Toyota Forklift 7FBRE12 7FBRE12C 7FBRE14 7FBRE14C 7FBRE16 7FBRE16C 7FBRE20 7FBRE20C 7FBRE25 7FBRE25C Service Manual 423260
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Toyota Forklift 7FBRE12 7FBRE12C 7FBRE14 7FBRE14C 7FBRE16 7FBRE16C 7FBRE20 7FBRE20C 7FBRE25 7FBRE25C Service Manual 423260 – PDF DOWNLOAD
Description
Toyota Forklift 7FBRE12 7FBRE12C 7FBRE14 7FBRE14C 7FBRE16 7FBRE16C 7FBRE20 7FBRE20C 7FBRE25 7FBRE25C Service Manual 423260 – PDF DOWNLOAD
FILE DETAILS:
Toyota Forklift 7FBRE12 7FBRE12C 7FBRE14 7FBRE14C 7FBRE16 7FBRE16C 7FBRE20 7FBRE20C 7FBRE25 7FBRE25C Service Manual 423260 – PDF DOWNLOAD
Language : English
Pages : 596
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Toyota Forklift 7FBRE12 7FBRE12C 7FBRE14 7FBRE14C 7FBRE16 7FBRE16C 7FBRE20 7FBRE20C 7FBRE25 7FBRE25C Service Manual 423260 – PDF DOWNLOAD
- TOYOTA’s reach truck program is intended for handling pallets indoors or alternatively other
types of loads using other load carriers. The trucks are operated seated in a protected and
ergonomic operator posi- tion. The reach trucks are available in different size classes and have as
standard a lifting capacity of up to 2500 kg and a lifting height of up to 10.5 m. - The trucks are equipped with a 48 V electrical system. The travel and lifting speeds are transistor
controlled to provide smooth operations. In addition, the travel function and the different
hydraulic functions have additional controls which further enhance these features. Different
speeds and steering can be set using parameters to give the best pos- sible individual setting for
the functions.
Application areas for TOYOTA’s reach trucks:
TOYOTA’s reach trucks are solely designed and manufactured to han- dle goods. The trucks should be
fitted with the appropriate accessories relevant to the application.
Prohibited applications for TOYOTA’s reach trucks:
TOYOTA’s reach trucks are designed for handling goods indoors. Unless the truck is
specially equipped, it is not permitted to use the truck for other purposes including the following
applications:
– In areas that contain dust or gases which can cause fires or ex- plosions
– As a tow-truck for trailers
– To tow other trucks
– To transport/lift passengers
– To drive on gravel or grass
TABLE OF CONTENTS:
Toyota Forklift 7FBRE12 7FBRE12C 7FBRE14 7FBRE14C 7FBRE16 7FBRE16C 7FBRE20 7FBRE20C 7FBRE25 7FBRE25C Service Manual 423260 – PDF DOWNLOAD
1- Table of contents........................................................................................... 3 2- General product information - M2.1.......................................................................... 21 2.1 Presentation of TOYOTA’s reach trucks.................................................................. 21 2.2 Application areas for TOYOTA’s reach trucks............................................................ 21 2.3 Prohibited applications for TOYOTA’s reach trucks...................................................... 21 2.4 Truck data............................................................................................. 22 2.5 Truck dimensions....................................................................................... 23 2.6 Identification plate, truck............................................................................ 24 2.7 Capacity plate......................................................................................... 24 2.8 Modification plate..................................................................................... 25 2.9 Identification plate, mast............................................................................. 25 2.10 Main components....................................................................................... 26 2.11 Warning and information plates and symbols............................................................ 28 3- General product information - M2.2.......................................................................... 29 3.1 Presentation of TOYOTA’s reach trucks.................................................................. 29 3.2 Application areas for TOYOTA’s reach trucks............................................................ 29 3.3 Prohibited applications for TOYOTA’s reach trucks...................................................... 29 3.4 Truck data............................................................................................. 30 3.5 Truck dimensions....................................................................................... 31 3.6 Identification plate, truck............................................................................ 32 3.7 Capacity plate......................................................................................... 32 3.8 Modification plate..................................................................................... 33 3.9 Identification plate, mast............................................................................. 33 3.10 Main components....................................................................................... 34 3.11 Warning and information plates and symbols............................................................ 36 4- Technical data - M4.1....................................................................................... 37 5- Technical data - M4.2....................................................................................... 41 6- Introduction, maintenance - P1.............................................................................. 45 6.1 Safety regulations with maintenance work............................................................... 45 6.2 Cleaning and washing................................................................................... 46 6.2.1 External cleaning................................................................................ 47 6.2.2 Cleaning the motor compartment................................................................... 47 6.2.3 Electrical components............................................................................ 47 6.3 Safe lifting........................................................................................... 48 7- Preventive Maintenance - P2.1............................................................................... 49 7.1 Maintenance chart...................................................................................... 49 8- Preventive Maintenance - P2.2............................................................................... 59 8.1 Maintenance chart...................................................................................... 59 9- Oil and grease specification - P3........................................................................... 69 10- Tools -P4.................................................................................................. 71 10.1 Super Seal............................................................................................ 71 10.1.1 AMP connector................................................................................... 72 10.1.2 AMP microtimer.................................................................................. 73 10.1.3 Diverse tools................................................................................... 74 11- Cab heating/ventilation - 0630............................................................................. 81 11.1 Air conditioning unit................................................................................. 81 11.1.1 Ventilation..................................................................................... 81 11.1.2 Main heater..................................................................................... 81 11.1.3 Auxiliary heater................................................................................ 81 11.1.4 Temperature..................................................................................... 81 11.1.5 Air direction................................................................................... 82 11.1.6 Fuses........................................................................................... 82 11.1.7 Air filter...................................................................................... 82 11.1.8 Emergency exit (12)............................................................................. 83 11.1.9 Lighting........................................................................................ 83 12- Driver Protection - 0840................................................................................... 85 12.1 General............................................................................................... 85 12.2 Tilt Stops............................................................................................ 86 12.2.1 Inspection and Adjustment....................................................................... 86 12.2.2 Removing the tilt stops......................................................................... 87 13- Electric pump motor - 1710.1............................................................................... 89 13.1 General............................................................................................... 89 13.2 Dismantling the pump motor............................................................................ 89 13.3 Dismantling and assembling the pump motor............................................................. 90 13.3.1 Dismantling..................................................................................... 90 13.3.2 Assembling...................................................................................... 91 13.4 Bearing replacement................................................................................... 92 13.4.1 Dismantling..................................................................................... 92 13.4.2 Assembling...................................................................................... 93 13.5 Installation instructions for external temperature sensor............................................. 94 14- Electric Pump Motor - 1710.2............................................................................... 97 14.1 General............................................................................................... 97 14.2 Dismantling the Pump Motor............................................................................ 97 14.2.1 Connection...................................................................................... 97 14.3 Removing and Replacing the Pump Motor................................................................. 98 14.3.1 Dismantling..................................................................................... 98 14.3.2 Assembling...................................................................................... 99 14.4 Bearing replacement................................................................................... 