R0
1226 Fitting a new brake disc on the hub, RRE160R0
1227 Fitting the brake in the support arm, RRE160R0
1228 Checking the wheel brake’s brake force0
123 Parking brake (3300)0
1231 General0
1232 Emergency release of the parking brake0
1233 Check of braking force0
Up to and including serial number 63083940
From and including serial number 63083950
1234 Removing the parking brake from the truck0
Disassembly and inspection of wear0
Method0
Adjusting the air gap0
Method0
1235 Installing the parking brake in the truck0
124 Drive wheel (3530)0
1241 General0
1242 Removing the drive wheel from the truck0
1243 Installing the drive wheel on the truck0
125 Wheel studs (3530)0
General0
1251 Wheel stud replacement0
126 Support arm wheel (3550)0
1261 Removing the support arm wheel from the truck0
1262 Removing the support arm wheel, RRE160R0
1263 Replacing wheel bearings, RRE160R0
1264 Fitting a support arm wheel to the truck, RRE160R0
1265 Replacing a wheel bearing – braked wheel (A)0
Version with disc brake0
1266 Replacing a wheel bearing – unbraked wheel (B)0
1267 Fitting a support arm wheel to the truck0
1268 Support arm wheel, (280mm wheel with 1050mm support arm width)0
General0
1269 Dismantling the wheel0
12610 Fitting the support arm wheel0
12611 Dismantling the wheel bearings0
12612 Assembling the wheel bearings0
12613 Wheel wear0
13 – Steering system 40000
131 Electric steering wheel (4310)0
1311 General0
1312 Replacing the steering wheel0
1313 Replacing the steering wheel knob0
1314 Replacing the pulse transducer on the steering wheel module0
1315 Removing the steering console from the truck0
1316 Replacing the wiring harness in the steering console0
1317 Fit the steering console in the truck0
132 Steering reference sensor (4350)0
General0
1321 Replacing the reference sensor [B17]0
133 Steering bearings (4380)0
1331 Steering bearing0
Replacing the steering bearing0
Method0
14 – Electrical system 50000
141 Battery (5110)0
1411 Battery recommendation0
Exide gel batteries (eg Sonnenschein)0
Hawker Evolution gel batteries0
Lithium-ion batteries (Li-ion)0
1412 Battery installation0
Replacement/installation of battery0
Procedure without battery changing table0
Procedure with battery changing table0
1413 Replacing/installing the lithium-ion battery0
Battery replacement0
1414 Installation of electrolyte mixing, fixed battery0
1415 Installation of electrolyte mixing, battery replacement0
142 LID (5200)0
1421 Replacing the LID0
1422 Replacing the LID cold store cab0
143 Replacing pedals (5300)0
1431 Accelerator and brake pedal0
1432 Safety pedal0
144 Control console (5510)0
1441 General0
1442 Replacement/installation of a control0
1443 Replacing the multi-function control0
Replacing the multi-function control’s buttons0
1444 Removing the control console from the truck0
1445 Replacing the access card’s circuit board0
1446 Dismantling the control console0
Installing an extra push button0
Replacing the travel direction selector with signal button0
Replacing the display0
1447 Assembling the control console0
1448 Placing the control console in the truck0
145 Magnetic sensor (5850)0
General0
1451 Replacing the magnetic sensor [B47]0
1452 Reference magnet0
146 Parameter settings0
1461 Configuration menu0
Calendar/hour counter menu0
Parameter menu (PAR)0
Setting driver parameters0
147 PIN menu0
1471 Activate PIN block menu0
1472 Menu for programming a PIN (P)0
148 Calibrations0
1481 Calibrating the hydraulic function control0
1482 Height measurement/reach movement length calibration0
Calibrating height measurement (option)0
1483 Valve calibration0
Lift valve calibration0
Lowering valve calibration with height indication0
Lowering calibration without height indication0
Reach movement valve calibration0
Calibration of the Ergo cabin0
1484 Weight calibration0
Calibrating the weight indicator0
149 Replacing the wiring harness0
1410 main computer unit MCU (A5)0
14101 Installing a new card in the truck0
14102 Power supply0
14103 Battery negative0
14104 Internal status monitoring0
14105 Resetting the battery indicator0
15 – Hydraulic system 60000
151 Hydraulic hygiene0
