Calibration

Electrical system 5000
Calibrations
T code Valid from serial no. Date Publication no.
815, 816 6070557 08/09/2010 7510399-020
14.8 Calibrations
14.8.1 Calibrating the hydraulic function

control
1. Use the arrow keys to select the upper left box. Use the +/- keys to
set the lever that is to be calibrated. (1 = lifting lever, 2 = reach
lever, 3 = tilting lever...)
2. Use the arrow keys to select the bottom left box.
3. Move the first lever to the max. position. Keep it in this mode and
press the green button.
The value is now stored as “Max”.
4. Release the lever so that it ends up in neutral (unactuated) mode.
Press the green button.
5. Move the lever to the min. position. Keep it in this mode and press
the green button.
6. Repeat steps 1 to 5 with all levers (5 in total). If any is missing, use
the factory setting by selecting the symbol at the bottom left and
pressing the green button.
7. To save the calibrations, switch off the truck by pressing the red
button.
14 – 24 Repair manual RRE140/160/180/200/250 © BT

Calibrations
Publication no. Date Valid from serial no. T code
7510399-020 08/09/2010 6070557 815, 816
14.8.2 Height measurement/reach movement

length calibration
The login screen may vary depending on the setting of parameter 503.
Figure Meaning
Movement must be upwards
Movement must be downwards
Calibration ready
Movement must be inwards
Movement must be outwards
Calibration ready
© BT Repair manual RRE140/160/180/200/250 14 – 25

Calibrations
815, 816 6070557 08/09/2010 7510399-020
Calibrating height measurement (option)

Reference sensor, free lift
The forks must be horizontal to the floor, i.e. not tilted.
1. From the operator’s position, look down into the fork carriage on
the right-hand inside of the mast. You will now be able to see the
free lift reference sensor, located ~0.8 m above the floor.
2. Lift the forks so that the sensor is approx. 50 mm below the upper
edge of the sensor rail.
3. Select screen 1 (if you have made the selection before, the speed
will be low on lifting).
4. Lift the forks. They will stop when the sensor leaves the upper edge
of the sensor rail.
5. Using a tape measure, measure the height of the forks manually
nearest to the mast. Check measure at the fork points to ascertain
that the forks and floor are level.
6. Enter the measured value (in mm) in the box at the bottom of the
screen and press the green button (I).
Pulse length for free lift sensor bearing
1. Move on to screen 2. If you are on screen 1, this is done by being
in the top box and pressing the plus button. Confirm using the
green button (I).
2. Lift the forks to the top of the free lift. They will automatically stop
when they reach the top.
nearest to the mast.
Max. free lift height
1. Move on to screen 3. If you are on screen 2, this is done by putting
the marker in the top box and pressing the plus button. Confirm
using the green button (I).
2. Lift the forks, slow them down when they get close to the max. free
lift height and continue lifting until the forks stop, which they will do
automatically at the max. free lift height. If point 2 has been done,
the forks will be at the top, therefore continue as described below.
3. Using the arrow keys, select the box along the bottom of the screen
and press the green button (I). The correct value is read and saved
automatically.

Calibrations
7510399-020 08/09/2010 6070557 815, 816
Reference sensor, main lift

green button (I).
2. Lift the main mast about 0.1 m above the free lift.
3. Lower the main mast to its "rest position".
automatically.
Pulse length for main lift sensor bearing
green button (I).
2. Attach a tape measure to the forks.
3. Measure the height of the forks manually. Measure closest to the
mast with the forks at the bottom of the main lift range.
4. Enter the measured value (in mm) in the middle box of the screen
and press the green button (I).
5. Lift the forks to the top of the main lift. They will automatically stop
when they reach it. If the full lift height cannot be reached, use the
highest possible height.
nearest to the mast.
Max. lift height
Note!
Make sure the ceiling height is sufficient to be able to lift the mast to
its maximum lift height.
2. Raise the forks to the top. (Reduce the speed of the forks as they
near the max. height)
automatically.
Applies from program 260038-010.
The displayed value in the box will be 4 mm lower than the max.
height to prevent the forks from being raised to the mechanical
stop.
Note!
If lift height limitation is required, the value for such is not entered
here but is instead entered in the lift height limitation parameter. The

Calibrations
815, 816 6070557 08/09/2010 7510399-020
programmed value in number 6 will then change when new

adjustment occurs.