99 14.4.1 Dismantling (D side)............................................................................100 14.4.2 Assembling......................................................................................100 14.4.3 Dismantling (N side)............................................................................100 14.4.4 Assembling (N side).............................................................................101 14.4.5 Carbon brushes and brush holders................................................................101 Commutator.........................................................................................101 Machining the commutator...........................................................................101 15- Electric Steering Motor - 1730.............................................................................103 15.1 General...............................................................................................103 15.2 Replacing the Steering Motor..........................................................................103 15.2.1 Dismantling.....................................................................................103 15.2.2 Assembling......................................................................................103 15.3 Removing and replacing the carbon brushes.............................................................104 16- Electric drive motor - 1760................................................................................105 16.1 General...............................................................................................105 16.2 Dismantling the drive motor...........................................................................105 16.3 Dismantling and assembling the drive motor............................................................106 16.3.1 Dismantling the drive motor.....................................................................106 Removing the gear wheel............................................................................106 Removing the brakes................................................................................106 16.3.2 Assembling the drive motor......................................................................107 Assembling the gear wheel..........................................................................107 16.4 Bearing replacement...................................................................................108 16.4.1 Dismantling.....................................................................................108 D-side.............................................................................................108 16.4.2 Assembling......................................................................................109 N-side.............................................................................................109 D-side.............................................................................................109 16.5 Installation instructions for external temperature sensor.............................................110 17- Mechanical drive gear unit - 2550..........................................................................113 17.1 General...............................................................................................113 17.2 Components/data for the drive assembly/transmission...................................................113 17.2.1 Component placement.............................................................................114 17.2.2 Technical data..................................................................................115 17.2.3 Dismantling the transmission....................................................................116 17.3 Replacing the drive motor/drive transmission..........................................................117 17.3.1 Dismantling the drive motor.....................................................................117 17.3.2 Dismantling the drive transmission..............................................................118 17.3.3 Assembling the transmission.....................................................................118 17.3.4 Installing the drive motor......................................................................119 Assembling the gear wheel..........................................................................119 17.4 Checking/replacing the oil............................................................................120 17.4.1 Checking/refilling the oil......................................................................120 17.4.2 Changing the Oil................................................................................120 17.5 Repairs...............................................................................................121 17.5.1 Replacing the drive shaft sealing ring..........................................................121 Dismantling........................................................................................121 Assembling.........................................................................................122 17.5.2 Leakage from the upper cover....................................................................123 17.5.3 Leakage from the lower cover....................................................................123 17.5.4 Replacing wheel bolts...........................................................................124 18- Travel brake system - 3100.1...............................................................................125 With support arm brake.....................................................................................125 18.1 General...............................................................................................125 18.2 Operating description.................................................................................125 18.2.1 Releasing the accelerator.......................................................................126 18.2.2 Travel direction selector.......................................................................126 18.2.3 Pressing down the brake pedal...................................................................126 18.2.4 Parking brake...................................................................................126 18.2.5 Emergency braking...............................................................................127 18.3 Electromechanical disc brake, drive motor.............................................................128 18.3.1 Assembling......................................................................................128 18.3.2 Dismantling.....................................................................................129 18.3.3 Inspection......................................................................................129 18.3.4 Assembling......................................................................................129 18.4 Maintenance...........................................................................................129 18.4.1 Adjusting the play..............................................................................130 18.4.2 Wear............................................................................................130 18.4.3 Check the braking force.........................................................................131 18.5 Multiple disc brake, support arm......................................................................132 18.5.1 Assembling......................................................................................132 18.5.2 Dismantling.....................................................................................133 18.5.3 Inspection......................................................................................134 18.5.4 Assembling......................................................................................134 18.6 Maintenance...........................................................................................134 18.6.1 Adjusting the play..............................................................................135 19- Travel brake system - 3100.2...............................................................................137 Without support arm brakes.................................................................................137 19.1 General...............................................................................................137 19.2 Operating description.................................................................................137 19.2.1 Releasing the accelerator.......................................................................137 19.2.2 Travel direction selector.......................................................................138 19.2.3 Pressing down the brake pedal...................................................................138 19.2.4 Parking brake...................................................................................139 19.2.5 Emergency brake.................................................................................139 19.3 Electromechanical disc brake, drive motor.............................................................139 19.3.1 Assembling......................................................................................139 19.3.2 Dismantling.....................................................................................140 19.3.3 Inspection......................................................................................140 19.3.4 Assembling......................................................................................141 19.4 Maintenance...........................................................................................141 19.4.1 Adjusting the play..............................................................................141 19.4.2 Wear............................................................................................142 19.4.3 Check the braking force.........................................................................142 20- Drive wheel - 3530.........................................................................................143 20.1 General...............................................................................................143 20.2 Dismantling the drive wheel...........................................................................143 20.3 Assembling the drive wheel............................................................................143 21- Fork/support arm wheel - 3550.1............................................................................145 21.1 General...............................................................................................145 21.2 Dismantling the wheel.................................................................................146 21.3 Assembling the wheel..................................................................................147 For wheels without brakes..............................................................................147 For wheels with brakes.................................................................................148 21.4 Dismantling/assembling the wheel bearings.............................................................149 21.4.1 265 mm wheel and 300 mm wheels without brakes...................................................149 Dismantling the bearing............................................................................149 Assembling the bearing.............................................................................149 21.4.2 300 mm wheel with brake and 350 mm wheel........................................................150 Dismantling the bearing............................................................................150 Assembling the bearing.............................................................................150 22- Fork/support arm wheel - 3550.2............................................................................151 22.1 General...............................................................................................151 22.2 Dismantling the wheel.................................................................................151 22.3 Assembling the drive wheel............................................................................152 22.4 Dismantling the wheel bearing.........................................................................152 22.5 Assembling the wheel bearing..........................................................................152 23- Mechanical steering system - 4100..........................................................................153 23.1 General...............................................................................................153 23.2 Replacing the steering generator......................................................................153 23.2.1 Dismantling.....................................................................................153 23.2.2 Assembling......................................................................................153 24- Steering angle sensor - 4350...............................................................................155 24.1 General...............................................................................................155 24.2 Procedure.............................................................................................155 24.2.1 Adjustment of directional sensor................................................................156 24.2.2 Adjustment of the steering angle sensor.........................................................157 25- Electrical system - 5000.1.................................................................................159 25.1 General...............................................................................................159 25.1.1 Electrical panel................................................................................159 25.2 List of symbols.......................................................................................160 25.3 Electrical diagram....................................................................................163 25.3.1 List of components..............................................................................174 