Repair Manual En: Applies From Serial Number: 6070557

Repair manual en
RRE140/160/180/200/250
Applies from serial number: 6070557
Order number: 7510399-020

Issued: 2012-10-03 ESP
© BT Industries AB
Document revisions:
Publishing Order Amendments

date number
2009-06-22 7510399-040 Completely new issue.
2009-12-22 7510399-040 Update:
Chapter: 4.1.3, 4.14.4, 5, 8.2.2, 8.5.2, 8.5.4, 8.5.5, 8.6.4,
13.2, 14.8, 15.6, 15.10, 15.11, 16.1.2, 20.1, 22.4
New:
Chapter: 4.1.1, 4.1.2, 4.1.4, 4.5.3, 4.7, 4.9.7, 9.3, 9.4.2, 9.4.3,
14.5, 15.1, 15.3.3, 20.2, 20.7
2012-09-03 7510399-040 Update:
Chapter 4.3.2 has been updated.
Chapter: 5 New parameters have been added.
Chapter: 20.1 (columns added referring to schematic pages),
20.6, 20.7, 21.2.3
Chapter: 8 Troubleshooting with new error codes.
Chapter: 7.4.2 Maintenance, checking fork yoke 1 item
added, updated items for checking for cracks.
Added replacing oil in gears at 1000h.
Chapter: 7.4.1 Maintenance, checking parking brake every
500 b-hour.
Chapter: 15.2 Instructions for replacing the filter has been
added
Chapter: 15.3 Instructions for replacing the valves has been
added
Chapter: 15.7, Free lift cylinder has been updated
Chapter: 22.4, Service instrument (CASTOR USB) for
programming has been added
Chapter: 11.3.2 oil change has been updated.
Chapter: 16.5 Fork carriage
This manual contains information on the following trucks:
T-Code Model: Serial number

815 RRE140, RRE140C, RRE140CC, 6070557-
RRE140E, RRE140EC, RRE140ECC,
RRE160, RRE160C, RRE160CC
RRE160E, RRE160EC, RRE160ECC
816 RRE180, RRE180C, RRE180CC, 6070557-
RRE200, RRE200C, RRE200CC,
RRE250, RRE250C, RRE250CC,
RRE250E, RRE250EC, RRE250ECC
© BT Repair manual RRE140/160/180/200/250

Contents
Order number Date Valid from serial number T-code
7510399-020 2012-10-03 6070557 815, 816
1 – Contents
2 – General introduction ......................................................................... 2-1
2.1 How to use the manual................................................................... 2-1
2.2 Warning symbols ........................................................................... 2-2
2.3 Pictogram....................................................................................... 2-2
3 – General safety rules .......................................................................... 3-1

3.1 Safety while working ...................................................................... 3-1
3.2 Electrical system ............................................................................ 3-2
3.3 Safe lifting ...................................................................................... 3-3
4 – Descriptions of functions ................................................................. 4-1

4.1 Chassis 0000 ................................................................................. 4-1
4.1.1 Operator’s cabin (0500) ................................................... 4-1
Versions for cold-store cabs ............................................ 4-1
Emergency exit from the cab ........................................... 4-2
4.1.2 Cab windows (0530) ........................................................ 4-3
Electrically heated windows ............................................. 4-3
4.1.3 Operator's seat (0620) ..................................................... 4-4
Adjustment: ...................................................................... 4-4
Button for seat heater ...................................................... 4-4
4.1.4 Cab heating/ventilation (0630) ......................................... 4-5
Climate control knobs ...................................................... 4-5
Ventilation ........................................................................ 4-5
Temperature .................................................................... 4-5
4.1.5 Operator protection (0840) .............................................. 4-6
Tilt stops .......................................................................... 4-6
Overhead guard ............................................................... 4-8
4.2 Motors 1000 ................................................................................... 4-9
4.2.1 General ............................................................................ 4-9
4.2.2 Electric pump motor (1710) ............................................. 4-9
General ............................................................................ 4-9
Design ............................................................................. 4-9
4.2.3 Electric steering motor (1730) ....................................... 4-11
General .......................................................................... 4-11
Design ........................................................................... 4-11
4.2.4 Fan motor/fan (1740) ..................................................... 4-12
4.2.5 Electric drive motor (1760) ............................................ 4-13
General .......................................................................... 4-13
Design ........................................................................... 4-13
4.3 Drive gear - 2000 ......................................................................... 4-14
4.3.1 General .......................................................................... 4-14
4.3.2 Design ........................................................................... 4-15
4.4 Brake system 3100 ...................................................................... 4-16
4.4.1 General .......................................................................... 4-16
Travel brake ................................................................... 4-16
Parking brake ................................................................ 4-16
Emergency brake .......................................................... 4-16
4.4.2 Drive motor brake (travel brake) .................................... 4-17
Accelerator released ...................................................... 4-17
Changing the direction of travel ..................................... 4-17
© BT Repair Manual RRE140/160/180/200/250 1– 1

Contents
T-code Valid from serial number Date Order number
815, 816 6070557 2012-10-03 7510399-020
4.4.3 Multiple disc brake, support arm (travel brake) ............. 4-18
General .......................................................................... 4-18
Design ........................................................................... 4-18
4.4.4 Disc brake on the drive motor (parking brake) .............. 4-19
General .......................................................................... 4-19
Design ........................................................................... 4-19
4.5 Steering system 4000 .................................................................. 4-20
4.5.1 General .......................................................................... 4-20
4.5.2 Design ........................................................................... 4-20
4.5.3 Sensor ........................................................................... 4-21
4.6 Operator compartment................................................................. 4-22
4.6.1 Truck control, overview .................................................. 4-22
Right-hand control panel, single control ........................ 4-22
Right-hand control panel, multi-control .......................... 4-22
Emergency off switch .................................................... 4-23
Steering wheel module .................................................. 4-24
Pedals ............................................................................ 4-24
4.6.2 Single-function controls ................................................. 4-25
4.6.3 Multi-function controls .................................................... 4-26
4.6.4 Central Information Display – CID ................................. 4-27
Navigation ...................................................................... 4-27
LED symbols ................................................................. 4-30
Information symbols ...................................................... 4-31
Operator parameter symbols – Overview ...................... 4-32
Blocking symbols – Overview ........................................ 4-33
Service functions ........................................................... 4-35
Calibration functions ...................................................... 4-37
Automatic calibration of lowering valve ......................... 4-38
Configuration functions .................................................. 4-40
Other functions .............................................................. 4-43
4.6.5 Load Information Display – LID (option) ........................ 4-45
LED symbols ................................................................. 4-45
Symbols in the display part ............................................ 4-46
4.7 sensors and sensors (5800)......................................................... 4-47
4.7.1 Inductive sensors ........................................................... 4-47
4.7.2 Position sensor .............................................................. 4-47
4.7.3 Magnetic sensor ............................................................ 4-48
4.8 Operation and connection sequences.......................................... 4-49
4.9 Functions ..................................................................................... 4-82
4.9.1 General overview ........................................................... 4-82
Terminology ................................................................... 4-82
Components .................................................................. 4-82
4.9.2 MCU – main control unit ................................................ 4-83
General .......................................................................... 4-83
Downloading software ................................................... 4-83
System communication ................................................. 4-83
4.9.3 ACT/ACH transistor regulators ...................................... 4-84
General .......................................................................... 4-84
4.9.4 Start-up .......................................................................... 4-84
4.9.5 Shutdown ....................................................................... 4-85
4.9.6 Driving ........................................................................... 4-85
Introduction .................................................................... 4-85
Acceleration and speed reduction ................................. 4-85
Reversing ...................................................................... 4-86
Brake ............................................................................. 4-86
Travel speed ................................................................. 4-87
1– 2 Repair Manual RRE140/160/180/200/250 © BT
Contents
7510399-020 2012-10-03 6070557 815, 816
4.9.7 OTP ............................................................................... 4-88

Travel speed reduction - steering angle ........................ 4-88
Travel speed reduction - extension of reach carriage ... 4-88
Speed reduction - main lift range ................................... 4-88
Prevention of lifting/lowering of the forks ....................... 4-88
Reduced extension speed ............................................. 4-88
4.9.8 Guide ............................................................................. 4-89
Steering position control ................................................ 4-89
Steering speed .............................................................. 4-89
Steering reference ......................................................... 4-90
Travel speed limitation ................................................... 4-90
Compass rose ............................................................... 4-90
4.9.9 Hydraulic system ........................................................... 4-91
Definitions ...................................................................... 4-91
Controls ......................................................................... 4-91
Lift .................................................................................. 4-91
Reach movement .......................................................... 4-92
Lift height limitation ........................................................ 4-92
Maximum height limitation ............................................. 4-92
Auxiliary/Extra functions (option) ................................... 4-93
4.10 Height preselector, description of function ................................... 4-94
4.10.1 Using the height preselector .......................................... 4-94
4.10.2 Symbols ......................................................................... 4-94
4.10.3 Buzzer ........................................................................... 4-94
4.10.4 Height preselector levels ............................................... 4-95
4.10.5 Level selection ............................................................... 4-95
4.10.6 Height programming ...................................................... 4-96
4.10.7 Height preselector and TruckCom ................................. 4-97
4.10.8 Lifting/lowering movement ............................................. 4-97
4.10.9 Parameter settings braking at height preselector .......... 4-98
4.11 Hydraulic system 6000................................................................. 4-99
4.11.1 General .......................................................................... 4-99
4.11.2 Tank ............................................................................... 4-99
4.11.3 Filter ............................................................................... 4-99
Return filter .................................................................... 4-99
Dehumidification filter .................................................... 4-99
4.11.4 Hydraulic pump ............................................................ 4-100
4.11.5 Valve unit ..................................................................... 4-100
Main valve block .......................................................... 4-100
Second valve block ...................................................... 4-101
4.11.6 Cylinders ...................................................................... 4-102
Main lift cylinders ......................................................... 4-102
Free-lift cylinder ........................................................... 4-102
Cylinders for the reach movement, cabin tilt, sideshift and fork
tilt ................................................................................. 4-102
4.11.7 Lift and lowering function ............................................. 4-103
Lifting and lowering of free lift ...................................... 4-103
Transition from free lift to main lift ............................... 4-103
Lifting and lowering of main lift .................................... 4-103
Reach movement, in and out ....................................... 4-103
Simultaneous operation of mast lift and reach movement . 4-
104
4.11.8 Extra functions ............................................................. 4-104

Contents
815, 816 6070557 2012-10-03 7510399-020
4.11.9 Cabin tilt (RRE Ergo) ................................................... 4-104

Hydraulic priority system ............................................. 4-104
Cabin tilt (RRE Ergo) during servicing ......................... 4-105
Cabin tilt in the event of hydraulic or electrical power loss 4-
105
4.12 Mast 7000 .................................................................................. 4-106
4.12.1 Mast and reach carriage .............................................. 4-106
4.13 Lifting devices ............................................................................ 4-107
4.13.1 Fork extensions ........................................................... 4-107
4.13.2 Telescopic forks ........................................................... 4-107
4.14 Accessories 9000....................................................................... 4-109
4.14.1 Radio equipment ......................................................... 4-109
4.14.2 Extra lighting ................................................................ 4-109
4.14.3 Extra warning lights/alarm ........................................... 4-110
4.14.4 Turn signal lights ......................................................... 4-110
4.14.5 Movement alarm .......................................................... 4-111
4.14.6 Positioning/TV equipment ............................................ 4-112
4.14.7 Extra electrical equipment ........................................... 4-114
4.14.8 Other extra equipment ................................................. 4-115
Fork spacers ................................................................ 4-115
Load rest ...................................................................... 4-116
E-bar ............................................................................ 4-117
Flashlight ..................................................................... 4-118
5 – Parameters ......................................................................................... 5-1

5.1 General .......................................................................................... 5-1
5.2 Displaying/changing parameters.................................................... 5-1
5.3 Operator parameters...................................................................... 5-2
5.3.1 Overview .......................................................................... 5-2
5.3.2 Connection to logged-in operator .................................... 5-3
5.3.3 Description ....................................................................... 5-4
Parameter 1 – Steering ................................................... 5-4
Parameter 2, 3 – Maximum travel speed ......................... 5-6
Parameters 4 and 5 – Acceleration/Retardation .............. 5-6
Parameter 6 – Cab tilt ...................................................... 5-6
5.4 General service parameters........................................................... 5-7
5.4.1 Overview .......................................................................... 5-7
5.4.2 Description ....................................................................... 5-7
Parameter 101/104 – Service/Logout .............................. 5-7
Parameter 105/106/114/115/117 (Travel alarms 1 and 2) 5-8
Parameter 107/108 – Battery ........................................ 5-10
Parameter 109/110/111/112 – Collision sensor ............ 5-14
Parameter 113 (shunt value) ......................................... 5-15
Parameter 116 (Door on cold store cab) ....................... 5-16
5.4.3 Service parameters, travel functions ............................. 5-17
5.4.4 Overview ........................................................................ 5-17
5.4.5 Description ..................................................................... 5-17
Parameter 201 – Deceleration when reversing ............. 5-17
Parameter 202/203/204 – Adjusting erroneous, maximum
travel speeds ................................................................. 5-18
Parameter 205/206/207 – Adjusting erroneous, maximum
travel speeds ................................................................. 5-18
Parameter 208 - Creep speed in travel direction
control ............................................................................ 5-19

Contents
7510399-020 2012-10-03 6070557 815, 816
Parameter 209/210 – Reduced maximum travel

speed above a certain lift height .................................... 5-19
speed with a certain reach length .................................. 5-20
Parameter 213 – Permanently reduced maximum
travel speed ................................................................... 5-20
Parameter 214 – Adjusting the maximum travel
speed in main lift range ................................................. 5-20
5.5 Service parameters, hydraulics.................................................... 5-21
5.5.1 Overview ........................................................................ 5-21
5.5.2 Description ..................................................................... 5-24
Parameter 301/302/303/304 – Extra valve function ...... 5-24
Parameter 305/306/307/308 – Max. oil pressure through
valve Q8 ........................................................................ 5-26
Parameter 313/314/315/316 – Closing time .................. 5-27
Parameter 317/318/319/320 – Max. oil flow through
valve Q8 ........................................................................ 5-27
valve Q9 ........................................................................ 5-28
Parameter 325/326/327/328 – Opening/closing time
valve Q8 ........................................................................ 5-28
valve Q9 ........................................................................ 5-29
Parameter 341/342 – Reducing the lifting/lowering
speed ............................................................................. 5-29
Parameter 343 – Reduction of reach speed .................. 5-30
Parameter 344 - Reduction of fork lowering speed
before floor level ............................................................ 5-30
Parameter 345- Lift/lower sensitivity .............................. 5-30
Parameter 347/348 – Prevent the lifting/lowering of
forks ............................................................................... 5-31
Parameter 349 - Fork weight ......................................... 5-31
Parameter 350 – Multi-function ..................................... 5-32
Parameters 358/359/360 – Deactivation of
hydraulic functions ......................................................... 5-33
Parameters 361/362/363/364/365 /366 – Function
related, maximum lift/lowering speeds .......................... 5-34
Parameter 367/368 – Fork limit for deactivating the
extension of the fork carriage and for sideshift .............. 5-35
Parameter 369 through 379 – Height preselector ......... 5-36
Parameter 380 through 386 – Lift height limitations ...... 5-38
Parameters 387 through 393 – Configuration of lift
height limitations ............................................................ 5-38
Parameters 395/396/397 – Function-related,
maximum lift heights ...................................................... 5-39
Parameters 398/399 – Operator profile dependent,
maximum lift heights ...................................................... 5-40
5.6 Service parameters, CID.............................................................. 5-41
5.6.1 Overview ........................................................................ 5-41
5.6.2 Description ..................................................................... 5-42
Parameter 503 – Login method ..................................... 5-42
Parameter 504/505/506/507 – Smart Access ................ 5-42
Parameters 508/509/512/513/514 – CID configuration . 5-47
Parameter 510/511 - Height pre-selector ...................... 5-49
5.7 Service parameters, General Function Unit GFU......................... 5-50

Contents
815, 816 6070557 2012-10-03 7510399-020
5.8 General factory parameters ......................................................... 5-51

5.8.1 Overview ........................................................................ 5-51
5.8.2 Description ..................................................................... 5-52
Parameter 1001 - Truck type ......................................... 5-52
Parameter 1002 - (Drive motor) ..................................... 5-52
Parameter 1003 – Pedal type ........................................ 5-52
Parameter 1004 - Steering servo .................................. 5-53
Parameter 1005 - Pump motor ...................................... 5-53
Parameter 1006 – Hydraulic pump ................................ 5-53
Parameter 1007 – Activation of hydraulic levers ........... 5-54
Parameter 1008 – Mast type ......................................... 5-54
Parameter 1009 – Height indication .............................. 5-55
Parameter 1010 - Weight indication .............................. 5-55
5.9 Factory parameters, activation of options .................................... 5-56
Parameter 1115 (Steering angle) .................................. 5-58
Parameter 1116 (Extended mast) ................................. 5-58
Parameter 1117 (Weight of load and fork height) .......... 5-59
....................................................................................... 5-59
Parameter 1118 (Main lift range) ................................... 5-59
5.10 Factory parameters, calibration ................................................... 5-61
6 – Installation ......................................................................................... 6-1

6.1 Transporting the truck .................................................................... 6-1
Method 1 .......................................................................... 6-1
Method 2 .......................................................................... 6-1
6.2 Initial operation............................................................................... 6-2
6.2.1 Tool .................................................................................. 6-2
6.2.2 Battery ............................................................................. 6-2
Placing the battery ........................................................... 6-2
Battery parameters .......................................................... 6-3
6.2.3 Mast, fitting ...................................................................... 6-3
6.2.4 Parameters on initial operation ........................................ 6-3
Load indicator .................................................................. 6-3
Ergo cabin ....................................................................... 6-4
Cold store cabin ............................................................... 6-4
6.2.5 Parameters for optional equipment ................................. 6-5
Height measurement (option) .......................................... 6-5
Travel speed limitation, height-dependent ....................... 6-5
Travel speed limitation, reach movement dependent ...... 6-5
Travel speed limitation, parameter-dependent ................ 6-6
Collision sensor (BT) ....................................................... 6-6
6.2.6 Test driving ...................................................................... 6-6
7 – Maintenance ....................................................................................... 7-1

7.1 Introduction, maintenance.............................................................. 7-1
7.2 Safety precautions for maintenance work ...................................... 7-2
7.3 Checks for cracks .......................................................................... 7-4
7.3.1 Visual inspection .............................................................. 7-4
7.3.2 Crack detection ................................................................ 7-5
Crack detection with liquid penetrants ............................. 7-5
Crack detection with magnetic yoke ................................ 7-5
7.4 Periodic maintenance .................................................................... 7-6
7.4.1 Every 500 B-hours/180 days ........................................... 7-6
7.4.2 Every 1000 B-hours/360 days ......................................... 7-8
7.4.3 Every 2000 B-hours/720 days ....................................... 7-13

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7510399-020 2012-10-03 6070557 815, 816
7.4.4 Every 3000 B-hours/1080 days ..................................... 7-13

7.4.5 Every 5000 B-hours/1800 days ..................................... 7-15
7.4.6 Annual status inspection ................................................ 7-15
7.5 Maintenance instructions ............................................................. 7-16
7.5.1 Cleaning and washing ................................................... 7-16
High-pressure washers .................................................. 7-16
Degreasing agents ........................................................ 7-16
Cleaning the truck exterior ............................................. 7-16
Cleaning the chain ......................................................... 7-17
Cleaning the motor compartment .................................. 7-17
Electrical components ................................................... 7-17
8 – Troubleshooting ................................................................................ 8-1

8.1 Abbreviations used in this section .................................................. 8-1
8.2 Truck help functions ....................................................................... 8-1
8.2.1 Error log menu ................................................................. 8-1
Description ....................................................................... 8-1
Access ............................................................................. 8-1
8.2.2 Error information menu .................................................... 8-2
Description ....................................................................... 8-2
Access ............................................................................. 8-2
8.2.3 Diagnostic screens .......................................................... 8-2
Access ............................................................................. 8-2
State 1 – Voltage from the control console levers ........... 8-3
State 2 – Digital signals from the truck control to CID .... 8-4
State 3 – Voltage from control/sensor to MCU ............... 8-5
State 4 – Digital input signals to MCU ............................ 8-6
State 5 – Digital output signals from MCU ...................... 8-8
State 6 – PWM output signals from MCU ....................... 8-9
State 7 – FCU (not used) ................................................. 8-9
State 8 – FCU (not used) ................................................. 8-9
State 9 – GFU (not used) ................................................ 8-9
State 10 – GFU (not used) .............................................. 8-9
State 11 – Temperature signals ................................... 8-10
State 12 – Voltage levels .............................................. 8-10
State 13 – Travel information ....................................... 8-11
State 14 – Steering information .................................... 8-12
State 15 – Lift/lowering information ............................... 8-13
Stage 16 – Reach movement information .................... 8-14
Stage 17 – Hydraulic information ................................. 8-15
State 18 – VNA (not used) ............................................. 8-16
State 19 – Pressure sensor for free and main lifts ........ 8-16
8.3 Initial troubleshooting ................................................................... 8-17
8.4 Troubleshooting using catch symbol............................................ 8-18
8.5 Troubleshooting using error codes............................................... 8-26
8.5.1 CID, warnings and errors ............................................... 8-28
8.5.2 MCU and other warnings and errors ............................. 8-32
8.5.3 Drive system error ......................................................... 8-42
8.5.4 Hydraulic system error ................................................... 8-55
8.5.5 Steering system, warnings and errors ........................... 8-88
8.5.6 GFU, warnings and errors ............................................. 8-95

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8.6 Troubleshooting without indications ............................................. 8-97

8.6.1 Mechanical brake (3000) ............................................... 8-97
8.6.2 Steering (4000) .............................................................. 8-97
8.6.3 Telescopic forks ............................................................. 8-98
8.6.4 Log on was normal, but one or several functions cannot
be used .......................................................................................8-99
9 – Frame/Chassis 0000 .......................................................................... 9-1