Calibrations
7510399-020 08/09/2010 6070557 815, 816
Calibrating reach movement length

1. Lower the forks.
3. This is where you can calibrate the reach movement offset value
and length, which produces gentler braking at the end position.
4. Start by calibrating "zero"; this is done by retracting the mast to the
home position, releasing the lever and taking hold of it again within
1 second. Hold the control until a “beep” is heard and the length
that can be read high up in the middle of the screen changes to
zero.
5. Release the lever.
6. Save the offset value by selecting the box in the middle of the
screen, using the arrow keys, and pressing the green button. The
information in question is now saved.
7. Extend the mast until it stops (mechanical stop).
automatically.
Calibration of the zero position for the fork tilt
2. This is the calibration of the zero position for the fork tilt, i.e. the
position where the back of the fork is tilted to zero degrees.
3. Tilt the forks until they are completely horizontal, verify this using a
spirit level/clinometer.
automatically.

Calibrations
815, 816 6070557 08/09/2010 7510399-020
14.8.3 Valve calibration

The valve mode is used to calibrate the valves. Valves that can be
calibrated are:
Number Valve E S
1 Free lift – X
2 Not used
3 Main lift – X
4 Not used
5 Reach movement, out X X
6 Reach movement, in X X
7 Cab up – X
8 cab down – X
The opening point (S) and closing point (E) in the valves need to be
calibrated according to the table above.
“E” only needs to be calibrated for valves 5-6. To perform calibration,
select the desired valve in the table above.
Lift valve calibration

Free lift and main lift valve calibration
1. Select valve 1.
2. Lower the forks to floor level.
3. Start by entering a value in the “S” box: 100 mA.
4. Lift the forks using the lever as usual. The forks should now slowly
move upwards. If the forks do not move, increase the value in the
“S” box, by 25 mA at a time, until the forks start to move.
5. At approximately 0.5–1 second intervals, press the minus button
until the forks halt.
6. Calibration 1 (free lift) is now complete.
7. Repeat on valve 3 (main lift). The main lift will now move.
8. Calibration 3 (main lift) is now complete.

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Mast transition lift
1. Log in as usual and select followed by

tf f . In this
mode, you can change certain parameters even though the truck is
running.
Note!
You should not change a parameter while you are actively running a
movement
2. Go to parameter 1261.
3. Lift the forks at full speed from free lift to main lift (approx. 1 m
above free lift). Observe how the fork carriage goes to the top at the
same as time the mast moves.
• If the forks do not reach "free lift top" within a reasonable distance
(approx. 1 m into main lift), increase the parameter value.
• If the fork carriage hits too hard, reduce the parameter value.
4. Change the parameter value and save it using the green button (I).
5. Repeat steps 1-5 until the upward transition is satisfactory.

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815, 816 6070557 08/09/2010 7510399-020
Lowering valve calibration with height indication

1. Check that parameter 344=1 in the logged out mode by
pressing followed by and . Enter 344 in the

.
upper field and press the down arrow to get to the lower field. Enter
1 and save the value by pressing the green button (I).
2. Log in as usual and select followed by . In this

running.
Note!
movement
3. Change parameter 1262 to 30 (Enter 1262 in the upper field and
press the down arrow to get to the lower field. Enter 30 and save
the value by pressing the green button (I).
Free lowering valve
2. Lower the forks at full speed from approx. 1 m height.
• If the forks stop before the mechanical stop, the parameter value
must be increased.
• If the fork carriage hits too hard against the stop, reduce the
parameter value.
4. Repeat steps 1–4 until the lowering is correct.
5. Pick up a load >500 kg
6. Lower the forks at full speed from approx. 1 m above free lift. Check
how the forks behave at the transition from main lift to free lift. The
forks should maintain a consistent speed the whole time.
• If the forks stop and then move again, the parameter value must be
increased.
• If the forks accelerate excessively and move quickly, the parameter
value must be decreased.
7. Only adjust the parameter if necessary.

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Main lowering valve

1. Keep the load on the forks (>500 kg).
how the mast behaves when it moves down to its lower position
past the two inductive transducers.
• If the mast moves too slowly down to the bottom, the parameter
value must be increased.
• If the mast moves down too quickly and hits the bottom with a thud,
the parameter value must be decreased.
5. Repeat steps 1-5 until the lowering is correct.
Reset
1. If parameter 344 was changed at the start of calibration, reset it by
first logging out and then pressing followed by
and
2. Move the mast down to the floor.

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815, 816 6070557 08/09/2010 7510399-020
Lowering calibration without height indication
1. Log in as usual and select followed by

tf f . In this
running.
Note!
movement
2. Change parameter 1262 to 30 (Enter 1262 in the upper field and
press the down arrow to get to the lower field. Enter 30 and save
the value by pressing the green button (I).
Main lowering valve
1. Pick up a load >500 kg.
how the mast behaves when it moves down to its lower position
past the two inductive transducers.
• If the mast moves too slowly down to the bottom, the parameter
value must be increased.
• If the mast moves down too quickly and hits the bottom with a thud,
the parameter value must be decreased.
5. Repeat steps 1-5 until the lowering is correct.