25.3.2 Diagram 1.......................................................................................178 25.3.3 Diagram 2.......................................................................................178 25.3.4 Diagram 3.......................................................................................179 25.3.5 Diagram 4.......................................................................................179 25.3.6 Diagram 5.......................................................................................180 25.3.7 Diagram 6.......................................................................................181 25.3.8 Diagram 7.......................................................................................181 25.3.9 Diagram 8.......................................................................................182 25.4 Description of function...............................................................................183 25.4.1 Ignition key in the 0 position..................................................................183 25.4.2 Ignition key in 1 position......................................................................184 25.4.3 Selection of travel direction...................................................................185 With the steering console..........................................................................185 With the left-hand handle..........................................................................185 With the speed control.............................................................................185 25.4.4 Driving.........................................................................................186 25.4.5 Steering........................................................................................186 25.4.6 Steering wheel indicator........................................................................187 25.4.7 Braking.........................................................................................187 Auto plug braking..................................................................................187 Motor brake (electric).............................................................................187 Foot brake.........................................................................................187 Parking brake......................................................................................188 25.4.8 Fork lift.......................................................................................188 25.4.9 Maximum height..................................................................................188 25.4.10 Maximum height.................................................................................189 25.4.11 Fork lowering..................................................................................189 25.4.12 Mast out/in....................................................................................189 25.4.13 Fork tilt up/down..............................................................................190 25.4.14 Hydraulic function 4...........................................................................190 25.4.15 Hydraulic function 5...........................................................................190 25.4.16 Height indication..............................................................................190 25.4.17 Height selection...............................................................................191 25.4.18 Operator - ID..................................................................................191 Without pin code...................................................................................191 With pin code......................................................................................191 26- 14Electrical System - 5000.2...............................................................................193 26.1 General...............................................................................................193 26.1.1 Electrical Panel................................................................................193 26.2 Symbol list...........................................................................................194 26.3 Electrical diagram....................................................................................196 26.3.1 Component List..................................................................................206 26.3.2 Figure 1........................................................................................210 26.3.3 Figure 2........................................................................................210 26.3.4 Figure 3........................................................................................211 26.3.5 Figure 4........................................................................................211 26.3.6 Figure 5........................................................................................212 26.3.7 Figure 6........................................................................................213 26.3.8 Figure 7........................................................................................213 26.3.9 Figure 8........................................................................................214 26.4 Functional Description................................................................................214 26.4.1 Key in Position 0...............................................................................215 26.4.2 Key in Position I...............................................................................215 26.4.3 Choice of travel direction......................................................................216 On the control console.............................................................................216 On the accelerator.................................................................................216 26.4.4 Driving.........................................................................................217 26.4.5 Steering........................................................................................217 26.4.6 Steering wheel indicator........................................................................218 26.4.7 Braking.........................................................................................218 Auto-brakes........................................................................................218 Motor brakes (electric)............................................................................218 Foot brakes........................................................................................218 Parking brake......................................................................................219 26.4.8 Fork lifting....................................................................................219 26.4.9 Maximum Height..................................................................................219 26.4.10 Fork lowering..................................................................................219 26.4.11 Mast out/in....................................................................................220 26.4.12 Fork tilt up/down..............................................................................220 26.4.13 Hydraulic function 4...........................................................................220 26.4.14 Driver identification..........................................................................221 Without pin code...................................................................................221 With pin code......................................................................................221 27- Battery - 5110.............................................................................................223 27.1 Battery dimensions....................................................................................223 27.2 Setting the battery parameters on 7FBRE trucks fitted with Hawker Evolution gel batteries.............224 27.2.1 General.........................................................................................224 27.2.2 Battery recommendation..........................................................................224 27.2.3 Battery installation............................................................................224 27.2.4 Recommended parameter setting for ventilation regulated batteries...............................225 27.2.5 Instructions for verifying the parameter setting................................................225 28- Transistor panel - 5460....................................................................................227 28.1 Frequency converter...................................................................................227 28.1.1 General description.............................................................................227 28.1.2 Terminal connections and pole bolts.............................................................228 28.1.3 Technical Data..................................................................................229 28.1.4 Installation of New Frequency Converter on Truck................................................229 28.1.5 Programming.....................................................................................229 29- Power electronics panel - 5660.............................................................................231 29.1 General description...................................................................................231 29.1.1 Terminal connections and pole bolts.............................................................232 29.1.2 Technical Data..................................................................................233 29.1.3 Installing a new transistor panel...............................................................233 29.2 Parameter.............................................................................................233 29.3 Diagnostics and trouble shooting......................................................................234 29.3.1 Displaying error codes, logging errors..........................................................234 29.3.2 Error codes, trouble shooting...................................................................235 29.3.3 Resetting an error..............................................................................235 29.4 Maintenance...........................................................................................236 29.4.1 Safety..........................................................................................236 29.4.2 Cleaning........................................................................................236 29.5 Hand terminal 1307....................................................................................237 29.6 Using the hand terminal...............................................................................239 29.6.1 Check and adjust parameters.....................................................................240 Use MORE INFO in PROGRAM MODE......................................................................240 29.6.2 Special program mode............................................................................241 29.6.3 Using TEST mode.................................................................................241 29.6.4 Using DIAGNOSTICS MODE..........................................................................241 29.6.5 SPECIAL DIAGNOSTICS MODE........................................................................242 30- Electronic card - 5710.1...................................................................................243 30.1 General description...................................................................................243 30.2 Terminal connections and voltages on A5...............................................................244 30.2.1 10X.............................................................................................244 30.2.2 20X.............................................................................................245 30.2.3 30X.............................................................................................245 30.2.4 40X.............................................................................................246 30.2.5 50X.............................................................................................246 30.2.6 60X.............................................................................................247 30.2.7 