9.1 General .......................................................................................... 9-1
9.2 Motor hood (0340) ......................................................................... 9-1
9.2.1 Opening the motor compartment ..................................... 9-1
RRE 140-RRE 250 .......................................................... 9-1
To open the motor compartment: .................................... 9-1
To close the motor compartment: .................................... 9-1
Replacing the motor hood ............................................... 9-2
Adjustment of motor hood ............................................... 9-2
9.3 Battery compartment components (0390)...................................... 9-4
9.3.1 Adjusting the battery bed ................................................. 9-4
9.4 Operator's cab (0500) .................................................................... 9-5
9.4.1 Cab tilting RRE 140 – 250 Ergo ...................................... 9-5
9.3.1 Cab windows (0530) ........................................................ 9-6
Fitting a window ............................................................... 9-6
9.3.2 Cab door (0550) .............................................................. 9-8
Disassembly of the door lock ........................................... 9-8
Tools required .................................................................. 9-9
Method ............................................................................. 9-9
Disassembly of the lock device ..................................... 9-10
9.4 Operator compartment (0600) ..................................................... 9-12
9.4.1 Operator's seat (0620) ................................................... 9-12
Disassembling the entire seat ....................................... 9-12
Replacing the seat switch .............................................. 9-13
Replacing the back rest ................................................. 9-14
Replacing the chair seat ................................................ 9-15
Replacing the seat heater switch ................................... 9-15
9.4.2 Cab heating/ventilation (0630) ....................................... 9-16
Replacing the air filter on the cold store cabin: .............. 9-16
Removing the fan and heater ........................................ 9-17
Replacing the potentiometers ........................................ 9-21
9.4.3 Internal fittings (0680) .................................................... 9-23
9.4.4 Disassembling/assembling the floor plate,
B version 0680 9-24
9.5 Safety equipment (0800).............................................................. 9-26
9.5.1 Checking the overhead guard (0810) ............................ 9-26
9.5.2 Adjusting the tilt stops (0840) ........................................ 9-27
10 – Motors 1000 ................................................................................... 10-1

10.1 Motor sensors .............................................................................. 10-1
10.1.1 Temperature sensor ...................................................... 10-1
Retrofitting an external temperature sensor .................. 10-2
10.1.2 Replacing the motor speed sensor ................................ 10-2
10.2 Pump motor (1710) ...................................................................... 10-3
10.2.1 General .......................................................................... 10-3
The pump motor dismantled .......................................... 10-3
10.2.2 Replacing the bearing on the pump motor .................... 10-4
Dismantling the pump motor .......................................... 10-4

Contents
7510399-020 2012-10-03 6070557 815, 816
Reassembling the pump motor ...................................... 10-6

10.3 Steering motor and steering unit (1730)....................................... 10-7
10.3.1 General .......................................................................... 10-7
10.3.2 Layout of the flange holes ............................................. 10-7
10.3.3 Removing the steering motor from the truck ................. 10-8
10.3.4 Fitting the steering motor in the truck ............................ 10-8
10.4 Fan motor/fan (1740) ................................................................... 10-9
10.4.1 General .......................................................................... 10-9
10.4.2 Replacing the frequency converter cooling fan ............. 10-9
Standard truck ............................................................... 10-9
Ergo truck ...................................................................... 10-9
10.4.3 Replacing the motor compartment cooling fan ............ 10-11
10.5 Drive motor (1760) ..................................................................... 10-12
10.5.1 General ........................................................................ 10-12
The drive motor dismantled ........................................ 10-12
10.5.2 Removing the drive motor from the truck .................... 10-13
10.5.3 Dismantling the drive motor ......................................... 10-15
10.5.4 Cleaning ...................................................................... 10-17
10.5.5 Assembling the drive motor ......................................... 10-18
10.5.6 Fitting the drive motor in the truck ............................... 10-20
11 – Drive gear 2000 .............................................................................. 11-1

11.1 General ........................................................................................ 11-1
11.2 Repair- and serviceability............................................................. 11-1
11.3 Measures ..................................................................................... 11-2
11.3.1 Checking the oil level. .................................................... 11-2
11.3.2 Oil change ..................................................................... 11-3
Oil refill table. ................................................................. 11-3
11.3.3 Leakage from the bottom cap ........................................ 11-4
11.3.4 Replacing the drive gear ................................................ 11-5
Special tools .................................................................. 11-5
Exposing the drive gear ................................................. 11-5
Removing a drive motor from the truck ......................... 11-5
Removing a steering motor from the truck .................... 11-5
Removing the drive gear from the truck ........................ 11-6
Fit the drive gear back in the truck ................................ 11-8
Placing the steering motor in the truck .......................... 11-9
Placing the drive motor in the truck ............................... 11-9
Concluding work ............................................................ 11-9
12 – Brake and wheel 3000 ................................................................... 12-1

12.1 Travel brake system (3100) ......................................................... 12-1
12.1.1 Removing the support arm's multiple disc brake ........... 12-1
12.1.2 Dismantling the multiple disc brake ............................... 12-1
Inspection ...................................................................... 12-2
Adjusting play ................................................................ 12-2
Assembling the multiple disc brake ............................... 12-3
12.1.3 Installing the multiple disc brake in the truck ................. 12-3
12.1.4 Checking the wheel brake's brake force ........................ 12-4
12.2 Parking brake (3300).................................................................... 12-5
12.2.1 General .......................................................................... 12-5
12.2.2 Emergency release of the parking brake ....................... 12-6
12.2.3 Checking the brake force ............................................... 12-6
12.2.4 Removing the parking brake from the truck ................... 12-7
Dismantling and checking for wear ................................ 12-8

Contents
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Adjusting the air gap .................................................... 12-10

12.2.5 Installing the parking brake in the truck ....................... 12-12
12.3 Drive wheel (3530) ..................................................................... 12-13
12.3.1 General ........................................................................ 12-13
12.3.2 Removing the drive wheel from the truck .................... 12-13
12.3.3 Installing the drive wheel on the truck ......................... 12-13
12.4 Wheel bolt (3530)....................................................................... 12-14
General ........................................................................ 12-14
12.4.1 Replacing wheel bolts .................................................. 12-14
12.5 Support arm wheel (3550).......................................................... 12-15
12.5.1 Removing the support arm wheel from the truck ......... 12-15
12.5.2 Replacing a wheel bearing - braked wheel (A) ............ 12-16
12.5.3 Replacing a wheel bearing - unbraked wheel (B) ........ 12-17
12.5.4 Fitting the support arm wheel to the truck ................... 12-18
12.5.5 Wheel wear and tear ................................................... 12-19
13 – Steering system 4000 .................................................................... 13-1

13.1 Electric steering wheel (4310)...................................................... 13-1
13.1.1 General .......................................................................... 13-1
13.1.2 Replacing the pulse transducer on the steering wheel module
13-1
13.1.3 Removing the operating console from the truck ............ 13-2
13.1.4 Replacing the wiring harness in the operating console . 13-4
13.1.5 Fitting the operating console in the truck ....................... 13-6
13.2 Steering reference sensor (4350) ................................................ 13-7
General .......................................................................... 13-7
13.2.1 Replacing the reference transducer [B17] ..................... 13-7
13.3 Steering bearings (4380) ............................................................. 13-8
13.3.1 Removing a steering bearing from the drive gear ......... 13-8
13.3.2 Fitting a steering bearing on the drive gear ................... 13-8
14 – Electrical system 5000 .................................................................. 14-1

14.1 Battery (5110) .............................................................................. 14-1
14.1.1 Battery recommendation ............................................... 14-1
Exide gel batteries (e.g. Sonnenschein) ........................ 14-1
Hawker Evolution gel batteries ...................................... 14-1
14.1.2 Battery installation ......................................................... 14-2
Replacement/installation of battery. .............................. 14-2
Procedure without battery changing table ..................... 14-3
Procedure with battery changing table .......................... 14-3
14.2 LID (5200) .................................................................................... 14-4
14.2.1 Replacing the LID .......................................................... 14-4
14.2.2 Replacing the LID cold store cab ................................... 14-5
14.3 Replacing pedals (5300) .............................................................. 14-6
14.3.1 Accelerator and brake pedal .......................................... 14-6
14.3.2 Safety pedal ................................................................... 14-6
14.4 Control console (5510)................................................................. 14-7
14.4.1 General .......................................................................... 14-7
14.4.2 Replacement/installation of a control ............................. 14-7
14.4.3 Replacing the multi-function control .............................. 14-8
Replacing the multi-function control's buttons. .............. 14-8
14.4.4 Removing the control console from the truck ................ 14-9
14.4.5 Replacing the access card's circuit board ................... 14-10
14.4.6 Dismantling the control console ................................... 14-12
Installing an extra push button ..................................... 14-14
1 – 10 Repair Manual RRE140/160/180/200/250 © BT

Contents
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Replacing the travel direction selector with signal button 14-

14
Replacing the display .................................................. 14-15
14.4.7 Assembling the control console ................................... 14-15
14.4.8 Fitting the control console in the truck ......................... 14-16
14.5 Magnetic sensor (5850) ............................................................. 14-18
General ........................................................................ 14-18
14.5.1 Replacing the magnetic sensor [B47] .......................... 14-18
14.5.2 Reference magnet ....................................................... 14-19
14.6 Parameter settings..................................................................... 14-20
14.6.1 Configuration menu ..................................................... 14-20
Calendar/hour counter menu ....................................... 14-20
Parameter menu (PAR) .............................................. 14-20
Setting operator parameters ........................................ 14-21
14.7 PIN menu ................................................................................... 14-22
14.7.1 Menu for activating a PIN block ................................... 14-23
14.7.2 Menu for programming a PIN (P) ................................ 14-23
14.8 Calibrations ................................................................................ 14-24
14.8.1 Calibrating the hydraulic function control ..................... 14-24
14.8.2 Height measurement/reach movement length calibration 14-
25
Calibrating height measurement (option) .................... 14-26
14.8.3 Valve calibration .......................................................... 14-29
Lift valve calibration ..................................................... 14-29
Lowering valve calibration with height indication ......... 14-31
Lowering calibration without height indication ............. 14-33
Reach movement valve calibration .............................. 14-35
Calibration of the Ergo cab .......................................... 14-38
14.8.4 Weight calibration ........................................................ 14-39
Calibrating the weight indicator ................................... 14-39
14.9 Replacing the wiring harness ..................................................... 14-41
14.10 main computer unit MCU (A5).................................................... 14-42
14.10.1 Installing a new card in the truck ................................. 14-42
14.10.2 Voltage supply ............................................................. 14-43
14.10.3 Battery negative ........................................................... 14-43
14.10.4 Internal status monitoring ............................................ 14-43
14.10.5 Resetting the battery indicator ..................................... 14-43
15 – Hydraulic system 6000 .................................................................. 15-1

15.1 Hydraulic hygiene ........................................................................ 15-1
15.1.1 Washing ......................................................................... 15-1
15.1.2 Packaging ...................................................................... 15-1
15.1.3 Handling ........................................................................ 15-1
15.1.4 Storage .......................................................................... 15-2
15.1.5 Work procedures ........................................................... 15-2
15.2 Hydraulic unit (6100) .................................................................... 15-3
15.2.1 Hydraulic tank, emptying ............................................... 15-4
15.2.2 Hydraulic system, bleeding ............................................ 15-5
15.2.3 Filter ............................................................................... 15-6
Overview ........................................................................ 15-6
Filter replacement (air and oil) ....................................... 15-7
15.2.4 Remove the pump motor from the truck ........................ 15-9
15.2.5 Replacing the hydraulic pump ..................................... 15-10
15.2.6 Fitting the pump motor in the truck .............................. 15-11
15.3 Main valve (6210)....................................................................... 15-12
© BT Repair Manual RRE140/160/180/200/250 1 – 11

Contents
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15.3.1 Emergency lowering of forks ....................................... 15-12

15.3.2 Replacing the main valve block ................................... 15-14
15.3.3 Replacing the lifting/lowering valves ............................ 15-16
Overview ...................................................................... 15-16
Method ......................................................................... 15-17
15.3.4 Adjusting the maximum opening pressure .................. 15-20
15.4 Hydraulic connections (6230) .................................................... 15-22
15.4.1 Tightening torques for hydraulic connections .............. 15-22
Tapered coupling with O-ring ...................................... 15-22
Tredo sealing ............................................................... 15-23
Pipe coupling ............................................................... 15-24
15.4.2 Quick change connector .............................................. 15-26
..................................................................................... 15-27
15.5 Hydraulic system, mast (6300)................................................... 15-28
15.5.1 Mast-mounted hose reel (6370) .................................. 15-28
General ........................................................................ 15-28
15.5.2 Fitting the hose reel ..................................................... 15-28
Spring preloading (turns) ............................................. 15-28
15.5.3 Checks after fitting ....................................................... 15-29
15.6 Main lift cylinder 6610 ................................................................ 15-30
General ........................................................................ 15-30
15.6.1 Overview ...................................................................... 15-31
Cylinder nomenclature ................................................. 15-31
Nomenclature for cylinder head ................................... 15-32
Nomenclature for piston .............................................. 15-32
15.6.2 Removing the air cylinder from the mast ..................... 15-33
15.6.3 Replacing the hose rupture valve ................................ 15-34
15.6.4 Dismantling the cylinder .............................................. 15-36
15.6.5 Dismantling the piston. ................................................ 15-38
Method ......................................................................... 15-38
15.6.6 Dismantling the cylinder head ..................................... 15-38
15.6.7 Fitting the cylinder head seals. .................................... 15-40
15.6.8 Fitting the piston seals ................................................. 15-42
15.6.9 Assembling the cylinder ............................................... 15-44
15.6.10 Assembling cylinder in the mast .................................. 15-46
15.7 Free lift cylinder (6620) .............................................................. 15-48
General ........................................................................ 15-48
15.7.1 Overview ...................................................................... 15-49
15.7.2 Removing the free lift cylinder from the truck .............. 15-51
15.7.3 Replacing the hose rupture valve, free lift cylinder ...... 15-51
Tools required .............................................................. 15-53
Method ......................................................................... 15-53
15.7.5 Dismantling the piston ................................................. 15-53
Method ......................................................................... 15-53
Method ......................................................................... 15-54
Method ......................................................................... 15-55
15.7.8 Fitting the piston seals ................................................. 15-56
Method ......................................................................... 15-57
..................................................................................... 15-59

Contents
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15.7.10 Assembling the free lift cylinder in the mast ................ 15-60
15.8 Reach cylinder (6650) ................................................................ 15-61
15.8.1 General ........................................................................ 15-61
15.8.2 Removing the reach cylinder from the truck ................ 15-61
15.8.3 Fitting the reach cylinder in the truck ........................... 15-62
15.9 Fork tilt cylinder (6660)............................................................... 15-63
15.9.1 General ........................................................................ 15-63
15.9.2 Remove the tilt cylinder from the truck ........................ 15-64
Mast with valve on the fork carriage: ........................... 15-64
Mast without valve on the fork carriage: ...................... 15-66
15.9.3 Fit the tilt cylinder in the truck ...................................... 15-68
Mast without valve on the fork carriage: ...................... 15-70
15.10 Cab tilt cylinder (6660) ............................................................... 15-72
15.10.1 General ........................................................................ 15-72
15.10.2 Overview ...................................................................... 15-72
15.10.4 Dismantling the piston rod ........................................... 15-76
15.10.7 Mounting the piston rod ............................................... 15-82
15.11 Sideshift cylinder (6670)............................................................. 15-86
15.11.1 General ........................................................................ 15-86
15.11.2 Overview ...................................................................... 15-87
15.11.3 Dismantling the cylinder from the truck ....................... 15-89
15.11.5 Dismantling the piston rod ........................................... 15-92
15.11.8 Mounting the piston rod ............................................... 15-98
15.11.9 Assembling the cylinder ............................................. 15-100
15.11.10 Refitting the cylinder in the truck .............................. 15-101
16 – Mast/Lift system 7000 ................................................................... 16-1

16.1 Main mast 1.6-2.5 t (7100) ........................................................... 16-1
16.1.1 Replacing the full mast .................................................. 16-1
16.1.2 Removing the mast from the truck ................................. 16-2
16.1.3 Adjusting mast play ....................................................... 16-5
General .......................................................................... 16-5
Preparations .................................................................. 16-5
Adjusting lateral play ..................................................... 16-8
Adjustment of radial play ............................................... 16-9
Adjusting the damper parts ............................................ 16-9
Adjusting the damper plate .......................................... 16-10
Refitting the mast ......................................................... 16-10
16.1.4 Replacing the mast damper plates ............................. 16-11
16.1.5 Placing the mast on the truck ...................................... 16-12
16.2 Main lift chain system (7120)...................................................... 16-16
16.2.1 General ........................................................................ 16-16

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16.2.2 Checking the chain ...................................................... 16-16

Noise ........................................................................... 16-16
Surface rust ................................................................. 16-16
Rusty links ................................................................... 16-16
Stiff links ...................................................................... 16-17
Bolt rotation ................................................................. 16-17
Loose bolts .................................................................. 16-17
Outline wear ................................................................ 16-18
Stretching .................................................................... 16-19
Damage ....................................................................... 16-19
Damaged plates .......................................................... 16-20
Damaged bolts ............................................................ 16-20
Dirty chain .................................................................... 16-20
16.2.3 Lubricating the chain ................................................... 16-20
16.2.4 Main lift chain system, adjusting the fork-to-floor distance ....
16-21
16.3 Reach carriage (7190) ............................................................... 16-22
16.3.1 Adjusting radial play in the reach carriage ................... 16-22
16.3.2 Adjusting axial play in the reach carriage .................... 16-24
16.4 Lifting devices (7400) ................................................................. 16-25
16.4.1 Forks ............................................................................ 16-25
General ........................................................................ 16-25
Inspection .................................................................... 16-25
Inspection intervals ...................................................... 16-25
Surface cracks ............................................................. 16-25
Difference in height between the fork tips ................... 16-26
Position lock ................................................................ 16-26
Readability of the markings ......................................... 16-26
Fork blades and back of fork carriage ......................... 16-26
Mounting fixtures on the fork ....................................... 16-26
16.4.2 Forks, repairs and testing ............................................ 16-27
Repairs ........................................................................ 16-27
Testing the yield point .................................................. 16-27
Fork ............................................................................. 16-27
16.5 Fork carriage.............................................................................. 16-28
16.5.1 Checking the fork carriage’s wear strip ....................... 16-28
16.5.2 Lubricating the fork carriage ........................................ 16-29
16.6 Fork spread unit ......................................................................... 16-30
16.6.1 Servicing the fork spread unit ...................................... 16-30
Replacing bearings ...................................................... 16-31
Roller replacement ...................................................... 16-31
16.7 Fork extensions with adjustable fork length ............................... 16-32
16.8 Manual telescopic forks ............................................................. 16-34
16.8.1 Installation ................................................................... 16-34
16.8.2 Maintenance ................................................................ 16-35
16.9 Hydraulic telescopic forks .......................................................... 16-36
16.9.1 Telescopic forks with separate flow dividers ............... 16-37
Fitting instructions ........................................................ 16-38
Initial operation of telescopic forks with separate flow dividers
16-38
16.9.2 Telescopic forks with integrated flow dividers ............. 16-39
Fitting instructions ........................................................ 16-40
Initial operation of telescopic forks with integrated flow divid-
ers ................................................................................ 16-40
16.9.3 Maintenance of telescopic forks .................................. 16-41

Contents
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16.9.4 Dismantling telescopic forks ........................................ 16-42

16.9.5 Assembling telescopic forks ........................................ 16-43
17 – Peripherals - 8000 .......................................................................... 17-1

17.1 Introduction .................................................................................. 17-1
18 – Extra equipment - 9000 ................................................................. 18-1

18.1 Introduction .................................................................................. 18-1
19 – Appendix “Destruction instructions” .......................................... 19-1

19.1 General ........................................................................................ 19-1
19.2 Marking of plastics ....................................................................... 19-1
19.2.1 General marking of products and packaging material ... 19-1
19.2.2 Marking according to our standard ................................ 19-2
Abbreviations ................................................................. 19-2
Marking examples ......................................................... 19-2
19.3 Pressure vessels.......................................................................... 19-3
19.3.1 Gas dampers ................................................................. 19-3
19.4 Sorting categories ........................................................................ 19-4
20 – Wiring diagram .............................................................................. 20-1

20.1 Components ................................................................................ 20-1
20.2 Component location ................................................................... 20-11
Figure 1 (Fork carriage) ............................................... 20-11
Figure 2 (Chassis wiring harness) ............................... 20-12
Figure 3 (Chassis wiring harness) ............................... 20-13
Figure 4 (Support leg brake) ........................................ 20-14
Figure 5 (Pedals) ......................................................... 20-14
Figure 6 (Motor wiring harness) ................................... 20-15
Figure 7 (Reach carriage wiring harness) ................... 20-16
Figure 8 (Level/position meter) .................................... 20-17
Figure 9 (seat) ............................................................. 20-18
Figure 10 (DC/DC) ....................................................... 20-19
Figure 11 (Driver position wiring harness) ................... 20-20
Figure 12 (Extra hydraulic function(s)) ........................ 20-21
Figure 13 (Travel alarm) .............................................. 20-22
Figure 14 (Roof wiring harness) .................................. 20-23
Figure 15 (Roof) .......................................................... 20-24
Figure 16 (Sound system) ........................................... 20-25
Figure 17 (Forks camera) ............................................ 20-26
Figure 18 (Battery harness) ......................................... 20-27
Figure 19 (Fuse box) ................................................... 20-28
Figure 20 (LID) ............................................................ 20-29
Figure 21 (Mast wiring harness) .................................. 20-30
Figure 22 (Fork carriage wiring harness) ..................... 20-31
Figure 23 (Reach carriage wiring harness options) ..... 20-32
Figure 24 (Working light wiring harness) ..................... 20-33
Figure 24 (Extra outlet DC) .......................................... 20-34
Figure 25 (T.W.I.S.) ..................................................... 20-34
Figure 26 (Shock Switch / Impact Manager) ............... 20-35
Figure 27 (Heated windows CC) ................................. 20-36
Figure 28 (Cabling driver position CC) ........................ 20-37
Figure 29 (Heater CC) ................................................. 20-38
Figure 30 (Cab heater wiring harness CC) .................. 20-39
Figure 31 (Safety switch for door CC) ......................... 20-40