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Free lowering valve

how the forks behave at the transition from main lift to free lift. The
forks should maintain a consistent speed the whole time.
• If the forks stop and then move again, the parameter value must be
increased.
• If the forks accelerate excessively and move quickly, the parameter
value must be decreased.
5. Repeat steps 1-5 until the transition is correct.
7. Move the forks to the middle of the free lift.
8. Lower the forks at the lowest possible speed.
9. If the speed is too high, the parameter value must be increased.
11. Repeat steps 7-10 until the speed is correct.
Reset
1. Move the load down to the floor.

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Reach movement valve calibration

Reach movement valve, out direction, starting point (S).
1. Select valve 5.
2. Enter 100 mA in the “S” box.
3. Retract the mast to its home position.
4. Extend the mast using the lever as usual. The reach carriage
should now slowly move out.
5. If the reach carriage does not move, increase the value in the "S"
box, by 25 mA at a time, until it starts to move on its own.
until the reach carriage halts.
7. Calibration of valve 5 (S) is complete.
Reach movement valve, in direction, starting point (S).
1. Select valve 6.
2. Enter 100 mA in the "S" box.
3. Start by running out the mast to its furthest position.
4. Retract the mast using the lever as usual. The reach carriage
should now slowly move in.
5. If the reach carriage does not move, increase the value in the "S"
box, by 25 mA at a time, until it starts to move on its own.
until the reach carriage halts.
7. Calibration of valve 6 (S) is complete.

Calibrations
7510399-020 08/09/2010 6070557 815, 816
Applies for program up to 260038-009.

Reach movement valve, out direction, end point (E).
1. Check that parameter 350=1.
2. Select valve 5 (reach movement valve, out direction).
3. Start by retracting the mast to its home position.
4. Enter -100 mA in the "E" box.
5. Run out the mast while lifting at full speed by using the levers as
normal.
6. If the reach carriage hits the end position, reduce the value using
the minus button and try again. Repeat until this does not happen.
7. Check that the set value is not too small by extending the mast and
then start to lift while reaching. If the running out movement slows
down when the lift starts, then the “E” value must be increased.
8. Check the settings by logging in to the usual mode and driving the
truck in the fork direction while at the same time running out the
reach carriage. Brake hard approx. 20 cm from the end position.
9. If the reach carriage hits the end position, reduce the value of
parameter 1275. Repeat until this does not happen.
10. Calibration of valve 5 is complete.
Applies for program up to 260038-009.
Reach movement valve, in direction, end point (E).
2. Select valve 6.
3. Enter -100 mA in the "E" box.
5. Run in the mast while lifting at full speed by using the levers as
normal.
6. If the reach carriage hits the end position, reduce the value using
the minus button and try again. Repeat until this does not happen.
7. Check that the set value is not too small by retracting the mast and
then start to lift while retracting. If the running in movement slows
down when the lift starts, then the “E” value must be increased.
8. Check the settings by logging in to the usual mode and driving the
truck in the fork direction while at the same time running in the
reach carriage. Brake hard approx. 20 cm from the end position.
9. If the reach carriage hits the end position, reduce the value of
parameter 1276. Repeat until this does not happen.
10. Calibration of valve 6 (E) is complete.

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Reach movement valve, out direction, stop distance (E).
2. Pick up a load ~1000 kg.
3. Select valve 5.
4. Start by retracting the mast to its home position.
5. Run out the mast while lifting at full speed by using the levers as
normal.
6. If the reach carriage hits the end position, increase the value using
the plus button and try again. Repeat until this does not happen.
The value increases by 12 mm, which is the graduation of the
measurement rail on the reach carriage.
Reach movement valve, in direction, stop distance (E).
2. Pick up a load ~1000 kg.
3. Select valve 6.
5. Run in the mast while lifting at full speed by using the levers as
normal.
6. If the reach carriage hits the end position, increase the value using
the plus button and try again. Repeat until this does not happen.
The value increases by 12 mm, which is the graduation of the
measurement rail on the reach carriage.
7. Calibration of valve 6 (E) is complete.