70X.............................................................................................247 30.2.8 80X.............................................................................................248 30.2.9 90X.............................................................................................248 30.3 Adjusting the lowering speed..........................................................................249 30.4 Show..................................................................................................249 30.5 Programming...........................................................................................250 30.5.1 Clock...........................................................................................250 30.5.2 Driver parameters (1-7).........................................................................251 30.6 Warning Codes.........................................................................................251 30.7 Error Codes...........................................................................................252 30.7.1 Error mode......................................................................................252 30.7.2 Safety logic....................................................................................252 30.7.3 Warning Codes without registration..............................................................253 Seat switch S89....................................................................................255 Safety switch (left-foot switch), S23..............................................................256 Accelerator, R1....................................................................................257 Brakes, R2.........................................................................................258 Fork control, joystick R11.........................................................................260 Tilt control, joystick R13.........................................................................261 Mast reach/retraction control, joystick R12........................................................262 Extra hydraulic functions, joystick R14 and joystick R15...........................................263 Battery measurement................................................................................265 Emergency switch...................................................................................266 Temperature sensor B1 in drive motor M1............................................................268 Drive motor's pulse transducer bearing, U11........................................................270 Temperature sensor B2 in the pump motor M3.........................................................271 Pump motor's pulse transducer bearing, U12.........................................................273 30.8 Warning codes with registration.......................................................................274 Hydraulic valve Y10/2 engages fork lift................................................................274 Hydraulic valve Y15 engages fork tilt up...............................................................275 Hydraulic valve Y14 engages fork tilt down.............................................................276 Hydraulic valve Y16 engages a extra hydraulic function, e.g. side shift or fork spread.................277 Hydraulic valve Y17 engages a extra hydraulic function, e.g. side shift or fork spread.................278 Hydraulic valve Y18 engages a extra hydraulic function, e.g. side shift or fork spread.................279 Hydraulic valve Y19 engages a extra hydraulic function, e.g. side shift or fork spread.................281 Hydraulic valve Y12 operates the retraction of the fork carriage.......................................282 Hydraulic valve Y13 operates the extension of the fork carriage........................................283 Hydraulic valve Y10/3 engages fork lowering............................................................284 Y5/Y6 are the coils in the support arm brakes..........................................................285 Fork control, joystick R11.............................................................................286 Tilt control, joystick R13.............................................................................287 Mast reach/retraction control, joystick R12............................................................288 Extra hydraulic functions, joystick R14 and R15........................................................289 Accelerator R1.........................................................................................290 30.9 Error Codes...........................................................................................291 30.9.1 Error codes with registration...................................................................292 Parking brake Y1...................................................................................292 Main contactor, K10, coil..........................................................................293 Main contactor, K10, contactor points..............................................................294 Main contactor, K10, contactor points..............................................................295 Potentiometer R2, brake............................................................................296 Steering motor, M6.................................................................................298 Steering motor, M6.................................................................................299 Steering generator, U1.............................................................................300 Steering motor, M6.................................................................................301 Fuse F61, 30 A.....................................................................................303 CAN communication..................................................................................307 CAN - communication between A5 and A1..............................................................308 CAN - communication between A5 and A1..............................................................309 CAN - communication between A5 and A2..............................................................310 CAN - communication between A5 and A2..............................................................311 CAN communication..................................................................................312 Temperature sensor B1 in drive motor M1............................................................313 Drive motor circuit................................................................................314 Main contactor, K10................................................................................316 Temperature sensor B2 in the pump motor............................................................317 Pump motor circuits................................................................................318 Pump motor, M3.....................................................................................319 Battery circuit....................................................................................320 Main contactor, K10................................................................................321 CAN - communication between A5 and A2..............................................................322 30.10 Operating Time.......................................................................................323 30.11 Parameter Settings...................................................................................323 30.11.1 Parameter 1....................................................................................326 30.11.2 Parameter 2....................................................................................326 30.11.3 Parameter 3....................................................................................326 30.11.4 Parameter 4....................................................................................326 30.11.5 Parameter 5....................................................................................327 30.11.6 Parameter 10...................................................................................327 30.11.7 Parameter 11...................................................................................327 30.11.8 Parameter 12...................................................................................327 30.11.9 Parameters 13 to 14............................................................................327 30.11.10 Parameters 15 and 16..........................................................................327 30.11.11 Parameters 17 and 18..........................................................................328 30.11.12 Parameter 19..................................................................................328 30.11.13 Parameter 20..................................................................................328 30.11.14 Parameter 21..................................................................................329 30.11.15 Parameter 22..................................................................................330 30.11.16 Parameter 23..................................................................................330 30.11.17 Parameter 24..................................................................................330 30.11.18 Parameter 25..................................................................................330 30.11.19 Parameter 27..................................................................................330 30.11.20 Parameter 28..................................................................................330 30.11.21 Parameter 29..................................................................................330 30.11.22 Parameter 37..................................................................................331 30.11.23 Parameter 38..................................................................................331 30.11.24 Parameter 39..................................................................................332 30.11.25 Parameters 40 to 42...........................................................................332 30.11.26 Other parameters..............................................................................332 30.11.27 Installing a new card in the truck............................................................333 31- Electronic card - 5710.2...................................................................................335 31.1 General description...................................................................................335 31.2 Terminal connections and voltages on A5...............................................................336 31.2.1 10X.............................................................................................336 31.2.2 20X.............................................................................................337 31.2.3 30X.............................................................................................337 31.2.4 40X.............................................................................................338 31.2.5 50X.............................................................................................338 31.2.6 60X.............................................................................................339 31.2.7 70X.............................................................................................339 31.2.8 80X.............................................................................................340 31.2.9 90X.............................................................................................340 31.3 Adjusting the lowering speed..........................................................................341 31.4 Show..................................................................................................341 31.5 Programming...........................................................................................342 31.5.1 Clock...........................................................................................342 31.5.2 Driver parameters (1-7).........................................................................342 31.6 Warning Codes.........................................................................................343 31.7 Error Codes...........................................................................................344 31.7.1 Error mode......................................................................................344 31.7.2 Safety