Contents
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Figure 32 (Cab tilt wiring harness) ............................... 20-40

Figure 33 (Control panel) ............................................. 20-41
Figure 34 (Control panel) ............................................. 20-42
Figure 35 (Steering arm) ............................................. 20-43
Figure 36 (MCU) .......................................................... 20-44
Figure 37 (Control motor) ............................................ 20-45
Figure 38 (Main valve block) ....................................... 20-46
20.3 Cable connections and pole bolts .............................................. 20-48
20.3.1 ACT/ACH transistor regulators .................................... 20-48
20.3.2 Connections to CID ..................................................... 20-50
20.3.3 Connections on the MCU ............................................ 20-52
20.4 Fuse box A9 ............................................................................... 20-54
20.5 Overview .................................................................................... 20-55
20.6 Details up to and including serial no. 6206800........................... 20-60
20.7 Detailed diagram cold-store cab ................................................ 20-85
20.8 Details up to and including serial no. 6206800......................... 20-110
20.9 Details cold store cab starting with 6206800 ............................ 20-136
21 – Hydraulics schematics ................................................................. 21-1

21.1 Main valve unit ............................................................................. 21-1
21.1.1 RRE Std. ....................................................................... 21-1
21.1.2 RRE Ergo ..................................................................... 21-2
21.2 Hydraulics schematics ................................................................. 21-3
21.2.1 Schematics designations ............................................... 21-3
21.2.2 List of symbols ............................................................... 21-4
21.2.3 Wiring diagrams RRE/RRE Ergo ................................... 21-5
22 – Tools ............................................................................................... 22-1

22.1 AMP connectors........................................................................... 22-1
22.2 MQS contacts .............................................................................. 22-2
22.3 CPC contacts ............................................................................... 22-4
22.4 Miscellaneous tools...................................................................... 22-5
23 – Appendix “Service data and grease specifications” .................. 23-1

23.1 General tightening torques........................................................... 23-1
23.1.1 Galvanised non-oiled bolts ............................................ 23-1
23.1.2 Untreated oiled bolts ...................................................... 23-2
23.2 Oil and grease specification ......................................................... 23-3
24 – Technical data ............................................................................... 24-1

General introduction
How to use the manual
7510399-020 2012-10-03 6070557 815, 816
2 – General introduction
2.1 How to use the manual

The service manual is divided into chapters containing the following
information:
• Safety regulations – This chapter includes general safety regula-
tions regaring working with the truck.
• Function – This chapter provides a basic description of the main
functions of the truck.
• Parameters – This chapter contains a basic description of the steer-
ing system's parameters.
• Installation – This chapter describes the work that needs to be done
before the truck is used for the first time.
• Maintenance – the chapter contains a general periodic maintenance
schedule and a detailed description of the maintenance to be carried
out.
• Troubleshooting – This chapter describes the error codes that ap-
pear in the display when the truck completely or partly stops work-
ing. The chapter also describes the reason why the errors occur and
suggested remedies.
• Actions chapter – This chapter describes the various parts of the
truck, what the parts look like and the service actions that need to be
carried out. The various chapters are organised according to BT's C-
code system.
• Appendixes – The appendixes contain:
- instructions for disposal
- information about electrical components and wiring diagrams
- hydraulics diagrams
- list of required tools
- information about general tightening torques
- oil and grease specifications
- technical data.

General introduction
Warning symbols
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2.2 Warning symbols

The following warning symbols are used in the repair manual:
DANGER!
DANGER! means there is a risk of accident potentially leading to
death or serious injury and material loss or damage. Always accom-
panied by the warning symbol.
WARNING!
WARNING! means that there is a risk of damage to components that
are sensitive to electro static discharge.
Follow the ESD-protection regulations.
Note!
NOTE! means there is a risk of material loss or damage if the instruc-
tions are not followed. Also used to draw attention to a non-standard
torque.
2.3 Pictogram
Pictograms are used, where possible, to describe certain elements.
Pictograms are maily used at moments requiring the loosening or tight-
ening of screws:
×n
s mm
A pictogram contains information about the type of screw head and an
arrow shows whether the screw should be loosened or tightened.
Text beneath the pictogram provides additional information about 's':
key size, 'n': the number of screws as well as the recommended torque
where necessary.
Another type of Pictogram is "Cut cable ties":
Additional information under the Pictogram can, for example, indicate

the number of cable ties to be cut.

General safety rules
Safety while working
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3 – General safety rules

Only personnel trained in servicing and repairing this type of truck are
authorised to carry out service and repair activities.
3.1 Safety while working

To ensure that you work safely and to prevent accidents while working
on a truck, remember the following:
• keep the area where servicing activities are performed clean. Oil or
water will make the floor slippery.
• use the correct working position. Service activities often involve
kneeling or bending forward. Try sitting on a toolbox, for example, to
relieve the strain on your knees and back.
• loose articles and jewellery may become trapped in the moving parts
of the truck. So never wear loose articles or jewellery while working
on the truck.
• use the correct tools for the work you are carrying out.
• keep all tools well maintained.
• store and transport old oil according to applicable local regulations.
• do not flush solvents, etc. down the drain unless they are intended to
be disposed of in this way.
Follow the local disposal regulations.
• heated paint gives off harmful gases. So use sanding or a paint strip-
per to remove the paint at least 100 mm around an area where any
welding/grinding is to take place.

Electrical system
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3.2 Electrical system

When working on the electrical system of the truck, remember the fol-
lowing:
• a short circuit may occur if metal objects come into contact with live
connections. This can result in burns. So remove watches, rings and
other metal jewellery before starting work.
• always use insulated tools while working on the electrical system.
• always switch off the truck's power supply before opening the hoods
to the drive assembly and the electrical system.
• disconnect the battery when using electric welding equipment. The
welding current may damage the battery.
• always remove the battery plug when carrying out maintenance on
the truck, unless the instructions in this service manual state other-
wise.
• blow electric motors clean using compressed air.
• clean electrical panels, electronic cards, connectors, contactors, so-
lenoid valves, etc. with a moist cloth and a cleaning agent that will
not damage the part.
IMPORTANT
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the electronic cards.

Safe lifting
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3.3 Safe lifting
All lifting must be carried out on a flat, nonslip and stable surface.
Asphalt floors must be avoided if possible.
• To prevent the truck moving while it is being lifted, it must not be lift-
ed with anyone on the platform or with the tiller arm in the lowered
position.
• If the drive wheel, which is braked, is being lifted the other wheel
must be chocked to stop the truck moving.
• Select the lifting point so that the lift is as light as possible, for exam-
ple one corner at a time. If the truck has marked lifting points on the
lower part of the chassis, these should be used for a well-balanced
lift.
• Ensure the area where you place the jack is clean and free of oil and
grease.
• Ensure there is no grease or oil on your hands or the jack lever.

Safe lifting
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• Use the lever supplied with the jack. If the lever is too short, it will re-
quire more effort than is necessary. If the lever is too long there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing – a poorly chocked truck may fall.
• Never work under a truck that is not blocked with supports or secured
by a lifting device.
• Place supports:
- as close to the raised part of the chassis as possible to reduce the
falling height if the truck tips over
- so that the truck cannot roll.
• Never place a support under the jack to increase the lifting height.
• Never work under a lifted truck without appropriate supports.

Descriptions of functions
Chassis 0000
Publication no. Date Valid from serial no. T code
7510399-020 2012-10-03 6070557 815, 816
4 – Descriptions of functions
4.1 Chassis 0000
4.1.1 Operator’s cabin (0500)

Versions for cold-store cabs
Both the standard and the tilting cabs are available to cold-store
specifications with or without a heated cab. They are all designed for
use in temperatures down to -35°C.
Properties
• All switches and electrical components are designed for use in cold
stores.
• The air supply to the hydraulic system is filtered to prevent
accumulation of air.
• The hydraulic system uses a special oil that withstands cold
temperatures.
• All exposed axles are manufactured in stainless steel.
• Exposed parts have been rust-protected with Tectyl ®
© BT Repair manual RRE140/160/180/200/250 4– 1

Chassis 0000
T code Valid from serial no. Date Publication no.
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Emergency exit from the cab
If the truck has stopped against an obstacle that blocks the door and
cannot be moved, the cab can be evacuated through the roof.
• Release the catches in the roof and raise the cover.
• Stand on the seat and armrest to get out onto the roof.
DANGER!
Risk of injury.
Risk of injury if the steering console is used as a step.
Never step up onto the steering console to climb onto the roof in case
of an emergency.
• Call for assistance to get down from the roof.
DANGER!
Risk of slipping.
The roof might be slippery.
Never stand on the roof.
4– 2 Repair manual RRE140/160/180/200/250 © BT

Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
4.1.2 Cab windows (0530)

Electrically heated windows
If the truck repeatedly enters and exists cold stores, the cab windows
may fog up. To prevent this, the truck can be ordered with electric
window heating.
• Press the button (a) to switch on this function. A symbol in the
button remains lit for as long as window heating is active. After a
preset time, this function is switched off and it will be necessary to
push the button once again to reactivate the function.
Note:
This function only operates if the climate control knob (b) has been
activated.
a b

Chassis 0000
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4.1.3 Operator's seat (0620)

The operator's seat is available in two different designs:
• For trucks in Standard design
• For trucks in Ergo design
An armrest (d) is an available option and the chair can also be fitted
with a safety belt to increase the operator's safety.
d In the seat there is a switch [B49] which must be activated; the operator
must sit in the seat in order for the truck to be driven.
Adjustment:
• Press button (a) to set the incline of the back rest.
• Lift the clamp (b) and release the lock to adjust the forward/
backward position of the seat.
• Set the seat suspension using the knob (c). To adjust suspension to
match your weight, sit on the chair and turn the knob until the green
arrow points straight up.
a
Button for seat heater
• Switch on the heater by pressing (I) on the button located on the left
c side under the seat. Heater operation is controlled by a thermostat.
b
• Switch off the heater by pressing (0) on the button.

Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
4.1.4 Cab heating/ventilation (0630)

Climate control knobs
For maximum operator comfort, it is possible to adjust the ventilation
and temperature as desired in the cab.
b
0
c a
Ventilation
• Turn knob (a) clockwise to start the fan. Release the knob at the
desired fan speed.
• Turn the knob to 0 to switch off the fan.
Temperature
• Turn knob (b) clockwise to switch on the heater. Release the knob
at the desired temperature setting.
• Turn the knob to 0 to switch off the heater.
Note:
Knob (a) serves as the main switch. It must therefore be activated to
enable operation of knob (b).
The cab has a number of air outlets (c) from which air and heat are
released into the cab. Make sure these outlets are not covered since
this may cause malfunction of the climate control system.

Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
4.1.5 Operator protection (0840)

Tilt stops
To increase truck capacity, tilt stops are fitted to some trucks. Tilt stops
are also available as an option.
It is permissible however to temporarily remove tilt stops when
transporting the truck, e.g. between different warehouses; but then it is
not permitted to use the truck for transporting loads.
DANGER!
Reduced stability.
Trucks without tilt stops can tip over if used to transport loads.
Ensure that tilt stops are refitted at the correct floor distance if they
have been temporarily removed.
The tilt stops are located on the rear corner of the support arm and
consist of stops (c), shims (b), bolts (d), and nuts (a) on the inside of the
chassis.
.
a
a
b b
c c d
d

Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
Width between
Model: Lifting height Note:
support arms
RRE140 900 All lift heights Tilt stops are optional
RRE140 1100 and 1300 All lift heights No tilt stops available
RRE160 900 and 1050 Lh ≤ 7500 The tilt stops can be removed
RRE160 900 and 1050 Lh ≤ 8000 The tilt stops cannot be removed
RRE180 900 All lift heights The tilt stops cannot be removed

Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
Overhead guard
The operator area is protected from falling objects by a casing with bars
(c) bolted into the roof of the cab shell.
The casing can be supplemented by a guard of finer mesh (b) and a
transparent top (a).
The truck may be fitted out with a protective grating (d) between the
cabin and the mast.

Motors 1000
7510399-020 2012-10-03 6070557 815, 816
4.2 Motors 1000
4.2.1 General
The truck motors are the drive motor, the pump motor for the
hydraulics, and the steering motor for rotating the drive unit (steering).
The drive and pump motor are three-phase AC motors. The steering
motor is a brushless DC stepper motor. The voltage for all motors is 48
Volts.
4.2.2 Electric pump motor (1710)

General
The pump motor is a three-phase AC motor. In the motor, there is a
thermocouple that measures the motor temperature, as well as a
toothed wheel with a sensor for measuring rotational speed and
direction.
There are two sizes of pump motor for the trucks.
On RRE140 – RRE160, TSA170-200-106 is used.
On RRE180 – RRE250, TSA170-180-072 is used.
Design

Motors 1000
815, 816 6070557 2012-10-03 7510399-020
4 – 10 Repair manual RRE140/160/180/200/250 © BT

Motors 1000
7510399-020 2012-10-03 6070557 815, 816
4.2.3 Electric steering motor (1730)

General
The steering motor is located on the drive unit housing. It receives
signals from the pulse generator located in the steering column. The
steering motor is equipped with a gear wheel working directly on the
gear rim of the drive gear.
The steering motor is available in two sizes, one which is used in
RRE140 – RRE160 and one that is used in RRE180 – RRE250.
Design
The steering servo's electronics (a) are directly mounted on the
steering motor.
The motor (b) is a brushless synchronous motor with permanently
magnetised rotor.
The steering motor is integrated with a two-stage planetary gear (c) that
has a gear wheel on its output shaft in direct contact with the gear rim
on the drive gear.
RRE180 – RRE250 RRE140 – RRE160
© BT Repair manual RRE140/160/180/200/250 4 – 11

Motors 1000
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4.2.4 Fan motor/fan (1740)

There are two cooling fans in the truck's motor compartment.
These are a radial fan (a) that cools the frequency converter of the
motors, and an axial fan (b) that ventilates the entire motor
compartment.

Motors 1000
7510399-020 2012-10-03 6070557 815, 816
4.2.5 Electric drive motor (1760)

General
The drive motor is a three-phase AC motor. In the motor, there is a
thermoelement that measures the motor temperature, as well as a cog
with a sensor for measuring rotational speed and direction.
There are two sizes of drive motor for the truck.
RRE140 – RRE160 uses TSA 170-200-073.

RRE180 – RRE250 uses TSA 280-180-100.
Design

Drive gear - 2000
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4.3 Drive gear - 2000
4.3.1 General
The drive gear is integrated with the motor and brake to form a
complete drive unit that can be steered through 360°.
The gear is a two-stage 90 degree gear and comes in two different
sizes, depending on the truck model.
• RRE140 – RRE160 has a GK25 gear and
• RRE180 – RRE 250 has a GK30 gear.
The drive unit is fitted to the chassis using 6 bolts. The steering
bearings and a gear ring for the steering motor are mounted at the top
of the gear unit.

Drive gear - 2000
7510399-020 2012-10-03 6070557 815, 816
4.3.2 Design
The drive gear is a two-stage 90 degree gear with conical roller
bearings on the drive shaft and pinion. The bearings are pre-tensioned
to reduce the risk of backlash.
The input shaft has splines with which the drive motor's output shaft
meshes.
The steering bearing is screwed into the drive shaft and can only be
replaced once the drive motor has been removed.
The gear rim is screwed into the gear and can be replaced once the
drive gear has been removed from the truck.
The output shaft has a hub for the wheel. The wheel bolts are stud bolts
that can be replaced.
The gear has two oil level plugs for checking/topping up the oil level.
The oil in the gear unit should normally be changed at 1000 h..
Drive gear, cross-section view

Brake system 3100
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4.4 Brake system 3100
4.4.1 General
The truck has three different types of brake:
• Travel brake
• Parking brake
• Emergency brake
Travel brake
The travel brake consists of two different systems:
• Regenerative plug braking using the drive motor.
• Two electromechanical multiple disc brakes fitted in the support arm
wheels (option)
Parking brake
The parking brake is made up of a single stage electromechanical disc
brake fitted on the drive motor which is engaged by means of spring
pressure. The parking brake is released electrically (DC voltage).
The parking brake is activated/is active as follows:
• The parking brake is activated automatically when the truck has
been stopped while being driven and the brake pedal is depressed
with the truck stationary. The brake is released when the accelerator
is depressed.
• The parking brake is activated automatically with a few seconds
delay when the operator leaves the truck.
• The parking brake remains active after the main power has been
switched on.
Emergency brake
Emergency braking of the truck takes place in the event of a fault with
the steering system or a serious fault in the electrical system.
The parking brake on the drive motor is the main emergency brake.
Plug braking can operate during emergency braking provided there is a
supply voltage. If there are support arm brakes on the truck, these are
also engaged during emergency braking.

Brake system 3100
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4.4.2 Drive motor brake (travel brake)

The truck is braked primarily by means of regenerative braking using
the drive motor. Plug braking can be obtained in three different ways,
namely:
• Releasing the accelerator when the truck is in motion
• Changing the direction of travel using the travel direction selector
while at the same time depressing the accelerator
• Depressing the brake pedal.
Accelerator released
Regenerative plug braking is automatically engaged when the
accelerator is released. The braking force can be adjusted using an
operator parameter.
Plug braking force is regulated to allow for the current speed and the
extent to which the accelerator is released. This works as follows:
• Braking at a high speed with the accelerator fully released results in
high brake force.
• Braking at a low speed with the accelerator fully released results in
lower brake force.
• Braking at a high speed, with the accelerator released halfway,
results in medium brake force.
Changing the direction of travel

When the direction of travel is changed during operation, the motor
brakes the truck so that the direction of travel can be changed. Here
plug braking is regulated by the position of the accelerator - the further
the pedal is depressed, the greater the force involved in braking.
The brake force when changing direction of travel can be adjusted
using a service parameter.

Brake system 3100
815, 816 6070557 2012-10-03 7510399-020
4.4.3 Multiple disc brake, support arm (travel

brake)
General
The brake is an electromagnetic multiple disc brake with multiple steel
discs.
The brake is engaged by energising the magnetic coil. The current in

the magnetic coil is regulated by a potentiometer in the brake pedal,
resulting in regulation of the brake force.
The brake acts as a secondary travel brake, along with plug braking,
and is engaged when the operator needs to brake hard, when the brake
pedal is depressed through more than 50%.
Design
The brake is fitted in the support arm wheels on a hub with splines and
a locking shoe (j) which takes up the braking force.

Brake system 3100
7510399-020 2012-10-03 6070557 815, 816
4.4.4 Disc brake on the drive motor (parking

brake)
General
The brake is a single stage electromechanical spring-loaded brake that
is released when the magnetic coil is energised. Polarity does not affect
its operation. The brake acts as a parking brake, as well as an
emergency and secondary travel brake at the end (final 10 %) of the
brake pedal movement.
Design
Pos. Component
a Magnet housing
b Brake disc
c Friction disc
d Hub

Steering system 4000
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4.5 Steering system 4000
4.5.1 General
The steering system is fully electric – what is known as a Steer-By-Wire
system. As a result, there is no mechanical contact between the
steering wheel and the steering drive wheel.
The steering wheel on the steering column is fitted directly to a twin
pulse generator. Rotating the steering wheel results in an electrical
signal, a pulse train, being transmitted to the following units:
• CID (Central Information Display), and on to
• MCU (Main Control Unit), and then to
• EPS (Electrical Power Steering), the electronics unit on the steering
servo motor.
Steering is progressive, which means that when the truck is operated at
low speed the steering wheel gearing ratio is higher than at high
speeds. This allows the truck to be operated in a safe and efficient
manner.
4.5.2 Design
The pulse generator in the steering wheel is connected to the CID (A1),
and data is sent via the CAN1 bus to the MCU (A5). In the MCU,
incoming data is logically processed to give the required response.
Once processing is complete, the data is sent via CAN2 to the EPS
(A2), which then makes the wheel rotate.
The EPS is fitted directly on top of the steering servo motor. The motor
has a power booster in the form of a two-stage planetary gear. The
planetary gear's output gear wheel is in constant contact with the gear
rim on the drive shaft.
The CID monitors the pulse train from the steering wheel. Monitoring is
continuous, so that any break in the cabling is detected immediately.
The MCU monitors the EPS and CAN buses, so any electrical faults in
the pulse generator, wiring or electronic unit will result in automatic
shut-down of the truck drive function.

7510399-020 2012-10-03 6070557 815, 816
4.5.3 Sensor
Steering angle reference sensor
Active area
The sensors have an active area, 12 x 12 mm, at the end of the
cylindrical body.
The sensitivity of the sensors is such that metallic objects within the
area
0 – 1.6 mm are detected.
To avoid erroneous detection, there should be a free area around the
sensor’s active area:
d2
a sa
Pos Description Min. Nom. Max. Unit

a Active area – 12×12 – mm
sa Detection guaranteed 0 – 1.65 mm
d2 Free area 6 – – mm

Operator compartment
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4.6 Operator compartment
4.6.1 Truck control, overview

Right-hand control panel, single control
The control panel contains the controls for all hydraulic functions, travel
direction and signals. The information display and keypad allow access
to the truck.
Right-hand control panel, multi-control

This has the same functions as single control, but they are located
differently.