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Calibration of the Ergo cab

This calibration need only be performed if cab tilt function feels jerky.
1. Start with the cab at its lowest position.
2. Select valve 7 (cab tilt up).
4. Move the lifting/lowering lever backwards to its end position. The
cab should not move.
5. If the cab moves upwards, reduce the value in the "S" box, 25 mA
at a time until it stops.
6. At approximately 0.5–1 second intervals, press the plus button until
the cab starts to lift.
Note!
Do not tilt the cab beyond its balancing point; the cab can fall
backwards!
8. Select valve 8 (cab tilt down).
9. Start by tilting the cab up 150 mm. (To do this, put the truck in
service mode and select cab tilt mode, raise the cab to max. 150
mm, switch off and return to the Ergo cab calibration valve 8).
11. Move the lifting/lowering lever forwards to its end position. The cab
should not move.
12. If the cab moves downwards, reduce the value in the "S" box, 25
mA at a time until it stops.
13. At approximately 0.5–1 second intervals, press the plus button until
the cab starts to sink.
15. Switch off the truck by pressing the red button (O) to save the
calibration.

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815, 816 6070557 08/09/2010 7510399-020
14.8.4 Weight calibration

The weighing mode is used to calibrate the fork load indication.
Note!
Incorrect weight calibration may result in incorrect speed and braking
power limits and that the load indication in CID/LID shows incorrect
values.
Calibrating the weight indication

Calibration of unloaded forks, free-lift
1. Lower the unloaded forks to the floor.
2. Select Weight calibration; enter 1 in the box at the top right.
3. Lift the forks at full speed to approximately 1 metre above the
ground.
4. Wait for approx. 10 seconds.
5. Read the weight on the CID display.
6. Using the arrow keys, select the middle box (to the right). Use the
plus/minus buttons to adjust the read value to 0 (± 5 kg). For each
change, be sure to press the green key to save the value.
Calibration with load, free-lift
1. Pick up a load with a known weight (~ 500 kg) with the forks. Lower
the load to the ground.
2. Change the value “1000” in the lower left box to the known weight
of the load.
3. Lift the forks at full speed to approx. 1 metre above the ground.
5. Select the lower right-hand box.
6. Read off the weight on the CID display. Use the plus/minus buttons
to adjust the read value to the known weight of the load (± 5 kg).
Calibration of unloaded forks, main lift.
1. Lower the unloaded forks to the floor.
2. Select calibration 2 in the upper right-hand box.
3. Lift the forks at full speed to approximately 1 metre up into the main
lift range.
5. Select the middle right-hand box using the arrow keys.
to adjust the read value to 0 (± 5 kg). For each change, be sure to
press the green key to save the value.

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Calibration with load, main lift.

1. Pick up a load with a known weight (~ 500 kg) with the forks. Lower
the load to the ground.
2. Change the value “1000” in the lower left box to the known weight
of the load.
3. Lift the forks at full speed to 1 metre up into the main lift range.
5. Select the lower right-hand box.
to adjust the read value to the known weight of the load (± 5 kg).
7. Switch off the truck with the red button to save the calibrations.

Calibration

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Electrical system 5000

14.8.1 Calibrating the hydraulic function

14 – 24 Repair manual RRE140/160/180/200/250 © BT

14.8.2 Height measurement/reach movement

Movement must be downwards

Movement must be inwards

Movement must be outwards

© BT Repair manual RRE140/160/180/200/250 14 – 25

Calibrating height measurement (option)

14 – 26 Repair manual RRE140/160/180/200/250 © BT

Reference sensor, main lift

© BT Repair manual RRE140/160/180/200/250 14 – 27

programmed value in number 6 will then change when new

14 – 28 Repair manual RRE140/160/180/200/250 © BT

Calibrating reach movement length

© BT Repair manual RRE140/160/180/200/250 14 – 29

14.8.3 Valve calibration

Lift valve calibration

14 – 30 Repair manual RRE140/160/180/200/250 © BT

Mast transition lift

1. Log in as usual and select followed by

© BT Repair manual RRE140/160/180/200/250 14 – 31

Lowering valve calibration with height indication

pressing followed by and . Enter 344 in the

2. Log in as usual and select followed by . In this

14 – 32 Repair manual RRE140/160/180/200/250 © BT

Main lowering valve

first logging out and then pressing followed by

© BT Repair manual RRE140/160/180/200/250 14 – 33

Lowering calibration without height indication

1. Log in as usual and select followed by

14 – 34 Repair manual RRE140/160/180/200/250 © BT

Free lowering valve

© BT Repair manual RRE140/160/180/200/250 14 – 35

Reach movement valve calibration

14 – 36 Repair manual RRE140/160/180/200/250 © BT

Applies for program up to 260038-009.

© BT Repair manual RRE140/160/180/200/250 14 – 37

Applies from program 260038-010.

14 – 38 Repair manual RRE140/160/180/200/250 © BT

Calibration of the Ergo cab

© BT Repair manual RRE140/160/180/200/250 14 – 39

14.8.4 Weight calibration

Calibrating the weight indication

14 – 40 Repair manual RRE140/160/180/200/250 © BT

Calibration with load, main lift.

© BT Repair manual RRE140/160/180/200/250 14 – 41

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