logic....................................................................................344 31.7.3 Warning Codes without registration..............................................................345 31.8 Warning codes with registration.......................................................................351 31.9 Error Codes...........................................................................................355 31.9.1 Error codes with registration...................................................................356 31.10 Running Time.........................................................................................366 31.11 Parameter Settings...................................................................................366 31.11.1 Parameter 1....................................................................................368 31.11.2 Parameter 2....................................................................................368 31.11.3 Parameter 3....................................................................................368 31.11.4 Parameter 4....................................................................................368 31.11.5 Parameter 5....................................................................................369 31.11.6 Parameter 10...................................................................................369 31.11.7 Parameter 11...................................................................................369 31.11.8 Parameter 12...................................................................................369 31.11.9 Parameters 13..................................................................................369 31.11.10 Parameters 15.................................................................................369 31.11.11 Parameter 20..................................................................................369 31.11.12 Parameter 21..................................................................................370 31.11.13 Parameter 23..................................................................................371 31.11.14 Parameter 24..................................................................................371 31.11.15 Parameter 25..................................................................................371 31.11.16 Parameter 26..................................................................................371 31.11.17 Parameter 27..................................................................................371 31.11.18 Parameter 28..................................................................................371 31.11.19 Parameter 38..................................................................................371 31.11.20 Parameter 39..................................................................................372 31.11.21 Parameters 40 to 42...........................................................................372 31.11.22 Other parameters..............................................................................372 31.11.23 Installing a new card in the truck............................................................373 32- Hydraulic system - 6000.1..................................................................................375 32.1 General...............................................................................................375 32.2 Symbols...............................................................................................375 32.2.1 Hydraulic chart 1 (2)...........................................................................377 7FBRE16, 20, 25, 7FBRE16C, 20C, 25C................................................................377 32.2.2 Hydraulic chart 2 (2)...........................................................................378 7FBRE16, 20, 25, 7FBRE16C, 20C, 25C, Integrated side shift.........................................378 32.3 List of symbols.......................................................................................379 32.3.1 Component placement 1 (2).......................................................................381 32.3.2 Component placement 2 (2).......................................................................382 32.4 Adjusting fork lowering...............................................................................383 32.5 Setting the maximum lifting capacity..................................................................384 33- Hydraulic system - 6000.2..................................................................................385 33.1 General...............................................................................................385 33.2 Symbols...............................................................................................385 33.2.1 Hydraulic chart 1 (3)...........................................................................387 7FBRE12, 7FBRE12C..................................................................................387 33.2.2 Hydraulic chart 2 (3)...........................................................................388 7FBRE14, 7FBRE14C, Integrated side shift...........................................................388 33.2.3 Hydraulic chart 3 (3)...........................................................................389 7FBRE14, 7FBRE14C..................................................................................389 33.3 List of symbols.......................................................................................390 33.3.1 Component placement 1 (2).......................................................................391 7FBRE12, 7FBRE12C..................................................................................391 33.3.2 Component placement 2 (2).......................................................................392 7FBRE14, 7FBRE14C..................................................................................392 33.4 Adjusting fork lowering...............................................................................393 33.5 Setting the max lifting capacity......................................................................394 34- Hydraulic pump - 6140.1....................................................................................395 34.1 General...............................................................................................395 34.2 Replacing the hydraulic pump..........................................................................395 34.2.1 Dismantling.....................................................................................395 34.2.2 Assembling......................................................................................396 35- Hydraulic pump - 6140.2....................................................................................397 35.1 General...............................................................................................397 35.2 Replacing the hydraulic pump..........................................................................397 35.2.1 Dismantling.....................................................................................397 35.2.2 Assembling......................................................................................398 36- Mast mounted hose reel - 6370..............................................................................399 36.1 General...............................................................................................399 36.2 Assembling............................................................................................399 36.3 Check after assembly..................................................................................400 37- Hydraulic cylinder - 6600..................................................................................401 37.1 General...............................................................................................401 37.2 Duplex mast...........................................................................................401 37.2.1 Dismantling the lift cylinders from the mast....................................................401 37.2.2 Dismantling the cylinder........................................................................402 37.2.3 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder.......402 37.2.4 Assembling the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder....403 37.2.5 Dismantling and assembling the lower brake valve................................................403 37.2.6 Assembling the cylinder.........................................................................403 37.2.7 Assembling the cylinder in the mast.............................................................404 37.3 Triplex mast..........................................................................................405 37.3.1 Dismantling the free lift cylinder from the mast................................................405 37.3.2 Dismantling the mast lift cylinders from the mast...............................................405 37.4 Cylinder seals........................................................................................405 37.5 Replacing wear parts in the cylinder..................................................................406 37.5.1 Securing........................................................................................406 37.5.2 Dismantling the cylinder........................................................................406 37.5.3 Replacing the lower support ring................................................................406 37.5.4 Replacing the O-ring on the top sleeve..........................................................407 37.5.5 Replacing the internal wear parts in the top sleeve.............................................407 37.5.6 Assembling the cylinder.........................................................................408 37.5.7 Assembling the free lift cylinder in the mast...................................................408 37.5.8 Assembling the mast lift cylinder...............................................................409 38- Main lift cylinder - 6610..................................................................................411 38.1 General...............................................................................................411 38.2 Tools.................................................................................................411 38.3 Dismantling the lift cylinders from the mast..........................................................412 38.4 Dismantling the cylinder..............................................................................412 38.4.1 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder.......413 38.4.2 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder...........413 38.4.3 Dismantling and assembling the hose rupture valve...............................................413 38.5 Assembling the cylinder...............................................................................414 38.5.1 Assembling the cylinder in the mast.............................................................414 39- Free lift cylinder - 6620..................................................................................415 39.1 General...............................................................................................415 39.2 Tools.................................................................................................415 39.3 Dismantling...........................................................................................416 39.3.1 Dismantling the cylinder........................................................................417 39.4 Dismantle the rod seal and the support ring...........................................................417 39.4.1 Assembling the rod seal and the support ring....................................................417 39.5 Dismantling the ram...................................................................................418 39.5.1 Assembling the ram in the free lift cylinder....................................................418 39.6 Dismantling and assembling the hose rupture valve.....................................................418 39.7 Assembling the cylinder...............................................................................419 39.8 Assembling............................................................................................419 40- Reach cylinder - 6650.1....................................................................................421 40.1 