1511 Washing0
1512 Packaging0
1513 Handling0
1514 Storage0
1515 Work procedures0
152 Hydraulic unit (6100)0
1521 Hydraulic tank, emptying0
1522 Hydraulic system, bleeding0
1523 Filter0
Overview0
Filter replacement (for air and oil)0
Method0
1524 Removing the pump motor from the truck0
1525 Replacing the hydraulic pump or the O- Ring0
1526 Fitting the pump motor in the truck0
153 Main valve (6210)0
1531 Emergency lowering of the forks0
1532 Replacing the main valve block0
1533 Replacing the lifting/lowering valves0
Overview0
Method0
1534 Adjusting the maximum opening pressure0
154 Hydraulic connections (6230)0
1541 Tightening torques for hydraulic connections0
Tapered coupling with O-ring0
Tredo seal0
Pipe coupling0
1542 Quick change connectors0
Overview0
Assembly0
Disassembly0
155 Hydraulic system, mast (6300)0
1551 Mast-mounted hose reel (6370)0
General0
1552 Fitting the hose reel0
Spring preloading (turns)0
1553 Checks after fitting0
156 Main lift cylinder 66100
General0
1561 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
1562 Removing the air cylinder from the mast0
1563 Replacing the hose rupture valve0
1564 Dismantling the cylinder0
Method0
1565 Dismantling the piston0
Method0
1566 Dismantling the cylinder head0
Method0
1567 Fitting the cylinder head seals0
Method0
1568 Fitting the piston seals0
Method0
1569 Assembling the cylinder0
Method0
15610 Assembling a mast cylinder0
157 Free lift cylinder (6620)0
General0
1571 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
1572 Removing the free lift cylinder from the truck0
1573 Replacing the hose rupture valve, free lift cylinder0
1574 Dismantling the cylinder0
Method0
1575 Dismantling the piston0
Method0
1576 Dismantling the cylinder head0
Method0
1577 Fitting the cylinder head seals0
Method0
1578 Fitting the piston seals0
Method0
1579 Assembling the cylinder0
Method0
15710 Assembling the free lift cylinder in the mast0
158 Reach cylinder (6650)0
1581 General0
1582 Removing the reach cylinder from the truck0
1583 Fitting the reach cylinder in the truck0
159 Fork tilt cylinder (6660)0
1591 General0
1592 Dismantling the tilting cylinder0
Mast with valve on the fork carriage0
Method0
1593 Removing a tilt cylinder from truck number 6395129-0
Mast with valve on the fork carriage0
Mast without valve on the fork carriage:0
Method0
1594 Mounting the tilting cylinder0
Mast with valve on the fork carriage0
Method0
Mast without valve on the fork carriage:0
Method0
1595 Mounting a tilt cylinder, from truck number 6395129-0
Mast with valve on the fork carriage0
1510 Cab tilt cylinder (6660)0
15101 General0
15102 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
15103 Dismantling the cylinder0
Method0
15104 Removing the piston rod0
Method0
15105 Dismantling the cylinder head0
Method0
15106 Fitting the cylinder head seals0
Method0
15107 Mounting the piston rod0
Method0
15108 Assembling the cylinder0
Method0
1511 Sideshift cylinder (6670)0
15111 General0
15112 Overview0
Cylinder nomenclature0
Nomenclature for cylinder head0
Nomenclature for piston0
15113 Dismantling the cylinder from the truck0
Method0
15114 Dismantling the cylinder0
Method0
15115 Removing the piston rod0
Method0
15116 Dismantling the cylinder head0
Method0
15117 Fitting the cylinder head seals0
Method0
15118 Mounting the piston rod0
Method0
15119 Assembling the cylinder0
Method0
151110 Refitting the cylinder in the truck0
16 – Mast/Lift system 70000
161 General0
162 Checking the chain0
1621 Noise0
1622 Surface rust0
1623 Rusty links0
1624 Stiff links0
1625 Bolt rotation0
1626 Loose bolts0
1627 Outline wear0
1628 Stretching0
1629 Damage0
16210 Damaged plates0
16211 Damaged bolts0
16212 Dirty chain0
163 Lubricating the chain0
164 Adjustment0
165 Main mast 16-25 t (7100)0
1651 Replacing the full mast0
1652 Remove the mast from the truck0
1653 Adjusting mast clearance0
General0
Preparations0
Adjusting lateral clearance0
Adjustment of radial clearance0
Adjusting the damper parts0
Adjusting the damper plate0
Refitting the mast0
1654 Replacing the mast damper plates0
1655 Replacing the free lift chain0