7510399-020 2012-10-03 6070557 815, 816
Emergency off switch
When the emergency switch off is depressed, the main contactor [Q10]
is opened, and this is indicated on the truck Central Information Display.
DANGER!
Risk of short-circuiting.
The truck battery circuits are still live even if the emergency switch off
is depressed.
When working on the electrical system, the battery must be
mechanically disconnected.
Indication on the Central Information Display on a login attempt with the

emergency switch off depressed.
Indication on the Central Information Display when the emergency

switch off is depressed and the truck is in logged-in mode.
Steering wheel module

815, 816 6070557 2012-10-03 7510399-020
The steering wheel module is used to steer the truck.
Pedals
a
b
c
The truck has three pedals: a - accelerator, b - brake pedal,

c – Safety pedal for operator presence.

7510399-020 2012-10-03 6070557 815, 816
4.6.2 Single-function controls

a b c
d
e
f
r
pq
h no
j m
g k
a: CID Central Information Display CID
b: Fork lift/lower
c: Fork carriage reach/retraction
d: Extra hydraulic function 1, e.g. fork tilt
e: Extra hydraulic function 2, e.g. side-shift of forks
f: Extra hydraulic function 3, e.g. fork spreading and extra hydraulic
function 4 together with ‘o’
g: Height preselector
k: Lift height limitation with override
m: Tilt, forks to horizontal position
n: Side shift, forks to middle position
o: Switching function for the fifth lever, see 'f'
p: Operator cabin tilt
q: Extra optional function
r: Extra optional function
h: Travel direction selector
j: Horn

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4.6.3 Multi-function controls
a d
c cb
k g
mn cd
cc
j ca
h
e r
opq
f
a: CID Central Information Display CID
c: Multi-control
ca: Fork lifting
cb: Fork lowering
cc: Reach carriage - in
cd: Reach carriage - out
d: Extra hydraulic function 1, e.g. fork tilting
e: Extra hydraulic function 2, e.g. side-shift of forks
f: Extra hydraulic function 3, e.g. fork spreading and extra hydraulic
function 4 together with ‘o’
g: Extra optional function
k: Extra optional function
m: Switching function for the fifth lever, see 'f'
n: Operator cabin tilt
o: Height preselector
p: Lift height limitation with override
q: Tilt, forks to horizontal position
r: Side shift, forks to middle position
h: Travel direction selector
j: Horn

7510399-020 2012-10-03 6070557 815, 816
4.6.4 Central Information Display – CID

A Central Information Display (referred to as “CID”), with its menu-
based information system, is used as the main instrument of
communication between the operator and the truck.
The CID contains coloured LED symbols and a monochrome graphic
display. To the right of the display, there is a keypad with the figures 0 to
9 and the buttons “green” (I) and “red” (O).
In logged-out mode, display backlight is switched off if there has been
no activity for 5 minutes. Once the keypad is activated, the lighting is
switched on again.
In logged-in mode, the display is always lit.
Navigation
1 2 3
4 5 6
+ 7 8 9
C 0
For menu navigation there are buttons with arrows, plus/minus (+/-), ‘i’
and ‘C’.
To select an icon press on the up/down arrow until the icon for the
function you require is highlighted with a stronger border. Then press
the green button (I) to select your chosen menu.
The C-button is used to move up through the levels, and the i-button is
used as a shortcut to the information screen or to the operator
information menu, depending on whether the truck is in logged-in or
logged-out mode.
When logging in without the CAN key or TruckCom, only a limited
number of functions are accessible and only icons for accessible
functions are displayed.

815, 816 6070557 2012-10-03 7510399-020
Login a
Screen
c
i c
j
Info Startup
Screen Screen
i i
User
Screen
i c
c Driver
| c info
Error
info
i i c
Teach
In
d e
Overview of the functions that are accessible without
the CAN key or TruckCom.
a Login procedure, d: Only read access
e: Parameter-based access, j: Logged in

7510399-020 2012-10-03 6070557 815, 816
Login a
Screen
C
i C
j
Info Startup
Screen Screen
User
Screen
C i C
Driver
i i info
i C
i
Teach
C
In
| C
Error i/C
info
i/C
C C i/C
i/C
| C
Diagn.
h
*
Overview of the functions that are accessible with

the CAN key or TruckCom.
a Login procedure, j: Logged in,
h: Also accessible with special PIN code
*: This function is not available.

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LED symbols
Once the truck is started, the LED symbols of the display come on for a
short time and then go out again.
In emergency travel mode all the symbols flash simultaneously.
a b c d e f g h
1 2 3
a. Travel direction - left.
Flashes when no travel direction is selected, comes on
permanently when travel direction is the same as drive wheel
direction.
b. Parking brake:
Comes on when the parking brake is engaged.
c. Travel direction - right.
Flashes when no travel direction is selected, comes on
permanently when travel direction is the same as fork direction.
d. Stop.
The truck has been stopped due to a critical error.
e. Cab tilt.
Cabin tilting is possible (RRE Ergo)
f. Warning.
Comes on when a warning is active.
g. Low battery.
Battery capacity is low: flashing when 10% remaining, on
permanently at 0%.
h. Extra.
Comes on when an extra hydraulic function is selected.

7510399-020 2012-10-03 6070557 815, 816
Information symbols
Symbol Description Symbol Description

Truck Truck
Reach carriage fully Reach carriage fully or

retracted. partly extended. Five-
stage indication.
Battery status
8 levels of charging are

indicated.
Completely full = Fully
charged.
Symbol Description Symbol Description Symbol Description

Information Timer Time
mode
Date, time and
hour recorder.
Operator Program
version.
Indicates the
active operator
profile.
Login
Login method Login method Login method
Login via ID unit
Log-in with PIN PIN code login
or unit connected
code verified by
to the MCU
T.W.I.S.
Reading ID unit. Emergency
Waiting for travel
identification via
ID unit
Height preselector.
Height Pick up Deposit
preselector
active
Delete height

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Operator parameter symbols – Overview

Steering sensitivity Max speed,
drive wheel direction
Max speed, Acceleration

fork direction
Automatic brake Height above free lift

once the Ergo cabin
starts tilting
Note: The symbol is
also used as a catch
symbol.
Steering sensitivity at Steering sensitivity at
high speed. low speed.
Note: The symbol is
also used as a catch
symbol.

7510399-020 2012-10-03 6070557 815, 816
Blocking symbols – Overview

Displayed for catch symbol actions, see “Troubleshooting using catch
symbol” on page 8–18.

Height limit. The travel speed has
been reduced via the
input to the MCU.
Function reactivation. Seat switch.
Safety pedal Temperature
ESO (Emergency Service

Switch Off)
Looking for reference Looking for lower

sensor. reference sensor.
Looking for upper Options: The reach

reference sensor. carriage position can
not be established with
certainty.
Main lift started. Cold store cabin – Door
open.
Ergo cabin tilted Fork movement

upwards. obstructed.
Brake activated at start- Fork lowering limit

up. reached.
Program version
incompatible.

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Service symbols – Overview

Service symbols are displayed either as a selection for a service
function or as an indication of which service functions are active.

Service mode. Service function for
tilting the cabin.
Service function for Pressure relief

operating the mast.
Service function for Service function for

main cylinder bleeding. testing the fans
Calibration mode Calibration of

proportional valves.
Control calibration. Calibration of the load

cells.
Calibration of sensors. Calibration of the

transition between free
lift and main lift.
Configuration mode Reset chosen
parameter to standard
value.
Setting operator and PIN code
service parameters.
PIN code, disable PIN code
Diagnostics. Read-out of the error

log.
Read-out of the Emergency driving

collision sensor log. mode.
Automatic calibration
Not available

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Service functions
The service symbols require that the CAN key or the TruckCom is
connected in order for them to be displayed.
The “Service” icon is selected in Information mode, which is indicated

by a double border. The function is activated by pressing the
green button.
When the “Service” function is activated, the service symbol is shown in

the display's upper left corner and the various sub-functions can be
chosen using the arrow keys + the green button.
Tilting the Ergo cabin.
The service function is used for tilting an Ergo cabin to and from the
service mode.
How to use the function, see “Cab tilting RRE 140 – 250 Ergo” on
page 9–5.
Operation of the single hydraulic function.
The service function is used to operate the free lift, main lift and reach
carriage without any interdependence between them.
• The free lift is operated using the lift/lowering control.
• The main lift is operated using the reach carriage control
• The reach carriage is opearted using the control for AUX1/Fork tilt.
All movements are slower than in normal operation.
In order to avoid error codes, the main lift must be lowered completely
before the service function is completed.

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Pressure relief
The service function for pressure relief is used to remove the pressure
from the hydraulic system before work begins.
Required in order to activate the function:
• Operator sitting in the seat
• Main lift lowered completely
• Control for lifting/lowering to the lowering setting.
Note:
Since all valves are opened (both for standard and optional
functions), the forks must be lowered fully and caution observed
when the service function is activated.
Bleeding the main cylinders.
The service function for bleeding is used to drain the air from the
hydraulic system.
To activate the function, the forks must be lowered completely.
When the function is active
• The pump flow is limited to 1/8 of the maximum main lift flow
• Both lifting valve [Q2] and lowering valve [Q4] for the main lift are
open.
The function switches off automatically after 5 minutes.
Forced running of the fans.
The service function starts the motor control fan and the motor
compartment fan.
The function is ended by logging out.

7510399-020 2012-10-03 6070557 815, 816
Calibration functions
The calibration functions require the CAN key or TruckCom to be
connected in order to be displayed.
The “Calibrating” icon is selected in Information mode, which is

indicated by a double border. The function is activated by pressing the
green button.
When the “Calibrating” function is activated, the calibrating symbol is

shown in the display's upper left corner and the various sub-functions
can be chosen using the arrow keys + the green button.
Calibration of proportional valves.
The function is used for calibrating the proportional valves' opening and
closing points. Each of the proportional valves are selected from a
calibration screen:
Screen for valve calibration. E = Closing point, S = Opening point.
Selection Valve Selection Valve

1 Free lift: Raise [Q3] 5 Reach: Out [Q7]
2 Not used 6 Reach: In [Q6]
3 Main lift Raise [Q2] 7 Ergo cabin Tilting up
[Q11]
4 Not used 8 Ergo cabin Tilting down
[Q21]
How to calibrate the various valves, See section "14.8.3 Valve

calibration".

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Automatic calibration of lowering valve

Not available at present.
This function is used for automatically calibrating opening and closing
points for the lowering valve.
See section 14.8.3, Valve calibration.
The pictures illustrate how it looks when you run the free lift and the
main lift.
Calibration of the hydraulic function control.
The function is used to adjust the end and mid positions for the CID
joysticks, see “Calibrating the hydraulic function control” on page 14–
24.
Calibrating weight measurement.
The function is used to calibrate the load measurement on the forks. By
default, the trucks have weight measurement in the free lift area but an
option is also available for measurement in the main lift area. Each of
the measurement areas are selected from a calibration screen:
Screen for weight calibration.
Selection Measurement area Selection Measurement area

1 Free lift 2 Main lift
Calibration of the weight measurement, see “Weight calibration” on

page 14–39.
Calibration of sensors.
The function is used to calibrate the sensors for the reach carriage and
the mast, the latter only if the truck has “Height indication”.
How to calibrate the various sensors, see “Height measurement/reach
movement length calibration” on page 14–25.

7510399-020 2012-10-03 6070557 815, 816
Calibration of the transition between free lift and main lift.

The function is used to calibrate the control of proportional valves for
lifting and lowering of the forks when they are in transition between the
free lift and the main lift.
The screen shows two calibration fields – the upper one for raising and
the lower one for lowering:
Screen calibration of the transition between free lift and main lift.
During calibration, the value for raising is stored in parameter 1261 and
for lowering in parameter 1262.

815, 816 6070557 2012-10-03 7510399-020
Configuration functions
Configuration functions are used for adjusting time and date display,
parameters and PIN codes.
Configuration functions that are accessible without the CAN key or
TruckCom:
• Parameters can be read but not changed
• The time can be changed but not the date.
Configuration functions that are accessible with the CAN key or
TruckCom:
• Parameters can be changed
• Time and date can be changed
• PIN code settings can be changed.
The “Configuration” icon is selected in Information mode, which is

indicated by a double border. The function is activated by pressing the
green button.
When the “Configuration” function is activated, the service symbol is

shown in the display's upper left-hand corner and the various sub-
functions can be chosen using the arrow keys + the green button.

7510399-020 2012-10-03 6070557 815, 816
Setting the date and time, the reading of the hour meter.
The calendar and hour counter menu display hour counter and
calendar data. If a service key is connected, the date and time can be
changed.
The hour counter menu displays the values for hour counters A, B, C, D
and S:
A Total time
B Active time
C Driving/Operating time
D Hydraulics time
S Time until service
If the service hour counter is deactivated, service parameter 101, the
service time is not displayed.
How to change the time and date, see “Calendar/hour counter menu”
on page 14–20.

815, 816 6070557 2012-10-03 7510399-020
Setting the parameters

Parameters may be changed from the parameter screen according to:
• Operator parameters on parameter 503 are set to allow this without
CAN key/TruckCom; otherwise one of these is required
• Service parameters require CAN key/TruckCom
• Factory parameters require special authorization.
The parameter screen shows two fields:

• The top field indicates the current parameter number, which can be
changed with + / - if the field is active
• The bottom bar displays the current parameter value. To the left the
parameter's minimum allowable value is displayed and the highest
allowable value is shown on the right.
When the symbol in the lower left-hand corner of the screen is active,
the parameter can be reset to its original value by pressing the green
button.
For more information about how to use the function, see “Parameter
menu (PAR)” on page 14–20.

7510399-020 2012-10-03 6070557 815, 816
Managing PIN codes

The PIN setting function is used for managing PIN codes; the menu can
only be reached when a service key is connected.
For more information about how to use the function, see “PIN menu” on
page 14–22.
Other functions
Diagnostic tool
For accessing and using the function, see “Diagnostic screens” on
page 8–2.
Read-out of the error log
For accessing and using the function, see “Error log menu” on page 8–
1.
Read-out of the collision sensor log
The symbol for the selection of readout of the collision sensor log is
only active if:
• parameters 110/111 are set at a value other than ‘0’
• the operator has logged in using a PIN code that allows access to
the collision sensor's log
• A CAN key is used
The collision sensor's log shows the last 10 times shocks greater than
that indicated in the parameters 110/111 were detected.
One of loggings is surrounded by a border that can be moved up/down

with the arrow keys between the other loggings, up to a maximum of
ten.
Pressing the green button activates the collision information screen
which shows details about the logging that has been chosen.
The collision information screen with details about date, time and
collision levels on x and y-axes.
For details about parameter setting and resetting methods, see
“Parameter 109/110/111/112 – Collision sensor” on page 5–14.

815, 816 6070557 2012-10-03 7510399-020
Emergency driving mode

Emergency travel mode means that all truck movement is limited and
error handling is disconnected:
• Travel speed: max 1.3 km/h which can be decreased in increments
of 10% using parameter 204
• Acceleration/retardation limited to 25% of the maximum value
• All hydraulic movements are limited to 20% of each of the maximum
values
• If the MCU previously detected that the main contactor's contacts
have fused, the software error status is reset.
If the truck is in emergency travel mode, this is shown through audio
signals, all LED icons flashing and the CID showing a large emergency
travel symbol. If LID is installed, this also shows a large emergency
travel symbol.
Emergency travel indication – CID Emergency travel indication –

LID
In emergency driving mode, calibration of the reach carriage's home
position can be performed without the normal requirements of a
maximum of 36 mm difference and high hydraulic operations.
Activation:
i
The login screen may vary depending on the setting of parameter 503.

7510399-020 2012-10-03 6070557 815, 816
4.6.5 Load Information Display – LID (option)

A Load Information Display, referred to from now on as “LID”, is
available as an option and is fitted in the truck's roof panel.
If a LID is installed, it is activated on the basis of parameter settings.
The display contains six coloured icons and a monochrome graphical

display.
When the operator is logged out, the display is off.
LED symbols
The coloured icons come on in the event of the following:
a b c d
AUX
e f
a. Height preselector active (green).
b. Not used
c. Sideshift in initial position (green).
4. Tilt in initial position (green).
e. Aux (yellow).
f. Not used
When the truck is operated in emergency travel mode, all the symbols
flash simultaneously.

815, 816 6070557 2012-10-03 7510399-020
Symbols in the display part

Displayed when the truck is not equipped with height pre-select
• Weight of load, rounded to the nearest 100 kg. If the weight is under
200 kg “– – – –” is displayed.
• Forks height above the floor in metres and centimetres.
The LID's display, without height preselector, when the load's weight is
less than 200 kg and the forks are 3.69 m above the floor.
Displayed when the truck is equipped with height pre-select
• Weight of load, rounded to the nearest 100 kg. If the weight is under
200 kg “– – – –” is displayed.
• Forks height above the floor in metres and centimetres.
• In the right half, information is displayed about the selected lifting
height
The LID's display, with height pre-select, when the load's weight is
between 1050 kg and 1150 kg and the forks are 10.89 m above the
floor. Right half: Height preselector (option).
In emergency travel mode, the LID shows
whilst all LED icons on the CID & LID flash and a buzzer sounds.

sensors and sensors (5800)
7510399-020 2012-10-03 6070557 815, 816
4.7 sensors and sensors (5800)
4.7.1 Inductive sensors

Inductive sensors are affected by metallic objects that are moved into
the sensor's active area.
The sensors used in this truck have protection against incorrect polarity
and have short-circuit protected outlets.
When inductive sensors are energised, they have a short start-up time,
≤50 ms.
4.7.2 Position sensor

Active area
The sensors have an active area, 25 × 25 mm, which is marked with
the symbol:
The sensitivity of the sensors is such that metallic objects within the
area
0 – 6.5 mm are detected.
To avoid erroneous detection, there should be a free area around the
sensor’s active area:
d2
a sa
d1
Pos Description Min. Nom. Max. Unit

a Active area – 25×25 – mm
sa Detection guaranteed 0 – 6.5 mm
d1 37.5 – – mm
Free area
d2 24 – – mm

sensors and sensors (5800)
815, 816 6070557 2012-10-03 7510399-020
4.7.3 Magnetic sensor

The sensor reacts to the permanent magnet located on the fork yoke.
The sensor has protection against incorrect polarity and has short-
circuit protected outlets.
[B47] [A5] – MCU

1 SOUTH
2
X131:18 INP. Sideshift sensor
left side
3
X131:32 INP. Sideshift sensor
right side
4 NORTH
X130:20 OUT.GND.DIGITAL
[A9] – FUSE CENTRAL MODUL
F73 OUT. 48 VDC

Operation and connection sequences
7510399-020 2012-10-03 6070557 815, 816
4.8 Operation and connection

sequences
Event: 1. Battery is connected

Action(s) The battery [G1] is connected [X3] or, with battery replacement cables,
[X1]
Influencing elements Main contactor [Q10] off
Key relay [K20] off
Fuse [F60] “+48 VDC ESO Circuit” OK
Resulting conditions Login possible.
Login method controlled by parameter 503.

815, 816 6070557 2012-10-03 7510399-020
Event: 2a. Login via unit connected to the MCU

Prior event 1. Battery is connected
Action(s) The operator uses the key or other unit connected to the MCU.
Input A5-X131:19 is activated.
Influencing elements Parameter 503 = ‘1’ or ‘2’
CID shows a key symbol when the truck is in logged-out mode:
Resulting conditions Login approved:

CID shows a status image for approx. 2 seconds:
Main contactor [Q10] on

Key relay [K20] on
Login rejected:
CID displays:
Main contactor [Q10] off

Key relay [K20] off

7510399-020 2012-10-03 6070557 815, 816
Event: 2b. Login via keypad

Action(s) The operator enters a four or five-figure PIN code, depending on the
parameter setting, + Enter “green button”
CID displays:
Parameter 503 = ‘5’ or ‘6’

CID displays:


Key relay [K20] on
Login rejected:
CID displays:

Key relay [K20] off

815, 816 6070557 2012-10-03 7510399-020
Event: 2c. Login via “ID key” option

Action(s) The operator presses the green button and then, within 5 seconds,
passes the ID key over the scanner.
CID shows a key symbol when the truck is in logged-out mode:
Once the green button has been pressed and during the 5-second
period during which login is permitted, the following is displayed:


Key relay [K20] on
Login rejected:
CID displays:

Key relay [K20] off

7510399-020 2012-10-03 6070557 815, 816
Event: 2d. Login to emergency travel mode

Action(s) From the login screen, ‘i’ is pressed, so that the CID displays the
“Information screen”. On the information screen, select:
and then press the green button.

Influencing elements –
Resulting conditions CID shows a status image for approx. 2 seconds:

Key relay [K20] on

815, 816 6070557 2012-10-03 7510399-020
Event: 3. Basic conditions

Prior event 2a. Login via unit connected to the MCU
or
2b. Login via keypad
or
2c. Login via “Access card” option
or
2d. Login to emergency travel mode
2a, 2b & 2c – CID displays the standard screen:
2d – CID displays the standard screen for emergency travel:
2d – During emergency driving and if a LID is installed and activated,

the following is displayed:
whilst all LED icons on the CID & LID flash and a buzzer sounds.
Action(s) Weight is put on the operator seat so that the sensor [B49] closes and
activates input A5-X130:41 “INP. SEAT SWITCH”
The safety pedal [B31] is depressed and activates input A5-X130:31
“INP. LEFT FOOT SWITCH”
Influencing elements The emergency stop button [S21] is not depressed.
Resulting conditions It is possible to drive the truck, 2a, 2b & 2c, according to the
parameters for the current operator profile and in emergency travel
mode, 2d, with greatly reduced speed for all functions.