General...............................................................................................421 40.2 Assembling and dismantling the reach cylinder.........................................................421 40.2.1 Dismantling.....................................................................................421 40.2.2 Dismantling the cylinder........................................................................422 40.2.3 Dismantle the rod seal and the support ring.....................................................422 40.2.4 Assembling the rod seal and the support ring....................................................422 40.2.5 Dismantling the ram.............................................................................422 40.2.6 Assembling the ram..............................................................................423 40.2.7 Assembling the cylinder.........................................................................423 40.3 Assembling............................................................................................423 41- Reach cylinder - 6650.2....................................................................................425 41.1 General...............................................................................................425 41.2 Assembling and dismantling the reach cylinder.........................................................425 41.2.1 Dismantling the cylinder........................................................................426 41.2.2 Dismantling the rod.............................................................................427 41.2.3 Dismantle the to sleeve seals...................................................................427 41.2.4 Assembling the top sleeve.......................................................................427 41.2.5 Fit the ram seal................................................................................427 41.2.6 Dismantling the rod.............................................................................427 41.2.7 Assembling the cylinder.........................................................................428 41.3 Assembling............................................................................................428 42- Tilt cylinder - 6660.1.....................................................................................429 42.1 General...............................................................................................429 42.2 Mast with valve on the fork carriage..................................................................430 42.2.1 Dismantling the fork carriage...................................................................430 42.2.2 Dismantling the cylinder........................................................................431 42.2.3 Dismantling the rod seal........................................................................431 42.2.4 Dismantling the ram.............................................................................431 42.2.5 Assembling the ram..............................................................................431 42.2.6 Assembling the rod seal.........................................................................432 42.2.7 Assembling the cylinder.........................................................................432 42.2.8 Assembling the fork carriage....................................................................432 42.3 Mast without valve on the fork carriage...............................................................433 42.3.1 Dismantling the fork carriage...................................................................433 42.3.2 Dismantling the cylinder........................................................................434 42.3.3 Dismantling the rod seal........................................................................434 42.3.4 Dismantling the ram.............................................................................434 42.3.5 Assembling the ram..............................................................................434 42.3.6 Assembling the rod seal.........................................................................435 42.3.7 Assembling the cylinder.........................................................................435 42.3.8 Assembling the fork carriage....................................................................435 43- Tilt cylinder - 6660.2.....................................................................................437 43.1 General...............................................................................................437 43.2 Assembling and dismantling the tilt cylinder..........................................................437 43.2.1 Dismantling the cylinder........................................................................438 43.2.2 Dismantling the rod.............................................................................439 43.2.3 Dismantling the ram seals.......................................................................439 43.2.4 Dismantle the top sleeve seals..................................................................439 43.2.5 Assembling the top sleeve.......................................................................439 43.2.6 Assembling the ram seal.........................................................................439 43.2.7 Dismantling the rod.............................................................................439 43.2.8 Assembling the cylinder.........................................................................440 43.3 Assembling............................................................................................440 44- Main mast - 7100.1.........................................................................................441 44.1 General...............................................................................................441 44.2 List of tools.........................................................................................441 44.3 Transporting the truck................................................................................442 44.4 Assembling the mast...................................................................................443 44.5 Dismantling the mast..................................................................................448 44.6 Adjust the play.......................................................................................449 44.6.1 Adjusting the mast play.........................................................................452 Lateral play.......................................................................................452 44.6.2 Radial play.....................................................................................453 44.7 Assembling............................................................................................453 45- Main mast - 7100.2.........................................................................................455 45.1 General...............................................................................................455 45.2 List of tools.........................................................................................455 45.3 Transporting the truck................................................................................456 45.4 Assembling the mast...................................................................................457 45.5 Dismantling the mast..................................................................................461 45.5.1 Chains, cylinders and hoses.....................................................................462 45.5.2 Dismantling the runner..........................................................................463 45.5.3 Inner guide.....................................................................................464 45.6 Assembling Duplex mast................................................................................467 45.6.1 Assembly-shimming the side play.................................................................467 45.6.2 Inner guide.....................................................................................468 45.6.3 Chains, cylinders and hoses.....................................................................468 45.6.4 Fork carriage...................................................................................469 45.6.5 Docking the mast in the truck...................................................................469 45.7 Assembling the Triplex mast...........................................................................469 45.7.1 Assembly-shimming the side play.................................................................469 45.7.2 Inner guide.....................................................................................470 45.7.3 Chains, cylinders and hoses.....................................................................470 45.7.4 Fork carriage...................................................................................471 46- Main mast - 7100.3.........................................................................................473 46.1 General...............................................................................................473 46.2 List of tools.........................................................................................473 46.3 Transporting the truck................................................................................474 46.4 Assembling the mast...................................................................................475 46.5 Dismantling the mast..................................................................................479 46.6 Adjust the play.......................................................................................480 46.6.1 Adjusting the mast play.........................................................................483 Lateral play.......................................................................................483 46.6.2 Radial play.....................................................................................484 46.7 Assembling............................................................................................484 47- Main lift chain system - 7120..............................................................................485 47.1 General...............................................................................................485 47.2 Checking the chain setting............................................................................485 47.3 Chain inspection......................................................................................485 47.3.1 Noise...........................................................................................485 47.3.2 Surface rust....................................................................................485 47.3.3 Rusty links.....................................................................................485 47.3.4 Stiff links.....................................................................................486 47.3.5 Bolt rotation...................................................................................486 47.3.6 Loose bolts.....................................................................................486 47.3.7 Outline wear....................................................................................487 47.3.8 Stretching......................................................................................488 47.3.9 Damage..........................................................................................488 47.3.10 Damaged discs..................................................................................489 47.3.11 Damaged bolts..................................................................................489 47.3.12 Dirty chain....................................................................................489 47.4 Cleaning..............................................................................................489 47.5 Lubrication...........................................................................................490 48- Battery charger - 8340.....................................................................................491 48.1 General...............................................................................................491 48.2 Installation..........................................................................................491 48.3 Functional description................................................................................492 48.3.1 Display