Removing the free lift chain0
Fitting the free lift chain0
Checking the chain bolt angle0
1656 Assembly of frame on truck0
166 Main lift chain system (7120)0
1661 Main lift chain system, adjusting the fork- to-floor distance0
167 Reach carriage (7190)0
Overview:0
1671 Adjusting the radial clearance in the reach carriage0
1672 Adjusting the axial clearance in the reach carriage0
168 Lifting devices (7400)0
1681 Forks0
General0
Inspection0
Inspection intervals0
Surface cracks0
Difference in height between the fork tips0
Position lock0
Readability of the markings0
Fork blades and back of fork carriage0
Mounting fixtures on the fork0
1682 Forks, repairs and testing0
Repairs0
Testing the yield point0
Fork0
169 Fork carriage0
1691 Checking the fork carriage’s wear strip0
1692 Lubricating the fork carriage0
1610 Fork spread unit0
16101 Servicing the fork spread unit0
Replacing the bearing0
Roller replacement0
1611 Fork extensions with adjustable fork length0
1612 Manual shuttle forks0
16121 Assembly0
16122 Maintenance0
1613 Hydraulic shuttle forks0
16131 Shuttle forks with separate flow dividers0
Fitting instructions0
Initial operation of shuttle forks with separate flow dividers0
16132 Shuttle forks with integrated flow dividers0
Fitting instructions0
Initial operation of shuttle forks with integrated flow dividers0
16133 Maintenance of shuttle forks0
16134 Wear0
16135 Wear plate welding information0
16136 Dismantling shuttle forks0
16137 Shuttle fork assembly0
17 – Peripherals – 80000
171 Introduction0
18 – Optional equipment – 90000
181 Smart Access 2 (SA2)0
1811 Replacing SA 20
Removing SA 20
Mounting the SA 20
182 Pre-Op Check0
1821 Replacing the Pre-Op Check0
Removing the Pre-Op Check0
Mounting the Pre-Op Check0
19 – Appendix “Destruction instructions”0
191 General0
192 Marking of plastics0
1921 General marking of products and packaging0
1922 Marking according to Standard0
Abbreviations0
Marking examples0
193 Pressure vessels0
1931 Gas struts0
194 Sorting categories0
20 – Wiring diagram0
201 Components0
202 Component location0
Figure 1 (Fork carriage)0
Figure 2 (Chassis wiring harness)0
Figure 3 (Chassis wiring harness)0
Figure 4 (Support leg brake)0
Figure 5 (Pedals)0
Figure 6 (Motor wiring harness)0
Figure 7 (Reach carriage wiring harness)0
Figure 8 (Level/position meter)0
Figure 9 (seat)0
Figure 10 (DC/DC)0
Figure 11 (Driver position wiring harness)0
Figure 12 (Extra hydraulic function(s))0
Figure 13 (Travel alarm)0
Figure 14 (Roof wiring harness)0
Figure 15 (Roof)0
Figure 16 (Sound system)0
Figure 17 (Forks camera)0
Figure 18 (Battery harness)0
Figure 19 (Fuse box)0
Figure 20 (LID)0
Figure 21 (Mast wiring harness)0
Figure 22 (Fork carriage wiring harness)0
Figure 23 (Reach carriage wiring harness options)0
Figure 24 (Working light wiring harness)0
Figure 25 (Extra outlet DC)0
Figure 26 (TWIS)0
Figure 27 (Shock Switch / Impact Manager)0
Figure 28 (Heated windows CC)0
Figure 29 (Cabling driver position CC)0
Figure 30 (Heater CC)0
Figure 31 (Cab heater wiring harness CC)0
Figure 32 (Safety switch for door CC)0
Figure 33 (Cab tilt wiring harness)0
Figure 34 (Control panel)0
Figure 35 (Control panel)0
Figure 36 (Steering arm)0
Figure 37 (MCU)0
Figure 38 (Control motor)0
Figure 39 (Main valve block)0
Figure 40 (Li-ion wiring harness)0
203 Cable connections and terminal posts0
2031 ACT/ACH transistor regulators0
2032 Connections to CID0
2033 Connections on the MCU0
204 Fuse box A90
205 Overview0
206 Details up to and including serial no 62068000
207 Detailed diagram cold-store cab0
21 – Hydraulics schematics0
211 Main valve unit0
2111 RRE Std0
2112 RRE Ergo0
212 Hydraulic diagrams0
2121 Schematics designations0
2122 List of symbols0
2123 Wiring diagrams RRE/RRE Ergo0
22 – Tools0
221 AMP connectors0
222 MQS connectors0
223 CPC contacts0
224 Other tools0
23 – Appendix “Service data and grease specifications”0
231 General tightening torques0
2311 Galvanised, non-oiled screws0
2312 Untreated, oiled screws0
232 Lubricants specification0
24 – Technical data0
Mast, maximum weight and maximum height0

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