7510399-020 2012-10-03 6070557 815, 816
Event: 4. Driving in fork direction

Prior event 3. Basic control criteria
Action(s) The travel direction selector [B36] is moved towards the forks and input
A1-X505:4 increases from approximately 2.6 V to approximately 4.7 V.
The accelerator [B32] is depressed and this has an effect on input A5-
X130:17.
Influencing elements Operator parameter 3: Maximum speed in fork direction.
Operator parameter 4: Acceleration.
Emergency login.
Resulting conditions The CID's indication for driving and fork direction comes on.
Output A5-X131:20 is increased to approximately +48 V and the
mechanical brake [Q1] is released.
Regarding the support arm brake: The PWM outputs A5-X131:39 and
A5-X131:12 are modulated so that the brakes [Q16] and [Q17] are
released.
The drive motor is supplied with three-phase voltage from the
transistor regulator [T1].
Event: 5. Driving in the drive wheel direction

Action(s) The travel direction selector [B36] is moved towards the drive wheel
and input A1-X505:4 decreases from approximately 2.6 V to
approximately 0.6 V.
The accelerator [B32] is depressed and this has an effect on input A5-
X130:17.
Influencing elements Operator parameter 2: Maximum speed in drive wheel direction.
Operator parameter 4: Acceleration.
Emergency login.
Resulting conditions The CID's indication for driving and drive wheel direction comes on.
Output A5-X131:20 is increased to approximately +48 V and the
mechanical brake [Q1] is released.
Regarding the support arm brake: The PWM outputs A5-X131:39 and
A5-X131:12 are modulated so that the brakes [Q16] and [Q17] are
released.
The drive motor is supplied with three-phase voltage from the

815, 816 6070557 2012-10-03 7510399-020
Event: 6. Braking in neutral

Prior event 4. Driving in fork direction
or
5. Driving in drive wheel direction
Action(s) The accelerator [B32] is released and this has an effect on input A5-
X130:17.
Influencing elements Operator parameter 5: Automatic braking.
Resulting conditions The frequency of the drive motor three-phase voltage is reduced.
Event: 7. Reverse braking

or
5. Driving in the drive wheel direction
or
6. Braking in neutral
Action(s) The travel direction selector [B36] is moved to the position opposite to
the travel direction and input A1-X505:4 is changed from
approximately 2.6 V to approximately 0.6 V or to approximately 4.7 V.
Service parameter 201 Reversing
Resulting conditions The frequency of the drive motor three-phase voltage is reduced to
change the phase sequence when the motor is idling, and then
increases to a frequency in line with the amount the accelerator is
depressed.
Event: 8. Depressing the brake pedal

or
5. Driving in the drive wheel direction
or
6. Braking in neutral
Action(s) The brake pedal [B32] is depressed and this affects inputs A5-X130:4
& A5-X130:18 in that the voltage is increased at one of them and
reduced to a comparable degree at the other.
Depressing the brake pedal

7510399-020 2012-10-03 6070557 815, 816
Event: 8. Depressing the brake pedal

Resulting conditions The frequency of the drive motor three-phase voltage is reduced.
When the brake pedal is depressed beyond 90% of its possible travel:
The voltage at output A5-X131:20 is reduced and the mechanical
brake [Q1] is activated.
When stationary:
When the pedal is depressed more than 5% of its stroke length, the
voltage at output A5-X131:20 is reduced, and the mechanical brake
[Q1] is activated.
Regarding the support arm brake:
When the pedal is depressed 50 - 90 % of its possible travel, PWM
outputs A5-X131:39 and A5-X131:12 are modulated so that the brakes
[Q16] and [Q17] are released.

815, 816 6070557 2012-10-03 7510399-020
Event: 9. Guide
Action(s) The steering wheel is rotated taking effect on the following inputs:
– A1-X504:13 “STEER SENSOR 1 PULSE A”
– A1-X504:4 “STEER SENSOR 1 PULSE B”
– A1-X504:11 “STEER SENSOR 2 PULSE A”
– A1-X504:2 “STEER SENSOR 2 PULSE B”
Resulting conditions Information is sent via the CAN bus to the steering servo electronics.
The steering servo motor rotates the drive unit so that its new position
corresponds to the position of the steering wheel.
Event: 10. Reach carriage operation: Out

Action(s) The control for the reach carriage [B21] is moved away from the
operator, and input A1-X505:11 increases from approximately 2.6 V to
approximately 4.7 V at the end position of the control.
Resulting conditions The pump motor is supplied with three-phase voltage from the
Output A5:OUT.(PWM) REACH OUT lowers the voltage
Current flows through the proportional valve [Q7]
The proportional valve [Q3] is opened in proportion to the current
flowing through it.

7510399-020 2012-10-03 6070557 815, 816
TILT AND SIDESHIFT SIDE SHIFT

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT
MAIN FREE REACH CABIN TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03368.wmf

815, 816 6070557 2012-10-03 7510399-020
Event: 11. Reach carriage operation: In

Action(s) The control for the reach carriage [B21] is moved towards the operator
and input A1-X505:11 is reduced from approximately 2.6 V to
Output A5:OUT.(PWM) REACH IN lowers the voltage
Current flows through the proportional valve [Q7]
flowing through it.

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03370.wmf

815, 816 6070557 2012-10-03 7510399-020
Event: 12. Fork lifting

Action(s) The control for the fork lift [B20] is moved towards the operator, and
input A1-X505:2 is reduced from approximately 2.6 V to approximately
0.6 V at the end position of the control.
Influencing elements Service parameter 1261 Transition flows during raising.
Free lift:
Output T2-K1:10 “OUT.(PWM) INITIAL MAST LIFT” reduces the
voltage.
Output A5-131:26 “OUT(PWM) MAIN MAST LIFT” retains full voltage.
Current flows through the proportional valve [Q3].
flowing through it.
Proportional valve [Q2] closed.
Transition between free lift and main lift:
Output T2-K1:10 “OUT.(PWM) INITIAL MAST LIFT” successively
increases the voltage at the same time as output A5-131:26
“OUT(PWM) MAIN MAST LIFT” successively reduces the voltage.
Proportional valve [Q3] begins to close at the same time as
proportional valve [Q2] begins to open.
Main lift
Output A5-131:26 “OUT(PWM) MAIN MAST LIFT” reduces the
voltage.
Output T2-K1:10 “OUT.(PWM) INITIAL MAST LIFT” retains full voltage.
flowing through it.

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03359.wmf
For the first step in the fork lift only the free lift works.

815, 816 6070557 2012-10-03 7510399-020

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03362 wmf
The second step in fork lift is when transfer between free and main lift
takes place

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03362.wmf
For the third step in the fork lift only the main lift works.

815, 816 6070557 2012-10-03 7510399-020
Event: 13. Fork lowering

Action(s) The control for fork lift [B20] is moved away from the operator, and
input A1-X505:2 increases from approximately 2.6 V to approximately
Influencing elements Service parameter 1262 Transition flows during lowering.
Resulting conditions Main lift
Output A5-131:40 “OUT(PWM) MAIN MAST LOWER” reduces the
voltage
Output T2-K1:2 “OUT.(PWM) INITIAL MAST LOWER” retains full
voltage
flowing through it
Proportional valve [Q5] closed
Transition between main lift and free lift:
Output A5-131:40 “OUT(PWM) MAIN MAST LOWER” successively
increases the voltage at the same time as output T2-K1:2 “OUT.(PWM)
INITIAL MAST LOWER” successively reduces the voltage.
Proportional valve [Q4] begins to close at the same time as
proportional valve [Q5] begins to open.
Initial lift:
Output T2-K1:2 “OUT.(PWM) INITIAL MAST LOWER” reduces the
voltage.
Output A5-131:40 “OUT(PWM) MAIN MAST LOWER” retains full
voltage.
flowing through it.

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03363.wmf
For the first step in the fork lowering only the main lift works.

815, 816 6070557 2012-10-03 7510399-020

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03364.wmf
In the second step of fork lowering both the main lift and free lift work

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03365.wmf
For the third step of fork lowering only the free lift works

815, 816 6070557 2012-10-03 7510399-020
Event: 14. Fork tilt, backwards/upwards

input A1-X505:17 is reduced from approximately 2.6 V to
Output A5-X131:37 “OUT.AUX DIRECTION A” reduces the voltage.
Output A5-X131:11 “OUT.AUX DIRECTION B” remains high.
Current flows through the coil [Q8].
The tilt cylinder is pressurised via the non-return valve.
On sideshift, or some other optional function: the following also
applies:
Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” remains high.
No current flows through the coil [Q18].

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03375.wmf

815, 816 6070557 2012-10-03 7510399-020
Event: 15. Fork tilt, forward/downward

Resulting conditions Output A5-X131:37 “OUT.AUX DIRECTION A” remains high.
Output A5-X131:11 “OUT.AUX DIRECTION B” reduces the voltage.
The oil in the tilting cylinder is drained to the tank.
On sideshift, or some other optional function: the following also
applies:
Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” remains high.
No current flows through the coil [Q18].

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03371.wmf

815, 816 6070557 2012-10-03 7510399-020
Event: 16. Sideshift, right

input A1-X505:3 is reduced from approximately 2.6 V to approximately
Influencing elements Sideshift as an optional function.
Output A5-X131:37 “OUT.AUX DIRECTION A” remains high.
Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” reduces the
voltage.
The piston rod end of the sideshift cylinder is drained to the tank.

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03379.wmf

815, 816 6070557 2012-10-03 7510399-020
Event: 17. Sideshift, left

Influencing elements Sideshift as an optional function.
Output A5-X131:37 “OUT.AUX DIRECTION A” remains high.
Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” reduces the
voltage.
The piston rod end of the sideshift cylinder is pressurised.

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03377.wmf

815, 816 6070557 2012-10-03 7510399-020
Event: 18. Ergo cabin, tilt up

Prior event 12. Fork lifting
Action(s) –
Influencing elements Factory parameter 1104: Permitted cabin tilting.
Factory parameter 1259: Calibration, Ergo cabin up
Resulting conditions Output T2-K1:10 “OUT.(PWM) CABIN TILT UP” reduces the voltage.
The proportional valve [Q11] opens in proportion to the voltage applied
to it.
The cabin tilt cylinder is pressurised.

7510399-020 2012-10-03 6070557 815, 816

(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03380.wmf

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Event: 18. Ergo cabin, tilt down

Prior event 13. Fork lowering
Action(s) –
Influencing elements Service parameter 355 Offset, cabin tilting down
Factory parameter 1104: Permitted cabin tilting.
Factory parameter 1260: Calibration, Ergo cabin down.
Resulting conditions Output T2-K1:2 “OUT.(PWM) CABIN TILT DOWN” reduces the
voltage.
The proportional valve [Q21] opens in proportion to the voltage
applied.
The cabin tilt cylinder is drained to the tank.
Event: 19. Logout

Prior event 2. Login
Action(s) The operator presses the red button.
Resulting conditions The login screen is displayed and login is possible.
The screen to be displayed is determined by service parameter 503.
Event: 20. Emergency lowering

Prior event –
Action(s) The emergency lowering valve is opened mechanically.
Resulting conditions Oil flows from the free and main lift cylinders, via the emergency
lowering valve, to the tank.

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(4 HYDR. FUNC.)
A 4
B 3
2
Q18
1 TILT

LIFT LIFT
B4
H2 H3 M2 M H1 A1 B1 A2 B2 A3 B3
150 bar
150 bar
Q8 Q9
Q4 Q5
Q6 Q7 Q21 Q11
Q2 Q3
250 bar
P
T MP
03366.wmf
Oil flow for emergency lowering

Functions
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4.9 Functions
4.9.1 General overview

Terminology
[ ] = reference to electrical component in the wiring diagram.
{high} = refers to a voltage level of around 48 V.
{low} = refers to a voltage level of around 0 V.
Components
ACT = Traction transistor regulator [T1] (AC Traction)
ACH = Lift transistor regulator [T2] (AC Hydraulic)
CAN = Communication network (Controller Area Network)
CID = Central display [A1] (Central Information Display)
EPS = Steering servo [A2] (Electronic Power Steering)
ESD = Static discharge (Electrostatic Discharge)
GFU = Universal unit (General Function Unit) [A8]
LID = Upper display [P6] (Load Information Display) (option)
MCU = Main processor [A5] (Main Control Unit)
All these components intercommunicate via two CAN buses with the
MCU connected to each. The CID and LID use the first CAN bus and
the EPS, ACT and ACH use the second.
In its closed position, the main contactor [Q10] supplies the power
stage of the truck, e.g. ACT and ACH.
In its closed position, the key contactor [K20] supplies other electronic
units

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4.9.2 MCU – main control unit
General
The MCU is the main processor in the truck and communicates with the
traction transistor regulator, the lift transistor regulator, the steering
servo and the displays via two CAN networks. The truck parameter and
error code settings are also stored in the MCU. A back-up copy of the
parameters is also saved in the CID.
The MCU monitors and regulates the truck functions relating to
steering, driving, braking, hydraulics, communication and various other
things.
Downloading software
The TruckCom service program must be used for downloading new
software. See the separate manual for TruckCom.
System communication
The MCU is connected to both CAN1 and CAN2 and acts as a hub for
CAN communication between the various processors in the truck.
CAN1 is used for communication between the MCU and the various
displays (CID and LID). CAN2 is used for communication between the
MCU, the steering servo (EPS), and the regulators (ACT and ACH).

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4.9.3 ACT/ACH transistor regulators
General
The transistor regulators have a green LED to indicate OK status. On
start-up, the LED flashes twice and then stays on.
The basic software for controlling the drive motor, pump motor and
various hydraulic valves, is stored in the transistor regulators.
The transistor regulators have dedicated internal monitoring of CAN
communication, DC voltage levels, their own temperature and motor
temperature.
Any malfunctions are registered by the transistor regulators, and the
information is sent via CAN to the MCU, which registers the error code
and displays it on the CID. Once an error is detected, it is also signaled
by the LED going out or starting to flash.
The transistor regulators are replaceable and can be reprogrammed
using TruckCom via CAN.
4.9.4 Start-up
The truck checks the system by testing the inputs, outputs, voltage and
communication, etc.

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4.9.5 Shutdown
Shutdown is initiated by pressing the red “Log out” button.
Subsequently, the main contactor must open before the key contactor.
The check that the main contactor opens is made by activating the ACT
transistor regulator, when stationary, to load the battery circuit. If the
contactor is open, the voltage is slightly reduced and the condition for
shutting down the electronics and opening the key contactor is met.
4.9.6 Driving
Introduction
To be able to drive the truck, the operator seat must be loaded, the
safety pedal depressed, a direction of travel selected, and the
accelerator depressed.
If the operator seat is not loaded and the safety pedal depressed, a
disable indication will be displayed in the CID.
If no direction has been selected, the green arrows that indicate
direction switch alternately.
If the accelerator is depressed before the safety pedal or the seat is
depressed, the accelerator must be released before then being
depressed again.
Acceleration and speed reduction

When the accelerator is depressed, the MCU will determine the highest
applicable speed and increase the speed by using the ACT to regulate
the frequency of the drive motor three-phase voltage.
Maximum speed is parameter-based.
Pressing hard on the accelerator results in sudden acceleration, and
pressing lightly results in more restrained acceleration.
Acceleration is parameter-based.
Once the accelerator is released, plug braking will be activated and the
speed will be reduced. The more the pedal is released, the greater the
retardation.
Retardation is parameter-based.
Monitoring
Acceleration is reduced when battery voltage is low, as well as in
emergency driving mode.
Retardation is reduced in emergency driving mode.
Speed is monitored so that actual speed is reduced when retardation is
requested.

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Reversing
If the travel direction selector is pressed in the opposite direction to the
one that was selected, the truck will use the motor brake to come to a
standstill before then changing direction of travel.
Brake
The brake pedal function has three different positions:
• If the pedal is depressed to a maximum of 50% of its possible travel,
the truck is braked by the motor.
• If the pedal is depressed between 50 and 90% of its possible travel,
the support arm brakes, which are not part of the standard
equipment, will be used, along with the motor brake.
• If the pedal is depressed by more than 90% of its possible travel, the
mechanical brake is activated, along with the two other brakes.
If the truck is equipped with support arm brakes, a pressure sensor that
measures the load on the forks determines the degree of brake force to
be used.
When the truck is at a standstill, the parking brake will be activated
once the brake pedal is depressed by more than 5 %.
Monitoring
The brake pedal has two channels in to the MCU. These are inverted to
each other. Both channels are monitored and must be within 0.25 –
4.75 V.
The parking brake, or the mechanical brake, only has two positions -
completely on or completely off.
The support arm brakes are controlled by the MCU and monitored for
short circuits and circuit breaks.
If an error is detected on the support arm brakes, the travel speed is
reduced to the speed that applies for a truck without support arm
brakes.

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Travel speed
The truck series maximum permitted travel speeds are:
Model/Equipment Drive wheel direction Fork direction (km/h)

(km/h)
Without With load Without With load
load load
Platform A 9.5 9.5 9.5 9.5
Platform B without support arm
brakes 11 9.5-11 11 9.5-11
(Par 1101 = ‘0’)
With support arm brakes
11 11 11 11
(Par 1101 = ‘1’)
With support arm brakes
(Par 1101 = ‘1’)
14 14 14 14
High speed option (Par 1113 =
‘1’)
The travel speed can be adjusted to the operator and the environment
using parameters.
Travel speed is also affected by:
• Warnings – Error code x:1xx
• Error – Error codes x:2xx to x:4:xx
• As special - Three separate inputs on the MCU that can generate
specific speeds The maximum speed set by the three inputs
is controlled by parameters 205, 206 and 207.
If the parking brake is released and the travel direction selector is held
in a specific direction, the truck will drive at around 1 km/h. The speed
can be changed by resetting a parameter.

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4.9.7 OTP
OPT is a collective term for a combination of five options. These five
options are:
- Travel speed reduction - steering angle
- Travel speed reduction - extension of reach carriage
- Travel speed reduction - mast splitting
- Prevention of lifting/lowering of the forks
- Reduced extension speed
Travel speed reduction - steering angle

The truck's travel speed is reduced depending on the current steering
angle. The function is activated using parameter 1115.
Note:
Each time the truck is started, a reference calibration is made and the
steering wheel is turned to the 0° steering angle.
Travel speed reduction - extension of reach carriage

The truck's travel speed is reduced depending on the current position
of the reach carriage. The more the reach carriage is extended, the
more the travel speed is reduced. The function is activated using
parameter 1116.
Note:
Each time the truck is started, calibration of the home position/reach
carriage is performed.
Speed reduction - main lift range

The truck's travel speed is reduced if the main mast is not in the
bottom position. In this case, the travel speed is automatically reduced
to 6 km/h. The function is activated using parameter 1118.
Prevention of lifting/lowering of the forks

If the truck's travel speed and the lift height are higher than the set
parameter values, lifting/lowering of the forks is prevented. The
function is activated using parameter 1114. The speed is set with
parameter 347 and the lift height with 348.
Reduced extension speed

Depending on the current fork height and the weight of the load, the
maximum extension speed of the reach carriage is reduced. This does
not affect the speed of carriage retraction. The function is activated
using parameter 1117.

Functions
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4.9.8 Guide
Steering position control
The truck has position steering that is speed-controlled. The pulse
generator in the steering wheel sends a steering speed to the CID, and
this is sent as a CAN telegram to the MCU. Then the MCU converts this
value into a variance reading from the current position and sends a new
setpoint to the EPS, which controls the steering motor.
Monitoring
The pulse sensor is a twin sensor and two separate pulse sets are
received by the CID. If the two signals do not reach the same level
within a given time limit, an error code is output.
There is also monitoring to ensure that the pulse generator speed is not
abnormally high.
Steering speed
At low travel speeds, the steered wheel movement is multiplied so that
large wheel movements are made with only small movements of the
steering wheel. At higher travel speeds, the steering speed is reduced
to prevent loss of sensitivity in the truck steering.
The steering speed can be adjusted using a operator parameter.
Monitoring
In the case of a high steering value the current steering speed must be
higher than a given speed, otherwise an error code is produced.
In the case of a low steering value, the speed must be under a given
speed, otherwise an error code is produced.
When the steering servo is deactivated, the actual steering speed must
be 0, otherwise an error code is produced.

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Steering reference
The steering sensor is used as a 180 degree reference for the 360
degree steering.
The MCU calculates the position and stores it in the memory. The
steering sensor emits an active signal as a result of a half turn of the
wheel; the value is changed at 90 and 270 degrees.
Monitoring
At start-up, the last known steering angle is used by the program. If the
steering angle has been changed during the time the truck has been
switched off, the saved steering angle is unreliable. Another steering
angle measurement then starts and restricts steering movement to 180
degrees until the sensor signal and steering angle have been updated.
The reference sensor is located at the steering angles ±90 degrees,
resulting in 180 degrees between each signal.
Once a steering angle has been updated for the first time after start-up,
the wheel position is checked each time the reference sensor is
passed. If the sensor signals are not received within a specified
tolerance or are completely absent, an error code is output.
Travel speed limitation

During start-up, travel is disabled until the steering servo is initialised
and ready.
No speed limitation is made on the basis of steering turning angle size.
Compass rose
In the truck symbol on the CID, a compass rose with 8 arrows is
displayed. This indicates the direction the truck is moving in. If the
operator has not selected the direction of travel, or if there is a steering
reference error, the arrow goes out.
The compass card indicates that the truck will be moving

in the drive wheel direction

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4.9.9 Hydraulic system

This section describes the standard functions of the hydraulic system.
Definitions
The various ranges for fork movement are free lift, transition and main
lift.
Free lift is the range where only the free lift cylinder is working.
Transition is the range where both the free lift and main lift cylinders
work. When the forks are raised through the transition range, lifting is
increasingly taken over by the main lift cylinders, with simultaneous
slowing of the free lift cylinder, as the forks approach the upper limit of
the transition range.
The main lift is the range beyond the free lift range where only the main
lift cylinders work.
Note that free lift, transition and main lift denote the ranges, and not the
extent to which the forks move up or down.
Controls
All control values are sent from the CID to the MCU via CAN.
The control that operates the function must be registered as unaffected
after start-up and before the function is used.
Lift
The mast and the forks' position in the mast are detected.
The main positions are free lift, transition up towards main lift, main lift
and transition down towards free lift.
Free lift and main lift use separate valves. For this reason, they can be
used simultaneously in the transition range.
Monitoring:
• Lift speed is reduced when battery capacity is low.
• The lift control is checked to ensure it is within 0.3 – 4.7 V.
• The electrical circuits of the lift and lowering valves are monitored for
short circuits and breaks in the cabling.