functions...............................................................................492 48.3.2 Charging process................................................................................492 48.3.3 Shutdown conditions.............................................................................493 48.3.4 Delayed power on and charging...................................................................493 48.3.5 Extra charging..................................................................................493 48.3.6 Equalised charging..............................................................................493 48.3.7 Current and voltage characteristics.............................................................493 48.3.8 Safety shutdowns................................................................................494 48.3.9 Display and keyboard............................................................................494 Reading of analogue measurement values.............................................................495 Error indication and error messages................................................................496 Reading statistics from the previous charge........................................................497 Reading of long term statistics....................................................................498 Storing parameters.................................................................................498 Reading parameters.................................................................................499 Battery specific parameters........................................................................499 Charger specific parameters........................................................................500 Mains voltage codes................................................................................500 Other functions....................................................................................500 Changing parameters................................................................................501 48.3.10 Acid circulation...............................................................................501 BTM with acid circulation..........................................................................501 Pump type APE, VPM.................................................................................502 Pump type API......................................................................................502 48.4 Service and maintenance...............................................................................502 48.4.1 Basic programming, code 30......................................................................502 48.4.2 Resetting the statistics, code 31...............................................................502 48.4.3 Calibrating the measurement value...............................................................503 Calibrating the current’s zero value and temperatures, code 21.....................................503 Calibrating the battery voltage’s measurement value, code 20.......................................503 Calibrating the charging current, code 25..........................................................504 Calibrating the mains voltage display, code 26.....................................................504 48.4.4 Calibrating and programming API.................................................................504 Calibrating zero pressure..........................................................................504 Calibrating the pressure...........................................................................504 Programming the alarm limits.......................................................................504 Programming the API function.......................................................................505 48.4.5 Adjusting the charging characteristics..........................................................505 48.4.6 Trouble shooting................................................................................505 Error message, analysis and action.................................................................506 Errors without indication..........................................................................507 48.4.7 Trouble shooting acid circulation...............................................................507 48.4.8 Service measures................................................................................507 Switching to the timer charger.....................................................................508 Replacing the display card.........................................................................508 Replacing the computer board.......................................................................508 Replacing the mother board.........................................................................509 Replacing the diodes...............................................................................509 48.4.9 Preventive maintenance..........................................................................509 49- Control/computer equipment - 8700..........................................................................511 49.1 General...............................................................................................511 49.2 Connection............................................................................................511 49.3 Layout................................................................................................512 49.3.1 Main window.....................................................................................512 49.3.2 Nodes...........................................................................................512 49.3.3 Icons...........................................................................................513 49.3.4 Tool buttons and menu list......................................................................514 49.3.5 Information window..............................................................................514 49.3.6 Status row......................................................................................514 49.4 Function for connection...............................................................................515 49.5 Function for disconnecting............................................................................515 49.6 Function for program downloading......................................................................515 49.6.1 Normal loading..................................................................................516 49.6.2 Loading in old versions of the electronic card..................................................516 49.6.3 Emergency loading...............................................................................516 49.7 Function for truck report.............................................................................517 49.8 Function for parameters...............................................................................518 49.9 Function for diagnostics..............................................................................520 49.9.1 Signal colours..................................................................................520 49.9.2 Tab for “Analogue”..............................................................................521 49.9.3 Tab for “Temperature”...........................................................................522 49.9.4 Tab for “Digital”...............................................................................523 49.10 Other menu functions.................................................................................524 49.10.1 Save to file...................................................................................524 49.10.2 Loading from a file............................................................................524 49.10.3 Resetting the CAN adapter......................................................................524 49.10.4 Deleting the fault code log....................................................................524 49.10.5 Resetting the hour meter.......................................................................524 49.10.6 Reading the fault code log.....................................................................524 49.10.7 Adjusting the date/time........................................................................524 49.10.8 Adjusting the hour meter on older cards........................................................525 49.10.9 Help...........................................................................................525 About TruckCom.....................................................................................525 49.10.10 Conclude......................................................................................525 49.11 Specifications.......................................................................................525 CAN-interface..........................................................................................525 49.12 Installation.........................................................................................526 49.12.1 Installation on a PC with Windows XP/ 2000/NT..................................................526 49.12.2 Installation on a PC with Windows 95/98........................................................526 49.12.3 In the event of any problems with communication with CAN.......................................527 49.12.4 Uninstallation.................................................................................527 50- Extra hazard warning lights/ alarm - 9370..................................................................529 50.1 General...............................................................................................529 50.2 Assembling............................................................................................529 50.3 Setting...............................................................................................530 51- Positioning equipment - 9390...............................................................................531 51.1 General...............................................................................................531 51.2 Height indication.....................................................................................531 51.3 Function..............................................................................................532 51.4 Display...............................................................................................533 51.5 Height pre-set........................................................................................534 51.6 Function..............................................................................................535 51.7 Display...............................................................................................536 51.7.1 Description of the display symbols..............................................................537 51.8 Assembly of height pre-set............................................................................538 51.9 Programming...........................................................................................538 51.9.1 Programming a level.............................................................................538 Collect level......................................................................................538 Leave level........................................................................................539 51.9.2 Deleting programmed levels......................................................................539 51.10 Automatic driving....................................................................................540 51.10.1 Collect load...................................................................................540 51.10.2 Depositing a load..............................................................................541 51.10.3 Inspection.....................................................................................541 51.11 Parameters...........................................................................................542 51.11.1 Parameter 1....................................................................................542 51.11.2 Parameter 2....................................................................................542 51.11.3 Parameter 3....................................................................................543 51.11.4 Parameter 4....................................................................................543 51.11.5 Parameter 5....................................................................................543 51.11.6 Parameter 7....................................................................................543 51.11.7 Parameter 8....................................................................................544 51.11.8 Parameter 9....................................................................................544 51.12 Programming parameters...............................................................................545 51.13 Error codes..........................................................................................547 52- TV equipment - 9390........................................................................................549 52.1 General...............................................................................................549 52.2 Camera mounted on fork................................................................................550 52.2.1 Colour camera A51...............................................................................550 52.2.2 Colour monitor A50..............................................................................550 52.2.3 Voltage converter A10...........................................................................552 53- Truck Logging System, code lock - 9420.....................................................................553 53.1 General...............................................................................................553 53.2 EV 1,EV 16 and S 16 Keyboard version..................................................................553 53.2.1 Login using a code (5 digit)....................................................................553 53.2.2 Logout..........................................................................................553 53.2.3 Login with fault reporting (5+1 digit)..........................................................554 Login..............................................................................................554 53.2.4 Login with extra code (5+3 digit)...............................................................554 53.2.5 Login with extra code and fault reporting (5+3+1 digit).........................................554 53.2.6 Changing the personal three digit code..........................................................555 53.3 EV1, EV16 and S16 code card version...................................................................555 53.3.1 Login...........................................................................................555 53.3.2 Logout..........................................................................................555 EV1................................................................................................556 53.3.3 Circuit diagram.................................................................................557 EV16...............................................................................................558 S16................................................................................................559 53.4 Collision sensor......................................................................................560 53.4.1 Circuit diagram.................................................................................562 53.5 Trouble shooting......................................................................................564 53.5.1 EV1.............................................................................................564 53.5.2 EV16 and S16....................................................................................564 54- Instructions for destruction...............................................................................565 54.1 General...............................................................................................565 54.1.1 Procedure.......................................................................................565 54.1.2 Abbreviations...................................................................................566 54.1.3 Sorting.........................................................................................566 54.2 Frame/chassis (0300)..................................................................................567 54.2.1 Dismantling.....................................................................................567 54.2.2 Material handling...............................................................................567 54.3 Operator's seat, cushion (0620).......................................................................568 54.3.1 Dismantling.....................................................................................568 54.3.2 Material handling...............................................................................568 54.4 Driver controls (0640)................................................................................569 54.4.1 Dismantling.....................................................................................569 54.4.2 Material handling...............................................................................569 54.5 Interior fittings (0680)..............................................................................570 54.5.1 Dismantling.....................................................................................570 54.5.2 Material handling...............................................................................571 54.6 Rollover guard/head guard (0810)......................................................................571 54.6.1 Dismantling.....................................................................................571 54.6.2 Material handling...............................................................................571 54.7 Finger/foot protectors (0820).........................................................................572 54.7.1 Dismantling.....................................................................................572 54.7.2 Material handling...............................................................................572 54.8 Finger/foot protectors (0820).........................................................................573 54.8.1 Dismantling.....................................................................................573 54.8.2 Material handling...............................................................................573 54.9 Finger protectors (0820)..............................................................................574 54.9.1 Dismantling.....................................................................................574 54.9.2 Material handling...............................................................................574 54.10 Electric motors (1700)...............................................................................575 54.10.1 Dismantling....................................................................................575 54.10.2 Material handling..............................................................................575 54.11 Electric fan motor (1740)............................................................................576 54.11.1 Dismantling....................................................................................576 54.11.2 Material handling..............................................................................576 54.12 Drive unit, final gear (2500)........................................................................577 54.12.1 Dismantling....................................................................................577 54.12.2 Material handling..............................................................................577 54.13 Wheels (3500)........................................................................................578 54.13.1 Dismantling....................................................................................578 54.13.2 Material handling..............................................................................578 54.14 Electric steering system (4300)......................................................................579 54.14.1 Dismantling....................................................................................580 54.14.2 Material handling..............................................................................580 54.15 General electric equipment (5100)....................................................................581 54.15.1 Dismantling....................................................................................581 54.15.2 Material handling..............................................................................581 54.16 Control system, drive function (5300)................................................................582 54.16.1 Dismantling....................................................................................582 54.16.2 Material handling..............................................................................582 54.17 Power system, drive function (5400)..................................................................583 54.17.1 Dismantling....................................................................................583 54.17.2 Material handling..............................................................................583 54.18 Control system, operation function (5500)............................................................584 54.18.1 Dismantling....................................................................................584 54.18.2 Material handling..............................................................................584 54.19 Steering/protective electronics (5700)...............................................................585 54.19.1 Dismantling....................................................................................585 54.19.2 Material handling..............................................................................585 54.20 Hydraulic unit (6100)................................................................................586 54.20.1 Dismantling....................................................................................586 54.20.2 Material handling..............................................................................586 54.21 Hydraulic system, fitted on the chassis (6200).......................................................587 54.21.1 Dismantling....................................................................................587 54.21.2 Material handling..............................................................................587 54.22 Hydraulic system, fitted on the mast (6300)..........................................................588 54.22.1 Dismantling....................................................................................588 54.22.2 Material handling..............................................................................588 54.23 Hydraulic cylinders (6600)...........................................................................589 54.23.1 Dismantling....................................................................................590 54.23.2 Material handling..............................................................................590 54.24 Main mast and mast (7100)............................................................................591 54.24.1 Dismantling....................................................................................591 54.24.2 Material handling..............................................................................591 54.25 Lift fork (7410).....................................................................................592 54.25.1 Dismantling....................................................................................592 54.25.2 Material handling..............................................................................592 54.26 Optional electric equipment (9300)...................................................................593 54.26.1 Dismantling....................................................................................593 54.26.2 Material handling..............................................................................593 54.27 Optional electric equipment (9400)...................................................................594 54.27.1 Dismantling....................................................................................594 54.27.2 Material handling..............................................................................594
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