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Reach movement
To detect reach carriage position, the reach movement uses a scale
with two corresponding sensors, [B26] and [B27]. Once the reach
carriage starts to approach its end position, the speed is reduced, and it
is stopped by means of a controlled movement.
Monitoring:
• The reach movement control is checked to ensure it is within 0.3 –
4.7 V.
• The electrical circuits of the reach valves are monitored for short
circuits and breaks in the cabling.
• The two digital signals of the reference sensors are monitored by
checking that the reach carriage has moved after 1 second when an
outward movement is requested.
Lift height limitation

The seven service parameters 380 – 386 may be used to set height
limitations, and parameters 387 – 393 are used to activate and to
specify whether the various limitations must apply.
When it comes to level selection, the limitations that have been set by
parameter will have higher priority than the height selection, and the
movement is stopped once the forks approach the limit. Continuation of
the lift is disabled. When this happens, a disable symbol is displayed in
the CID.
Lift height limitations that are not parameterized as “Mandatory” may be
overridden with a cancel button. Pressing the button removes the
limitation for 5 seconds. Within this period the forks are permitted to
pass the next limit. Once the forks have passed the limit, they are
permitted to stay at that height until they are lowered back under the
limit.
Maximum height limitation

The maximum lift height is set by a factory parameter. Once the forks
reach this level, the movement is stopped and lift continuation is
prevented. The cancel button for lift height limitation cannot be used to
override this limit.

Functions
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Auxiliary/Extra functions (option)

All the hydraulic functions in this section, as listed below, are connected
to the hydraulic main valve's extra outputs: AUX (auxiliary).
The functions cannot be used at the same time as certain other
hydraulic functions.
All extra functions can be calibrated by means of a number of
parameters.
Fork tilt
Fork tilt uses the first auxiliary output.
If an angle sensor is connected, a LED icon comes on in the LID
(option) when the forks are in their initial position, in other words, when
the angle is zero degrees.
Automatic fork tilting to horizontal position
• Activation: Parameter 1111
• Calibration: Parameter 1264
Automatic fork tilting to horizontal position requires the fork tilt option, a
tilt sensor and an option button.
When the button is held depressed, the forks automatically move to the
horizontal position.
Side-shift
Sideshift uses the second auxiliary output.
If a sensor is connected to measure the mid position, a LED icon in the
LID (option) comes on once the mid position is reached.
Automatic side-shift to centre position
• Activation: Parameter 1110
Automatic side-shift to centre position requires the side-shift option and
an option button.
When the button is held depressed, the forks automatically move to the
centre position.
Fork spread and telescoping forks
The telescopic forks use the third auxiliary output and forkspread uses
the fourth auxiliary output.

Height preselector, description of function
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4.10 Height preselector, description of

function
4.10.1 Using the height preselector

To be able to use the height preselector functions, the factory
parameter for the height preselector (HPS, Height PreSelection) must
be set.
If the parameter has been set, height preselector mode is activated
once the truck is started.
Height preselector mode can be activated and deactivated by
depressing and holding down the preselector button on the CID for 3
seconds.
4.10.2 Symbols
Height preselector mode is indicated in the CID by the following
symbols:

Height Pick up
preselector
active
Delete height Deposit
4.10.3 Buzzer
The CID buzzer is used to warn of an error, for instance if a level that
has been entered is not programmed, or if the entered level does not
exist.
The buzzer is also used to inform the operator when a target has been
achieved.

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4.10.4 Height preselector levels

The height preselector levels are organised in aisles with levels – heights –
defined for each aisle. A maximum of 200 heights can be stored and service
parameter 511, Aisle configuration, gives the number of heights/aisle.
The applicable parameter values are listed below:
Value Aisles Heights/aisle

1 1 200
2 2 100
3 4 50
4 5 40
5 8 25
6 10 20
7 20 10
8 40 5
In the CID and LID displays, the aisles and levels are written in the format
“aa:nnn”, where “aa” is the aisle and “nnn” is the level for the row.
Depending on the setting of the parameter for the number of aisles, there can
be one or two digits for the aisle and one to three digits for the level.
4.10.5 Level selection

The height preselector levels are selected using the CID keypad.
To select a level, press the digits on the keypad, leaving no more than 0.5 of a
second between each one that you press. Once the final digit has been
entered, the level selected will appear approximately 0.5 seconds later.
When an aisle is to be selected, the digits are entered in the same way as for a
level, but the sequence is ended by pressing the green button (I).
Levels can be selected irrespective of the aisle. If a new aisle is selected, any
previous levels selected are reset
Event Display
Press the number 1 --:--
Press the number 4 (within 0.5 s) --:--
Press the green button (I) (within 0.5 14:--
s)
Press the number 9 14:--
Wait 0.5 s until level 9 is selected 14:9

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4.10.6 Height programming

Note:
Height programming requires that parameter 510 allows free access
or that the CAN key/TruckCom is connected.
There is space for 200 different collect and deposit levels.
Once the user screen is displayed, press buttons 1 – 9 to remove the
height preselector screen:
From this screen, pressing the i-button makes the teach-in screen for
the height preselector appear:
The CID screen displays a box containing the selected aisle and level.
The forks' present level is given under the box.
On the right are the pallet symbols for pick up and deposit, with the
programmed heights shown underneath.
Plus/minus or numerical buttons are used to specify the level. When
the green button is pressed, the current height is stored for the selected
level.
The current height is saved as a collect height, and the deposit height is
saved automatically as the difference for the current height as
determined by service parameter 378 for the collect/deposit difference.
The new heights will be displayed under the pick up and deposit
symbols.
The deposit height can be programmed individually using the arrow
buttons. Using the arrow buttons, you can select the icon for deposit
height. Then press the green button.
The deposit height must be within the minimum and maximum values
specified with service parameter 378. If the height is outside this
interval, it will not be saved and the buzzer will sound as a warning.
To leave the programming screen, press the C-button.

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4.10.7 Height preselector and TruckCom

The height preselector can also be managed via TruckCom. This
makes it possible to enter the saved heights on a PC or PDA.
In this way, you can archive them in a file and update a truck using the
settings from the file.
4.10.8 Lifting/lowering movement

When the sequences are performed, the lift movements are checked by
the service parameters 341, 342, 371 – 377 to get them to interrupt the
movement at the right height, and as gently and precisely as possible.
The transfer near the target height is limited by a curve that is defined
by a number of parameters:
vlift
375
341
373
htarg
371
372 dlift
374
342
376
341: Max. lift speed, 342: Max lowering speed, vlift: Lift speed, htarg:
Target height, dlift: Lift movement length
Once the forks are nearer to the target height than that defined by
parameters 375/376, Braking Distance Lift/Lower, the movement slows
in three stages to the height set by parameters 373/374, Creep
Distance Lift/Lower.
Once the forks are nearer to the target height than the creep distance,
the forks move at the speed defined by parameters 371/372, Creep
Speed Lift/Lower.
Once the forks reach the target height, the movement is stopped.
If the measured stop height differs from the target height by more than
the maximum error, defined by parameter 377, Max. Stop Height Error,
a warning code is displayed at the same time as the CID emits a
warning sound.

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4.10.9 Parameter settings braking at height

preselector
Settings for lifting and lowering parameters work the same except that
lowering is dependent on correctly calibrated free and main lowering
valves. See chapter 14.8.3 Valve calibration. If these valves are
incorrectly calibrated, it may be impossible to set the parameters so
that the forks stop at the right height.
The following points describe how to set lifting parameters:

1. Set creep distance 100 mm (parameter 373).
2. Select a height preselector level or activate lift height limitation and
lift the forks to 100 mm below the target height so they just reach
the creep distance.
3. Lift the forks and change the creep speed (parameter 371) so that
the right speed is reached.
4. Interrupt the height preselection sequence with (C) and lower the
forks approx. 2 metres.
5. Set a braking distance of 500 mm (parameter 375).
6. Lift the forks with full speed until they stop. Adjust the creep
distance (parameter 373) so that the forks stop at the right height
while at the same time the creep distance is as short as possible.
7. If necessary, repeat steps 4 - 6 until the desired results are
achieved. It may be possible to adjust the braking distance if you
see that the forks can decelerate to to the creep distance by good
margin.
Repeat the procedure, except with lowering and using the
corresponding lowering parameters (372, 374 and 376).

Hydraulic system 6000
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4.11 Hydraulic system 6000
4.11.1 General
The hydraulics on the truck consist of a pump that takes oil by suction
from the tank and pumps it to the main valve located in the reach
carriage.
The main valve distributes the oil to the reach cylinder and the mast.
The return oil from the reach cylinder and mast is pumped via the main
valve through the filter to the tank.
4.11.2 Tank
The tank has a capacity of approximately 25 litres. It is manufactured
from electrically conductive plastic.
Topping up of the hydraulic oil is via the return filter. The tank is
equipped with a separate plug for the control of the oil level.
The hydraulic oil from the hydraulic system and the breathing air are
filtered by the return filter. There is no filter between the tank and the
pump.
4.11.3 Filter
Return filter
The hydraulic oil from the hydraulic system and the tank breathing air
are filtered by the return filter.
Filtering is very important for the service life of the hydraulic oil and
hydraulic system. Filtering of the hydraulic oil is by means of a filter
element with a filter rating of 10 micrometres. Once the filter element is
saturated with particles, a bypass valve opens and the hydraulic oil
goes straight to the tank, bypassing the filter element without being
filtered. The air filter and filter element can be replaced.
Dehumidification filter
For applications where there is air humidity, the intake air has to be
dehumidified before reaching the tank. If this does not happen there is
a risk of the air condensing and water mixing with the hydraulic oil.
In the cold store version, the dehumidification filter is used in
combination with a special return filter with a specially adapted breather
filter connection for connecting to the dehumidification filter.

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4.11.4 Hydraulic pump

The pump is of gear wheel type (inner gear wheel) with fixed
displacement and is driven directly by the electric motor. The metallic
contact surfaces in the pump require very good lubrication, placing
strict requirements on the grade of hydraulic oil. They also require that
the motor rpm does not drop below a specified minimum value.
4.11.5 Valve unit

Main valve block
The main valve block is located on the reach carriage. There are two
different versions of the main valve block: one for RRE and one for RRE
Ergo.
RRE main valve RRE Ergo main valve
The valves for main lift, free lift, reach movement and cabin tilt are
pressure-compensated proportional valves. By means of pressure
compensation, the flow through the valve is kept constant for a given
valve deflection, irrespective of the load on the forks/cylinder.
The valve slides of the main valve block's proportional valves are
individually adjusted and cannot be replaced.
Pressure limitation
To protect the system against overpressure there is a pressure limiter
DV1 in the main valve block. The pressure limiter opens once the
system pressure exceeds 25 MPa (250 bar).
Thanks to the main cylinders' and free lift cylinder's proportional areas,
no adjustment of the pressure limiter is needed to set the maximum
load. The valve block comes supplied with the pressure limiter DV1 set
at 25 MPa (250 bar).
For the reach movement and (where applicable) cabin tilt, there are
also pressure reducing valves DV2 and DV3, set at 15 MPa (150 bar).

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Calibration of lowering valves and lift valves

The lowering valves for main lift Q4 and free lift Q5, and the lift valves
for main lift Q2 and free lift Q3 need calibrating to operate to their
optimum.
For the lowering valves Q4 and Q5, the opening point is to be calibrated
via the “Service” function on the CID, see “Valve calibration” on
page 14–29. The opening point gives the function its lowest lowering-
speed.
For the lowering valves Q4 and Q5 the maximum opening point, which
gives the function its maximum lowering speed, should also be
adjusted. The adjustment is made mechanically, see “Adjusting the
maximum opening pressure” on page 15–20.
For the lift valves Q3 and Q5, the opening point must be calibrated. For
the lift valves the opening point is very important for maintaining
optimum transition from free lift to main lift.
Emergency lowering valve
On the top of the valve block is an emergency lowering valve (arrow) for
the mast. Both the main lift cylinders and the free lift cylinder are
connected to the emergency lowering valve.
The emergency lowering valve is opened by loosening a 3 mm allen
screw in the valve unit. The screw only needs opening 1½ turns to
activate emergency lowering.
Note:
The screw must only be tightened to 2.5 Nm on closing.
Second valve block

Located in the fork carriage is a valve block in one of two versions - for
fork tilt and sideshift, or for fork tilt and extra functions.
Apart from these valve blocks there is the option of an additional one or
two extra hydraulic functions using an extra valve block in one of two
versions - for one or two hose reels.

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4.11.6 Cylinders
Main lift cylinders
The main lift cylinders are single-action cylinders without pistons. The
diameter of the rod determines the pressure area and the rod is
controlled in the cylinder tube by a control belt. Hydraulic oil surrounds
the whole rod up to the top sleeve. Sealing against leaks occurs in the
top sleeve.
Free-lift cylinder
The free lift cylinder is a single-action sealed piston cylinder.
Cylinders for the reach movement, cabin tilt,

sideshift and fork tilt
For the reach movement, cabin tilt, sideshift and fork tilt, double-action
cylinders with piston seal are used.

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4.11.7 Lift and lowering function

Lifting and lowering of free lift
The free lift is controlled by the proportional valve, Q3/Q5, which is a
replaceable cartridge type.
On free lift lifting, the pump is started and the proportional valve Q3 is
fully opened. The lifting speed is regulated by the pump speed.
Free lift is lowered using the proportional valve Q5.
Transition from free lift to main lift

The valve block has separate connections and proportional valves for
main lift (Q2) and free lift (Q3). This allows a smooth transition from free
lift to main lift, by reducing valve opening for Q3 at the same time as
increasing valve opening for Q2.
In a similar fashion, the proportional valves Q4 and Q5 give smooth
transition on lowering, by reducing valve opening for Q4 at the same
time as increasing valve opening for Q5.
Lifting and lowering of main lift

The main lift is controlled by the proportional valve, Q2/Q4, which is a
replaceable cartridge type.
On main lift lifting, the pump is started and the proportional valve Q2 is
fully opened. The lifting speed is regulated by the pump speed.
Main lift is lowered using the proportional valve Q4.
Reach movement, in and out

The valve for control of the reach movement, Q6/Q7, is a proportional
slide valve which is not replaceable.
For reach movement in the IN direction, the pump is started and valve
Q6 is activated. For reach movement in the OUT direction, the pump is
started and valve Q7 is activated. The speed of the reach movement is
regulated by the pump speed, with valves Q6 and Q7 providing soft
start and stop for the function.
The pressure limiter DV2 opens if the pressure exceeds 15 MPa (150
bar) on reach movement in the OUT direction. On reach movement in
the IN direction, the pressure is limited by DV1 to 25 MPa (250 bar).

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Simultaneous operation of mast lift and reach

movement
Under normal circumstances the flow for mast lift and the reach
movement are regulated by pump speed.
To allow simultaneous operation of these functions, the flow must
instead be limited using the proportional valves Q2/Q3 and Q6/Q7.
This reduces the maximum speed of mast lift and reach movement
when simultaneously operated.
4.11.8 Extra functions

Extra functions are activated by valve Q8/Q9, non-replaceable, in the
main valve block.
If Q8 is activated, pump pressure P is connected to connection A1, and
connection B1 is connected to T (tank return).
If Q9 is activated, pump pressure P is connected to connection B1, and
connection A1 is connected to T (tank return). Pump speed regulates
the speed, and current limitation of the electric motor determines the
pressure level for the extra function.
4.11.9 Cabin tilt (RRE Ergo)

Cabin tilt is controlled by a proportional slide valve, Q11/Q21, non-
replaceable.
To lift the cabin (tilt it up), the pump is started and Q11 is activated, and
to lower the cabin, Q21 is activated.
Hydraulic priority system

The priority system means cabin tilt takes priority over mast lift.
If both functions are activated, cabin tilt will not be affected, whereas
the flow for mast lift is limited.
The normal position of the priority system valve directs the pump flow to
the proportional valve for cabin tilt Q11/Q21.
If Q11/Q21 is open, the flow travels to the cabin tilt cylinder, and if Q11/
Q21 is not open, the pressure increases and causes the priority system
valve to move, so that the flow travels to mast lift Q2/Q3.
If Q2/Q3 is open, the flow travels to the main lift cylinders or the free lift
cylinder, respectively; if Q2/Q3 is not open, the pressure increases and
affects the pressure reducing valve, DV1, which opens the path to the
tank.

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Cabin tilt (RRE Ergo) during servicing

During servicing, the cabin must always be tilted so that its centre of
gravity passes the centre of rotation; the cabin will then drop gently into
its end position, the service position.
DANGER!
Risk of crushing.
You cannot stop the cab tilt motion with the hydraulics once the
balancing point has been passed.
Make sure that nobody/nothing is behind or close to the cab when
tilting.
To raise the cabin up out of the service position, the pump is started and
Q21 is activated.
Cabin tilt in the event of hydraulic or electrical

power loss
If required, the cabin can be tilted up with a traverse, without the valve
being activated. However, in such a case Q21 must be activated, once
the cabin is to be tilted back. On the magnetic tube to Q21 there is an
allen screw, the emergency lowering screw, which allows opening of
Q21 in the event of the electronics being out of action.

Mast 7000
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4.12 Mast 7000
4.12.1 Mast and reach carriage
The mast and reach carriage are available in a number of different

sizes that can be combined in a specific way. The reach carriages and
mast that are suitable for the truck are determined by factors such as
the width between the support arms, load capacity and the lift height of
the mast.
When ordering a replacement mast, TMHE Technical Support should
be contacted to identify the right mast for the truck in question.

Lifting devices
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4.13 Lifting devices
4.13.1 Fork extensions

The standard fork can be extended, allowing you to transport bulkier
items. When the fork extension is fitted, a check is made that it is
suitable for fitting to a standard truck fork (see the details on the
identification plate). Only use in pairs when the specified fork
dimensions match, and the length of the truck fork is greater than or
equal to the minimum permitted truck fork length.
Note:
Please note that load capacity is reduced once the fork extensions
are attached.
Note:
The fork extension must not be used if the mounting is unsafe or if it
is damaged, dirty or icy. The chamfered underside must face
downwards. Daily visual inspection is recommended.
4.13.2 Telescopic forks

KOOI forks, manufactured by the Meijer Special Equipment Company
in the Netherlands are specially designed forks with a thickness of 56
mm. This flatter fork can be used for load carriers with lower tunnel
heights. The telescopic forks are fitted in the same way as normal
forks and can be moved in their holders in the same way. All forks
have an identification plate on their upper surface. The plates contain
important information on the fork’s technical data, e.g. the maximum
load capacity of the fork.
The telescopic forks are operated using a closed, self-lubricating oil
circuit. These forks come supplied with oil that meets an ISO 4406
cleanliness standard code of 17/12.
The telescopic forks must be tested every year in line with ISO 5057
requirements (see the Maintenance section). The international
standard must be applied when checking the forks, with the exception
of those sections that refer to “fork blades and shafts”, as the inner fork
must not be subjected to wear.

Lifting devices
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The identification plates of the telescopic forks have had an L and an R

added to them. The forks are fitted on the left and right fork holder,
respectively, as viewed from the operator seat. The forks are pushed up
on the fork holder so that the locking catch fits in the holder recess.
Along the rear of the fork holder there is a distribution valve.
The maximum fluid pressure for the telescopic forks is 20 MPa (200
bar).

Accessories 9000
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4.14 Accessories 9000
4.14.1 Radio equipment

The CD/Radio unit is placed in the ceiling panel and the loudspeakers
in the roof over the operator. The CD player has a “shake memory” and
it can handle recordings in .mp3 and .wma formats. A separate user
manual is supplied with the truck.
4.14.2 Extra lighting

The truck can be equipped with headlights to provide additional lighting
in dark areas. The headlights can be positioned in the mast direction (2
lamps) or in the drive wheel direction (2 lamps). They can also be
combined so there are 4 lamps in total. The headlights are mounted on
the overhead guard. The work lights are lit using the switch in the
ceiling console. Height over overhead guard is 130 mm.

Accessories 9000
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4.14.3 Extra warning lights/alarm

A warning light can be mounted on the truck to warn persons within the
truck's working area. The warning light is mounted on the overhead
guard above the overhead guard panel so that the light is visible from
all directions around the machine yet there is no risk of blinding the
operator. Height over overhead guard is 118 mm.
The light can be activated in different ways:
• To activate the function, see parameter 1112.
• To set when the lamp should flash, see parameter 115.
• To specify the frequency, see parameter 106.
4.14.4 Turn signal lights

To make bystanders aware of the intended truck travel direction, two
direction indicators (car type) can be mounted on the left-hand and
right-hand side of the overhead guard.
• To activate the function, see parameter 1109
• Direction is selected using the CID keypad. Button 1 activates the
right-hand direction indicator, while button 7 activates the left-hand
direction indicator. Flashing ceases once the operator starts to
straighten the steering wheel again and passes 10° or presses the
button again.
Note:
Note that if the height preselector is activated, the direction indicator
function will be deactivated.

Accessories 9000
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4.14.5 Movement alarm

The truck can be equipped with a buzzer that sounds a signal at regular
intervals to warn people within the working area of the truck.
There are a number of different options when it comes to programming
the warning signal:
• To activate the function, see parameter 1108
• To set when the signal should sound, see parameter 114
• To specify the frequency, see parameter 105

Accessories 9000
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4.14.6 Positioning/TV equipment

To facilitate the positioning of the forks in the load carrier, the truck can
be equipped with positioning-/TV equipment consisting of a small
camera that is fitted to the left fork and a 7 inch colour screen placed in
the operator's compartment.
The monitor is supplied with 12 V and can be used in ambient

temperatures of 0°C to +60°C. The camera electronics and optics are
mounted in an aluminium housing. It is not possible to replace the lens
with another one with a different focal length. The electronic
components generate enough heat and additional heaters are not
required when operating the system in a cold-store. Colour changes
may appear at temperatures above 70 °C. The camera may also be
used on truck equipped with monochrome (B/W) monitors.
~350

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Screen options:
8 M
A B C D
Pos. Designation/function
A Button/changes monitor settings
B Button/switches between inputs AV1 and AV2
C Button/menu for monitor settings
D Button/power supply
The menu has the following setting options:
Menu Affects
selection
Bright Brightness from 1 to 100
Contrast Contrast from 1 to 100
Colour Colour intensity from 1 to 100
Default Resets all options to their default values
Backlight Backlight level from 1 to 100
AV2 AV1 or AV2 at monitor start-up
Scales 16:9 or 4:3
• Move between different menu options using button B.

• To change a setting, first select the menu option. Move button A up
or down to change the setting.
• New settings can be stored by holding button C depressed or by
switching the monitor on and off with button D.

Accessories 9000
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4.14.7 Extra electrical equipment

The truck can be equipped with a DC/DC converter (with/without socket
in the instrument panel) to supply power to equipment such as a PC,
scanner, etc. The converter on the input side is protected against
polarity reversal, short circuit and thermal overload. The chassis is not
live, and the in/outputs are galvanically separated. The truck can be
fitted with maximum three converters. One is used for standard option
as CD/radio and camera. Another two can be ordered and combined as
described below. The socket (output) is located next to the E-bar profile
on the instrument panel.
DC/DC converter 48V/12V incl. Can be combined with: DC/DC converter

socket in instrument panel 48V/24V
DC/DC converter 48V/24V incl. Can be combined with: DC/DC converter,
socket in instrument panel 48V/12V
DC/DC converter 48V/12V Can be combined with: DC/DC converter
48V/24V incl. socket
DC/DC converter 48V/24V Can be combined with: DC/DC converter,
48V/12V incl. socket

Accessories 9000
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4.14.8 Other extra equipment

Fork spacers
Adding spacers to the rear of the forks will allow you to reach further in
front of the truck. It can be useful if the pallet protruding varies in the
racking e.g. when working together with mast tilting trucks that has
greater fork movement. They reduce the risk of collisions with racking
uprights and loads already placed in the rack. There are three different
sizes: 50, 100 and 120 mm.
Note:
The load centre distance is increased which affects stability and
reduces capacity. Observe rated capacity and load centre of the truck!
600
650
50 mm
30
80

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Load rest
The truck may be equipped with a load support that is attached to the
fork carriage. The load support increases the stability of the load when
handling high loads. The load support exist with different heights for
adapting to the height of the handled load.

Accessories 9000
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E-bar
Use the E-bar profile for quick and easy installation of optional
accessories, such as a computer equipment, scanner, writing tablet,
etc. The accessories are then easily accessible from the operator's
position.
Accessories can be fixed with standard brackets. The brackets can be

used on all trucks with E-bar profile, making it easy to move equipment
between the trucks.

Accessories 9000
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Flashlight
The truck can be fitted with a fire extinguisher. It is useful in areas
where flammable materials are handled, always at hand in case of fire.
Two versions of fire extinguisher are available:

Type Size Standard Market
Standard ABC 2 kg EN3 Countries following EU
regulations
USA ABC 2 kg ANSI/UL711 & ANSI/UL299 Countries following
American regulations
A = Combustible material such as paper, wood, cardboard and plastic.

B = Ignitable or combustible fluids such as petrol, kerosene, grease and
oil.
C = Electrical equipment such as devices, cables and power sockets.

Parameters
General
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5 – Parameters
5.1 General
The truck's control system can store a number of different parameters.
These are used to configure the truck according to the task to be
performed. The parameters are divided into groups:
- Operator parameters – The operator parameters (range 1–100)
are used to adapt the truck's response to a specific operator or to
the task. Up to 10 operator parameter profiles can be stored.
- Service parameters – The service parameters (range 101–
1000) are used to adapt the truck's performance/response; they
cover all other parameters not covered by the operator
parameters.
- Factory parameters – (range 1001-1250). Truck-specific
parameters.
- Calibration parameters – The calibration parameters (range
1251–1500) store the value generated on calibration of valves,
weight indication, etc. These must not be changed manually.
Operator parameters are displayed and changed only for a selected
operator, but if a CAN service key is connected, the parameters for all
operators can be displayed and changed. Operator parameters can be
changed by the operator if the truck's program is set up for this.
The service parameters can be changed once a suitable CAN service
key or PDA/PC has been connected to the truck.
Factory parameters can ONLY be changed once a specially configured
PDA/PC has been connected to the truck.
5.2 Displaying/changing parameters

For instructions on how parameter settings are displayed and changed,
see Chapter 14.6.

Parameters
Operator parameters
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5.3 Operator parameters
5.3.1 Overview
Par. Description
1 The steering's progressiveness
2 Maximum speed, drive wheel direction
3 Maximum speed, fork direction
4 Acceleration
5 Automatic braking when speed is reducing
6 Fork height above floor level once the Ergo cab
starts to tilt
7 Test parameter 1
8 Test parameter 2
9 Test parameter 3
10 Test parameter 4

Parameters
Operator parameters
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5.3.2 Connection to logged-in operator

The operator parameters can be adjusted individually to the available
login profiles. The parameter’s connection to the operator is done by a
combination of operator and parameter numbers where the single digit
always corresponds to the parameter.
Parameter
Operator
range
1 1 – 10
2 11 – 20
3 21 – 30
4 31 – 40
5 41 – 50
6 51 – 60
7 61 – 70
8 71 – 80
9 81 – 90
10 91 – 100

Parameters
Operator parameters
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5.3.3 Description
Parameter 1 – Steering
The steering angle sensitivity can be individually adjusted between 1
and 10 for driving at both low and high speed. 1 gives the lowest
speed of steering movement in relation to the steering wheel
movement and 10 gives the highest speed.
s
10
9
8
7
6
5
4
3
2
1
v
s: steering sensitivity, v: travel speed,

snail: low speed range, hare: high speed range
If the steering feels too sluggish or unresponsive in any of the low or
high speed ranges, the corresponding value is changed upwards or
downwards through the setup screen for operator parameter 1.
In the setup screen, the low speed range is represented by a snail
and the high speed range by a hare.
Defa Incre
Par. Description Min. Max. Unit
ult ment
1L Steering movement in 1 5 10 1 –
relation to steering wheel
1H movement, parameter 1 5 10 1 –
screen display
1 257 1285 2570 1 –

Parameters
Operator parameters
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1 2 3 4 5 6 7 8 9 10
1 257 513 769 1025 1281 1537 1793 2049 2305 2561
2 258 514 770 1026 1282 1538 1794 2050 2306 2562
3 259 515 771 1027 1283 1539 1795 2051 2307 2563
4 260 516 772 1028 1284 1540 1796 2052 2308 2564
5 261 517 773 1029 1285 1541 1797 2053 2309 2565
6 262 518 774 1030 1286 1542 1798 2054 2310 2566
7 263 519 775 1031 1287 1543 1799 2055 2311 2567
8 264 520 776 1032 1288 1544 1800 2056 2312 2568
9 265 521 777 1033 1289 1545 1801 2057 2313 2569
10 266 522 778 1034 1290 1546 1802 2058 2314 2570
11
Low speed range value is displayed as it is entered, but the actual steering sensitivity is
–
that which applies for "low speed = 10".
255
Table to aid reading steering parameters in TruckCom

The parameter shown via TruckCom is a combination of the sensitivity
values low speed and for high speed.
Valid combinations can be read out by seeking the value in the table
and reading off the values for the snail and the hare.
Example:
1538 gives parameter values for low speed = 2 and high speed = 6.

Parameters
Operator parameters
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Parameter 2, 3 – Maximum travel speed

These two parameters are used to limit the maximum travel speed for
the logged-in operator profile.
For parameters 2 and 3, 100% corresponds to a travel speed of 11 km/
h.
Par. Description Min. Default Max. Increment Unit
Maximum speed, drive wheel
2 1 10 10 1 10%
direction
Maximum speed, fork
3 1 8 10 1 10%
direction
Example:
If operator profile ‘1’ has parameter ‘2’ set to 80 %, operator profile‘2’
has their corresponding parameter ‘12’ set to 70 %, the maximum travel
speed is limited to:
• 8.8 km/h for operator profile ‘1’
• 7.7 km/h for operator profile ‘2’
Note:
The maximum travel speed can also be limited by the service
parameters and it is always the lowest speed for a parameter that is
the limiting one.
Parameters 4 and 5 – Acceleration/Retardation

These two parameters can be used to get a smoother acceleration/
deceleration where the application or operator profile so requires.
4 Acceleration 3 8 10 1 10%
Automatic braking when
5 3 8 10 1 10%
reducing acceleration
Parameter 6 – Cab tilt

This parameter is for setting the fork height above the floor level when
the operator wants the cab (E-model) to start tilting upwards.
Fork height above floor level 10,00
6 500 2000 100 mm
once the Ergo cab starts to tilt 0
Note:
To activate the function, see parameter 1104 and for downward tilting
see parameter 355.
Note:
To turn off the cab tilt display on the CID, see parameter 514

Parameters
General service parameters
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5.4 General service parameters
5.4.1 Overview
Par. Description
101 Service intervals
104 Time to automatic log-out
105 Frequency of output for alarm 1
106 Frequency of output for alarm 2
107 Battery size
Battery status when acceleration and lift speed are
108
limited
109 Resetting procedure for logged data
110 Collision sensor sensitivity in X-axis
111 Collision sensor sensitivity in Y-axis
112 Resetting procedure after collision
113 Shunt resistance
114 Activation pattern for travel alarm 1 – X131:23
115 Activation pattern for travel alarm 2 – X131:21
116 Drive function with open door in cold-storage cab
117 Collision sensor's alarm
118 MEWP presence buzzer possible
5.4.2 Description
Parameter 101/104 – Service/Logout
101 Service intervals 0 0 5000 1 h
104 Time to automatic log-out 0 20 120 1 min
Parameter 101 specifies the truck's service interval in operating hours.

Use this parameter to determine the service interval of the truck. The
buzzer sounds and 2:005 is shown on the CID when the service
counter is at zero. The counter shows the time that has passed since
the truck was last serviced.
If an earlier service intervention is required, simply activate this
parameter without adjusting the time.
If the value is set to '0', then no service interval is set and the CID's hour
meter screen does not show the 'S' field – Remaining time to service.
Parameter 104 gives the time, in minutes, before automatic logout if
the truck is inactive.
If the value is set to ‘0’, logout takes place after 4 hours.

Parameters
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Parameter 105/106/114/115/117 (Travel alarms 1

and 2)
There are two dedicated outputs for travel alarm on the MCU. One
has by default been assigned to the buzzer and one to the warning
lamp. Both can be configured regarding frequency and activation
pattern.
Note:
The "travel alarm 1" function is activated by parameter 1108 and
the "travel alarm 2" function is activated by parameter 1112.

Frequency for output of travel
105 0 0 2 1 –
alarm 1
Frequency for output of travel
106 0 0 2 1 –
alarm 2
Activation pattern for travel
114 0 0 255 1 –
alarm 1 – X131:23
Activation pattern for travel
115 0 0 255 1 –
alarm 2 – X131:36
117 Collision sensor's alarm 0 0 1 1 –
118 MEWP buzzer 0 0 1 1
Parameter 105 states how travel alarm 1 (buzzer), output X131:23,

will sound when it is active:
Value Type
0 Continual
1 1 tone pulse/sec
2 2 tone pulses/sec
Parameter 106 states how travel alarm 2 (warning lamp), output

X131:36, will flash when it is active:
Value Type
0 Continual
1 1 flash/sec
2 2 flashes/sec

Parameters
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Parameter 114 states the activation pattern for travel alarm 1 –

X131:23
Parameter 115 states the activation pattern for travel alarm 2 –
X131:36
The function that activates travel alarms 1 or 2 Value
Driving in the drive wheel direction 1
Driving in fork direction 2
Fork lifting 4
Fork lowering 8
Cab tilting up 16
Reach carriage in motion 32
Option in motion 64
Truck started up 128
Example:
If you want travel alarm 1 to be active when driving in the drive wheel
direction and in the fork direction and travel alarm 2 active when you lift
and lower the forks.
Parameter 114 is then set to 1 + 2 = 3 and parameter 115 is set to 4 + 8
= 12.
Travel
Parameter
alarm
105 106 114 115 1108 1112
1 0/1/2 1-255 0/1
2 0/1/2 1-255 0/1
Parameter 117 states how the alarm is given when the collision sensor
is activated:
Value Type
Repeated tone
0
pulses
1 One tone pulse
Note:
for setting the collision sensor’s sensitivity, see parameters 110 and
111.

Parameters
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Parameter 107/108 – Battery

107 Battery size 1 9 20 1 –
Battery status when
108 acceleration and lift speed 0 5 20 5 %
are limited
Parameter 107 specifies the capacity of the battery on the truck.

The parameter can also be used to compensate for different ways of
driving by:
• increasing the value to discharge the battery even more
• reducing the value if the battery gets discharged too much.
For recommended parameter settings see the table below.
Value: RRE180 – 250 Value: RRE140 – 160 Battery
– 13 465 Ah
14 11 620Ah
11 10 775 Ah
9 – 930Ah
.
You must specify which type of battery the truck is equipped with. The
following should be taken into account in order to set the meter for the
battery discharge level:
• Acid density when the battery is fully charged, to check the quality
of battery. This value should be in the range 1.27-1.29.
Please note that the acid density may vary between different
battery brands.
• When the lifting capability is reduced (the battery is discharged to
80%) the value should be close to 1.14 but not lower.
Freely ventilated batteries
See the table for recommended parameter settings for free ventilated
batteries.
DANGER!
Battery service life will be reduced if the value of parameter 107 is
set too high. As a default, parameter 107 is set for normal truck
handling. Other applications may require a different setting of
parameter 107. Check that the parameter setting is the correct one
using the instructions below.

Parameters
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Verifying the parameter setting for freely ventilated

batteries
1. Charge the battery.
2. Operate the truck in its normal application until the battery indicator
indicates a discharged battery (0% in the display).
3. Disconnect the battery from the truck and allow it to rest for at least
two hours.
Note:
Do not charge or discharge during this time.
4. Measure the density of the acid in the battery at room temperature.
If the density is below 1.15 g/cm3, the parameter value must be
reduced. If the value is considerably higher than 1.15 g/cm3, the
risk of damage to the battery is reduced. At the same time,
however, the operating time of the truck decreases. If extended
operating time is desired, then increase the parameter value, but
by no more than one unit.
Note:
Each change must be followed up by a new verification of the
parameter setting.

Parameters
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Parameter settings for valve-regulated batteries

(VRLA).
BT recommends that when setting parameter 107 in a Reflex truck
with Hawker Evolution batteries, the recommended value for wet
batteries should be reduced by six (6) units.
DANGER!
Battery service life will be reduced if the value of parameter 107 is
set too high. As a default, parameter 107 is set for normal truck
handling. Other applications may require a different setting of
parameter 107. Check that the parameter setting is the correct one
using the instructions below.
When checking the charging state on a discharged 48 V battery, its
no-load voltage should be measured after a rest period. Zero
indication should occur at no-load voltage, which must not be below
2.02 V/cell or 48.48 V.
See the instructions below.
Instructions for verifying the parameter setting

1. Charge the battery.
2. Use the truck in its normal application until the battery indicator
shows a discharged battery (0 % on the display).
3. Disconnect the battery from the truck and allow it to rest for at
least two hours.
Note:
Do not charge or discharge during this time.
4. Measure battery voltage at +20°C. If the voltage is less than Uend
(see the table below), the parameter value must be reduced. If
the value is considerably higher than Uend, the risk of damage to
the battery is reduced. At the same time, the operating time of
the truck is reduced. If a longer operating time is required, the
parameter value can be slightly increased.
5. Each change must be followed up by a new verification of the
parameter setting.
Battery type Battery voltage at reset, Uend

Hawker Evolution 48.48 V

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 108 is used to specify the level of the battery's residual

capacity according to the CID battery discharge symbol, when the
acceleration and lift speed are limited to 70% of maximum
performance.
Another, not parameter-controlled, limitation occurs when the CID
battery charge symbol shows 0%. In this case, the following are limited:
• Acceleration – 30% of maximum performance
• Lifting -50 % of maximum performance

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 109/110/111/112 – Collision sensor

The parameters for collision sensitivity must be set during truck
installation.
If a collision sensor is installed on the CAN bus, this registers when the
truck bumps against something. If a collision exceeds a certain force,
set by parameters 110 and 111, it is interpreted as a collision, and the
truck speed is reduced to creep speed, a signal is heard and error code
2:106 is displayed. For setting how the alarm is to be given when the
collision sensor is activated, see parameter 117.
Information about the collision is stored in the truck's internal memory.
The last ten registered collisions can be read directly on the display
along with the operator's identity, which can be read via the PIN code.
Other information is obtained via TruckCom, where the collision levels
and times can also be read.
See the table below for information about the possible values:
Resetting procedure for
109 0 0 2 2 –
logged data
Collision sensor sensitivity in
110 0 0 100 1 –
the X-axis (forward/reverse)
Collision sensor sensitivity in
111 0 0 100 1 –
the Y-axis (right/left)
Resetting procedure after
112 0 0 1 1 –
collision
Parameter 109 specifies whether or not the information from the

collision sensor is to be deleted during login:
Value Function:
0 Save data on login
2 Delete data on login

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameters 110/111 specify the level (along the X/Y axes) at which the
truck's functions are to be blocked in the event of a collision:
Par. Function: Value Meaning
0 Inactivated
X:110/ Collision sensor sensitivity in 1 Lowest sensitivity
Y:111 each direction | |
100 Highest sensitivity
X-axis regards movements in the truck's fork/drive wheel line and Y-

axis regards movements sideways.
Note:
If the parameter value for the collision sensor is set to 0 (zero), this
will disable the collision sensor function as well the logging function.
This should only be done when T.W.I.S. is present.
Practical tests have shown that a value of 15 or higher corresponds to
a powerful collision. The absolute value is, however, affected by local
conditions and driving style and therefore a different value may be
necessary.
Parameter 112 specifies the condition for how the truck is to be taken
into operation again after the collision sensors have been triggered:
Value Function:
0 Login with a special PIN code is required
1 The truck must be restarted
The PIN code required to reset the collision sensor is entered in the
login profile Block: 10, Profile: 1.
Parameter 113 (shunt value)

The value from the present minus rail at 20°C, which is used as the
current measurement shunt.
If the value is set too low, the MCU will believe that power is greater
than it actually is The battery meter will then step down faster and the
truck will stops.

Shunt resistance for BDI
280/
113 (resistance of actual shunt 50 1000 1 µΩ
335
resistance on copper rail).
Note:
Standard value: B version 280 and E version 335 µΩ

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 116 (Door on cold store cab)

Incre
Par. Description Min. Default Max. Unit
ment
Drive function with open door on
116 0 0 1 1 –
cold store cab.
Specifies the driving function when the door on the cold store cab is
open.
Value Drive function
0 Driving not possible
1 Driving limited to 2.5 km/h
Value 0 means that the truck cannot be driven when the door is open.
Value 1 means that the operator can drive at max. 2.5 km/h.
Note:
In order to activate the function, change parameter 1105 to 1 and to
reduce the speed, change parameter 202.

Parameters
7510399-020 2012-10-03 6070557 815, 816
5.4.3 Service parameters, travel functions
5.4.4 Overview
Par. Description
201 Retardation reversing of travel direction
202 Adjusting the creep speed max. 2.5 km/h
203 Adjusting the half-speed max. 4 km/h
204 Adjusting the safety speed, max. 1.3 km/h
205 Adjusting travel speed 1 via input X131:17
209 Lift height when travel speed, P210, is limited
210 Setting the travel speed above lift height, P209
211 Reach length when travel speed, P212, is limited
212 Setting the travel speed above reach length, P211
213 Permanent speed reduction
214 Adjusting the travel speed in the main lift range
5.4.5 Description
Parameter 201 – Deceleration when reversing
Parameter 201 may be used to get a smoother retardation when the
application requires this for all operator profiles.

Brake force when reversing
201 50 100 100 10 %
the travel direction

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 202/203/204 – Adjusting erroneous,

maximum travel speeds
These parameters are used to reduce the speeds which are normally
set as maximum travel speeds in connection with warnings or errors.
Adjusting the creep speed
202
max. 2.5 km/h
Adjusting the half-speed max.
203 30 100 100 10 %
4 km/h
Adjusting the safety speed
204
max. 1.3 km/h
Crawl speed is set when the cold-store truck has a door open.
The speed can be reduced from 2.5 km/h.
Half-speed is set when the cab is not in its lowest position, the mast is
not lowered in the free lift range or when the truck does not know where
the forks are (seeking reference sensor is shown).
The speed can be reduced from 4km/h.
The safety speed is set when the truck is started in emergency drive
mode.
The speed can be reduced from 1.3km/h.
Parameter 205/206/207 – Adjusting erroneous,

maximum travel speeds
Adjusting travel speed 1 via
205
input X131:17
206 0 100 100 10 %
input X131:31
207
input X131:4
These parameters are used to adjust the maximum travel speed when
one of three pre-defined inputs on the MCU is affected.
The speed can be reduced from full speed (100%) =14km/h.
The function is available when 48V is connected to the input.
Note:
The parameters can be combined with one of the 361/362/363/364/365/
355 parameters and/or 395/396/397 if one of the inputs is to limit the
travel speed, lift/lower speeds and/or lift height

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 208 - Creep speed in travel direction

control
With this parameter, the creep speed function can be removed in the
travel direction control. This function is available when the travel
direction selector is kept activated for a longer time.
The parking brake must first be released before the truck can begin to
travel.
If '0' is indicated, then the feature will be inactive.
Creep speed in travel direction
208 0 1 1 1 –
controls activated (1 km)
Value Function:
0 Inactivated
1 Activated

speed above a certain lift height
With the parameter pair 209/210, it is possible to activate and adjust a
speed limitation when the forks are raised above a certain height.
Lift height where the travel
209 0 0 15000 100 mm
speed is limited
Setting the travel speed 0.1
210 0 140 140 5
above a certain lift height km/h
Value
Function:
P209
No limitation of travel speed, P210
0
inactive
Lift height where limitation of travel
1 – 15000
speed is commenced

Parameters
815, 816 6070557 2012-10-03 7510399-020

speed with a certain reach length
With the parameter pair 211/212, it is possible to activate and adjust a
speed limitation when the reach carriage is extended beyond a certain
length.
Reach carriage position when
211 0 0 840 10 mm
travel speed is limited
Setting the travel speed over 0.1
212 0 140 140 5
a certain reach length km/h
Value
Function:
P211
No limitation of travel speed, P212
0
inactive
Reach carriage position “from
1 – 840 innermost position” when limitation of
the travel speed is commenced
Parameter 213 – Permanently reduced maximum

travel speed
Parameter 213 can be used to adjust the truck’s maximum travel speed
permanently.
Setting the truck’s maximum 0.1
213 0 140 140 5
travel speed km/h
Parameter 214 – Adjusting the maximum travel

speed in main lift range
Parameter 214 can be used to decrease the travel speed to 4 km/h
when the forks are in the main lift range.
This parameter is only used when height indication is used.
Adjusting the travel speed in 0.1
214 0 1 1 1
the main lift range km/h
Value Function:
0 Travel speed = 8 km/h
1 Travel speed = 4 km/h

Parameters
Service parameters, hydraulics
7510399-020 2012-10-03 6070557 815, 816
5.5 Service parameters, hydraulics
5.5.1 Overview
Par. Description
301 Extra valve function 1
Extra valve function 1, output A. Maximum oil pressure through
305
valve Q8
306
valve Q8
307
valve Q8
308
valve Q8
Extra valve function 1, output B. Maximum oil pressure through
309
valve Q9
310
valve Q9
311
valve Q9
312
valve Q9
313 Extra valve function 1, time for closing valve selected in P301.
317 Extra valve function 1, output A. Maximum oil flow through valve Q8
321 Extra valve function 1, output B. Maximum oil flow through valve Q9
325 Extra valve function 1, output A. Opening/closing time valve Q8
329 Extra valve function 1, output B. Opening/closing time valve Q9
341 Reduction of lifting speed

Parameters
815, 816 6070557 2012-10-03 7510399-020
Par. Description
342 Reduction of lowering speed
343 Reduction of reach speed
344 Reduction of lowering speed before floor level
345 Sensitivity for lifting and lowering
Prevent lifting/lowering of forks, above the programmed travel
347
speed
348 Prevent lifting/lowering of forks, above the programmed lift height
349 Fork weight
350 Multi-function
355 Down tilt of Ergo cab
Deactivate hydraulic function when the reach movement is not in
358
the home position.
359 Monitoring of the hydraulic input
360 Deactivation of hydraulic functions
361 Limitation of lift speed 1, via input X131:17
364 Limitation of lowering speed 1, via input X131:17
Lowest height for forks in order for the fork carriage to be pushed in
367
and sideshift to function
Lowest height for forks in order for the fork carriage to be extended
368
and sideshift to function, limit
369 Height preselector: Automatic fork tilt, function selection
370 Height preselector: Automatic fork tilt, angle
371 Height preselector: Creep speed, lifting
372 Height preselector: Creep speed, lowering
373 Height preselector: Creep distance, lifting
374 Height preselector: Creep distance, lowering
375 Height preselector: Braking distance, lifting
376 Height preselector: Braking distance, lowering
377 Height preselector: Maximum stop tolerance
378 Height preselector: Distance collect-deposit
379 Height preselector: Load detection
380 Lift height limitation 1
387 Configuration of lift height limitation 1

Parameters
7510399-020 2012-10-03 6070557 815, 816
Par. Description
395 Limitation of lift height 1 via input X131:17
398 Activation pattern for profile-controlled lift height limitation
399 Profile-controlled lift height limitation

Parameters
815, 816 6070557 2012-10-03 7510399-020
5.5.2 Description
Parameter 301/302/303/304 – Extra valve function
These parameters are used for setting which functions and valves the
hydraulic lever will activate.

301 Extra valve function 1 0 0 31 1 –
Value Valve Note

1 Q18 –
2 Q12 –
4 Q14 –
8 Q15 –
Switches the function between the valves,
16 Q8/Q9
which changes the direction of movement.
Example:
Value 0 means that only Q8/Q9 are activated by extra valve function.
Value 1 means that Q18 and Q8/Q9 are activated simultaneously by
the extra valve function. Q8/Q9 are used to provide the direction and
Q18 for the choice of function.
Value 17 = 1+16 means that Q18 and Q8/Q9 are activated
simultaneously, but with Q8/Q9 in reverse order. This produces
hydraulic movement in the opposite direction.
Note:
To start the functions, see parameter 1007.
For clarification see the picture on the following page.

© BT
TILT (3 HYDRAULIC FUNCTIONS)
A 2
B 1
7510399-020
Publication no.
TILT Q8/Q9 = 0
Q9/Q8 = 16
TILT AND SIDESHIFT (4 HYDRAULIC FUNCTIONS)

Date
A 4
Repair manual
B 3 SIDE SHIFT
REACH
2012-10-03
2 Q8/Q9 + Q18 = 1
Q18
1 Q9/Q8 + Q18 = 17
TILT
A1 B1 A2 B2
150 bar
TILT AND ONE EXTRA FUNCTION (4 HYDRAULIC FUNCTIONS)

Q14
A2 A 2
Q8 Q9 Q6 Q7 A B2 B 1
Q12 TILT
6070557
Q8/Q9 + Q14 = 4
B Q9/Q8 + Q14 = 20
A1
B1 Q8/Q9 + Q12 = 2
Hose reel Q9/Q8 + Q12 = 18
RRE140/160/180/200/250
Valid from serial no.
250 bar EXTRA HYDRAULIC FUNCTION
TILT AND TWO EXTRA FUNCTIONS (5 HYDRAULIC FUNCTIONS)

Q15
Q8/Q9 + Q14 + Q18 = 5
T A3 Q9/Q8 + Q14 + Q18 = 21
EXTRA HYDRAULIC FUNCTION TILT AND SIDESHIFT (6 HYDRAULIC FUNCTIONS)
A B3
M Q14
B A 2
Q8/Q9 + Q15 = 8 A 4
A2 Q9/Q8 + Q15 = 24 3
B 1 B SIDE SHIFT
T code
B2 TILT Q8/Q9 + Q14 = 4

815, 816
Q12 2
Q9/Q8 + Q14 = 20 Q18
A1 1
B1 Q8/Q9 + Q12 = 2 TILT
Hose reels Q9/Q8 + Q12 = 18
Parameters
EXTRA HYDRAULIC FUNCTION
5 – 25
Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 305/306/307/308 – Max. oil pressure

through valve Q8
These parameters set the max. oil pressure for the valve(s) that have
been selected for use in parameters 301 - 304.
The oil comes from valve Q8, output A on the main valve block.
Extra valve function 1 output A.
Max. oil pressure through valve
305 10 100/82 100 1 –
Q8 (Value 82 applies to
RRE250)
Maximum oil pressure through
306 10 100/82 100 1 –
valve Q8
(Value 82 is for RRE250)
307 10 75/62 100 1 –
valve Q8
308 10 100/82 100 1 –
valve Q8
Parameter 309/310/311/312 – Max. oil pressure

through valve Q9
These parameters set the max. oil pressure for the valve(s) that have
been selected for use in parameters 301 - 304.
The oil comes from valve Q9, output B on the main valve block.
Max. oil pressure through valve
309 10 100/82 100 1 –
Q9 (Value 82 applies to
RRE250)
Extra valve function 2 output B.
310 10 100/82 100 1 –
valve Q9
311 10 75/62 100 1 –
valve Q9
312 10 100/82 100 1 –
valve Q9

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 313/314/315/316 – Closing time

These parameters set the time for the closing of the valve(s) that have
been chosen for use in parameters 301 - 304.
Extra valve function 1, time for
313 closing valve selected in 0 25 50 1 –
parameter 301
parameter 302
parameter 303
parameter 304

valve Q8
These parameters set the max. oil flow for the valve(s) that have been
selected for use in parameters 301 - 304.
The oil comes from valve Q8, output A on the main valve block.
Extra valve function 1, output
317 A. Maximum oil flow through 12 57 300 1 –
valve Q8
valve Q8
valve Q8
valve Q8

Parameters
815, 816 6070557 2012-10-03 7510399-020

valve Q9
These parameters set the max. oil flow for the valve(s) that have been
selected for use in parameters 301 - 304.
The oil comes from valve Q9, output B on the main valve block.
321 B. Maximum oil flow through 12 47 300 1 –
valve Q9
valve Q9
valve Q9
valve Q9

valve Q8
These parameters set the opening and closing times for valve Q8 when
this is used in connection with the valve selected in parameters 301 -
304.
The first two figures XX (xxyy) when programming, give the opening
time and the last two YY (xxyy) the closing time.
However, 0 will not be displayed if this is the first figure.
325 101 0505 9999 1 20 ms
Opening/closing time valve Q8
326 101 0505 9999 1 20 ms
327 101 0505 9999 1 20 ms
328 101 0505 9999 1 20 ms

Parameters
7510399-020 2012-10-03 6070557 815, 816

valve Q9
These parameters set the opening and closing times for valve Q9 when
this is used in connection with the valve selected in parameters 301 -
304.
The first two figures XX (xxyy) when programming, give the opening
time and the last two YY (xxyy) the closing time.
However, 0 will not be displayed if this is the first figure.
329 101 0505 9999 1 20 ms
330 101 0505 9999 1 20 ms
331 101 0505 9999 1 20 ms
332 101 0505 9999 1 20 ms
Parameter 341/342 – Reducing the lifting/lowering

speed
With these parameters, the fork’s lifting/lowering speeds can be
reduced, which will apply to all operators.
Parameter 341 is used to reduce the lifting speed while parameter 342
is used to reduce the lowering speed.
The function is affected without activating any input on the MCU.
341 Reduction of lifting speed 30 100 100 10 %
342 Reduction of lowering speed 30 100 100 10 %

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 343 – Reduction of reach speed

Here the reach movement speed can be reduced for the truck, which
will apply to all operators.
343 Reduction of reach speed 30 100 100 10 %
Parameter 344 - Reduction of fork lowering speed

before floor level
Here, the braking of the forks can be activated before the forks reach
floor level.
The lowering speed will be ~40 % of the maximum speed from 300mm
and ~20 % from 100mm above floor level.
Reduction of lowering speed
344 0 1 1 1 –
before floor level
Value Function:
0 Inactivated
1 Activated
Parameter 345- Lift/lower sensitivity

Used to set the sensitivity of the joystick
This parameter is applicable on software version -008 and newer

Reduction of joystick lift/lower
345 40 40 80 10 %
sensitivity

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 347/348 – Prevent the lifting/lowering of

forks
With these parameters, the lifting and lowering of the forks is stopped
when the truck is being driven faster than X km/h (parameter 347) and
the forks are above lifting height Y mm (parameter 348). However, you
can lift and lower the forks while driving at a higher speed than the
stated one if you have the forks below the stated lift height (parameter
348).
Note:
To enable this function, see parameter 1114

Prevent lifting/lowering of
0.1
347 forks, above the programmed 0 140 140 5
km/h
travel speed
Prevent lifting/lowering of
348 forks, above the programmed 0 0 15000 10 mm
lift height
Value
Function:
P348
0 Function not activated
Lift height where the lifting and
1 – 15000
lowering of the forks is stopped
Parameter 349 - Fork weight

With this parameter, you set the weight of the forks. The value is used
as a reference when measuring weights with empty forks during
training. Using this procedure, the program can fine-tune the weight of
the empty forks, which is then used to calculate the weight of the forks.
Note:
If heavier forks or additional units are mounted, the new weight must
be specified

349 Fork weight 0 240 1000 10 kg

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 350 – Multi-function

This parameter enables simultaneous lifting/lowering of the forks
together with extension/retraction of the reach carriage. It is also
possible to set whether lifting movement should have priority.

350 Multi-function 0 1 2 1 –
Value Function:
Deactivated, lifting has
0
priority
1 Activated
Deactivated, current
2
function has priority
Parameter 355 - Down tilt of Ergo cab

With this parameter, the starting point for the Ergo cab to tilt downwards
is specified, and this will apply for all operators .
Note:
To start the function, see parameter 1104, and to adjust upward tilting,
see the operator parameters ending with number 6.

Down tilting of Ergo 10.00
355 500 500 100 mm
cab 0

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameters 358/359/360 – Deactivation of hydraulic

functions
This parameter makes it possible to deactivate any hydraulic function
depending on input.

Deactivation
358 hydraulic functions 0 0 1023 1
Monitoring hydraulic
359 0 0 63 1
functions
Deactivation
360 0 0 1023 1 –
hydraulic functions
Value Function:
1 Fork lifting
2 Fork lowering
Reach movement
4
out
8 Reach movement in
16 Cab tilt up
32 Cab tilt down
64 Aux 1
128 Aux 2
256 Aux 3
512 Aux 4
Example:
Values 3 = 1+2, switches off both fork lifting and fork lowering.
Values 1023 =1 + 2 + 4 + 8 + 16 + 32 + 64 + 128 + 256 + 512 switch off
all functions.

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameters 361/362/363/364/365 /366 – Function

related, maximum lift/lowering speeds
Using these parameters, it is possible to set the limits for the lifting/
lowering speeds when external signals 1-3 have been activated.
Signal 1 = input 131:17
When one of these signals has been activated, the lifting or lowering
speed will be reduced according the speed limit set by the
corresponding parameter. The speed is set as a percentage value.
There are individual parameters for lifting/lowering for each of the three
signals.
Note:
The parameters can be combined with one of the 205/206/207
parameters and/or 395/396/397 if one of the inputs is to limit the travel
speed, lifting/lowering speeds and/or lift height

Limitation of lift speed 1, via
361
input X131:17
362
input X131:31
363 0 100 100 10 %
input X131:4
Limitation of lowering speed
364
1, via input X131:17
365
2, via input X131:31
366
3, via input X131:4

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 367/368 – Fork limit for deactivating the

extension of the fork carriage and for sideshift
With these parameters, you set the value when you want the extension
of the fork carriage and sideshift to be disabled.
When the forks are below the set value, retraction of the reach carriage
is disabled.
Sideshift also is disabled under the set value, except when the reach
carriage has been completely extended.
With parameter 367, you set the height in mm and with parameter 368
you configure the function.
Lowest height for forks in order for
367 the fork carriage to be pushed in 0 0 15000 10 mm
and sideshift to function
Lowest height for forks in order for
368 the fork carriage to be extended 0 0 4 1 –
and sideshift to function, limit
Value Function:
0 Inactivated
Activated, manual
1
override
Activated, manual and sideshift
2
override
Activated, manual and reach
3 movement
override
Activated, manual, sideshift and
4
reach movement override
Activated, manual, sideshift or reach
5
movement override
Activated, manual, sideshift or reach
6
movement override (with AUX3)
Manual override is possible by using the lift height limitation override

button.
Automatic bypass is possible by centring the sideshift unit or fully
extending the reach carriage.
For sideshift bypass to work, automatic sideshift centring must have
been activated beforehand. See parameter 1110.
If value 4 is selected, then both conditions must be fulfilled in order to
activate the bypass function.
Both sideshift and reach carriage extension can be operated while the
lift height limit button is kept pressed.

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 369 through 379 – Height preselector

The parameters in the range 369–379 are used to set the height pre-
selection function.
Note:
The height preselector is activated by factory parameter 1103.

Automatic fork tilt,
369 0 3 3 1 –
function selection
Automatic fork tilt,
370 0 50 60 1 0.1º
angle
371 Creep speed, lifting 0 7 100 1 %
372 Creep speed, lowering 0 10 100 1 %
373 Creep distance, lifting 0 35 100 1 mm
Creep distance,
374 0 35 100 1 mm
lowering
375 Braking distance, lifting 0 550 1000 10 mm
Braking distance,
376 0 550 1000 10 mm
lowering
Maximum stop
377 0 10 100 1 mm
tolerance
378 Distance collect-leave 40 120 250 1 mm
379 Load detection 0 200 500 5 kg
Parameter 369/370. Parameter 369 indicates whether the backs of the

forks are to be placed in the vertical position in both the collecting and
depositing sequences.
This is used when stopping at a level indicated with the height pre-
selection.
The angle of the back of the forks is stated using parameter 370.
Forks tilt to horizontal position on depositing sequence.
Forks tilt up to angle set in parameter 370 on pick-up sequence.
Note:
To activate the function, see parameter 1111
Value
Function:
P369
0 Inactivated
1 Function for collect load
2 Function for leave load
Function for both collect
3
and deposit

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 371/372 specifies the creep speed as a percentage of the

maximum speed for lifting and lowering respectively, in the immediate
vicinity of the programmed stop height.
Parameter 373/374 defines the range around the stop height, for lifting
and lowering respectively, where the creep speed applies.
Parameter 375/376 defines the range where braking can take place
from the maximum speed to creep speed, for lifting and lowering
respectively.
Parameter 377 specifies the tolerance for the stop height as “a ± p377”.
If the lifting or lowering movement cannot be stopped within the
tolerance, an error code is given together with an acoustic alarm.
Parameter 378 specifies the distance which is automatically created
between the collect and deposit heights.
Parameter 379 specifies the weight of the load on the forks at which
the height preselector will detect that there is a load, and automatically
change from collect to deposit level.
Note:
For other adjustments of the height preselector, see parameters 510
and 511
Note:
For more information about height pre-selection, see section 4.10
F
P372
P374
P376
P377
P378
P379
P377
P371
P373
P375

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 380 through 386 – Lift height limitations

With parameters 380 through 386, seven lift height limitations can be
programmed. If several limitations are used, the lowest parameter
number is to be programmed with the lowest height limitation and
thereafter in ascending parameter/height order.
The various limitations can be configured using parameter 387 up to
and including 393.
Note:
The lift height limitation function is activated by factory parameter
1107.

383 Lift height limitation 4 10 10 15000 10 mm
Parameters 387 through 393 – Configuration of lift

height limitations
Parameters 387 through 393 specify whether the respective lift height
limitation is to be activated and if it is to be possible to lift above it:
Configuration of lift height
387
limitation 1
388
limitation 2
389
limitation 3
390 0 0 2 1 –
limitation 4
391
limitation 5
392
limitation 6
393
limitation 7
:
Value
Function:
P387 – P393
0 Not active
1 Possible to override
2 Stop

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameters 395/396/397 – Function-related,

maximum lift heights
These parameters are used to adjust the maximum lift height when one
of three pre-defined inputs on the MCU is affected.
In this case, you cannot pass the levels using the override switch.
The function is available when 48 V is connected to the input.

Limitation of lift height 1 via
395
input X131:17
396 0 0 15000 10 mm
input X131:31
397
input X131:4
Value
P395/396/ Function:
397
0 Not active
1 – 15000 Lift height limitation in mm
Note:
The parameters can be combined with one of the parameters 205/206/
207 if one of the inputs is limited to both speed and lift height
Example:
• Input X131:17 is to only limit the travel speed to 80 %
• Input X131:31 is to only limit the lift height to 7000 mm
• Input X131:4 is to limit the travel speed to 40 % and the lift height to
3000 mm:
In Par. Value Unit
205 80 %
X131:17
395 0 mm
206 100 %
X131:31
396 7000 mm
207 40 %
X131:4
397 3000 mm

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameters 398/399 – Operator profile dependent,

maximum lift heights
These parameters are used to limit the maximum lift height for one or
more operator profiles.
398 Coupling to operator profiles 0 0 1023 1 –
399 Lift height limitation 0 0 15000 10 mm
Lift height is limited The value is added to

for profile P398
1 1
2 2
3 4
4 8
5 16
6 32
7 64
8 128
9 256
10 512
Example:
Lift height is to be limited to 6500 mm for operator profiles 3, 7 and 8.
Parameter 399 is then set to 6500 and parameter 398 is set to “4 + 64 +
128 = 196”.

Parameters
Service parameters, CID
7510399-020 2012-10-03 6070557 815, 816
5.6 Service parameters, CID
5.6.1 Overview
Par. Description
503 Login method
504 Smart Access, departments 1 - 8
505 Smart Access, departments 9 - 14
506 Smart Access, truck types 1 - 8
507 Smart Access, truck types 9 - 16
508 Display of load information
509 Buzzer activation
510 Height preselector, operator access
511 Height preselector, number of aisles
512 Truck family
513 Date format
514 Display of cab tilt information

Parameters
815, 816 6070557 2012-10-03 7510399-020
5.6.2 Description
Parameter 503 – Login method
This parameter is used to define the type of login used for the truck and
whether the operator has the possibility of changing the operator
parameters.
503 Login method 0 3 8 1 –
Value
Function: Access
P503
The operator is permitted
Key (input X131:19 on
1 to change operator
MCU)
parameters
The operator is not
Key (input X131:19 on
2 permitted to change
MCU)
operator parameters
3 Keypad with 100 PIN codes to change operator
parameters
The operator is not
4 Keypad with 100 PIN codes permitted to change
operator parameters
5 Keypad with T.W.I.S. to change operator
parameters
The operator is not
6 Keypad with T.W.I.S. permitted to change
operator parameters
Smart Access identification
7 to change operator
system
parameters
The operator is not
Smart Access identification
8 permitted to change
system
operator parameters
Parameter 504/505/506/507 – Smart Access

Note:
Normally you do not change parameters 504/505/506/507 via the CID
parameter menu. The Smart Access setup card is used instead. How
this is done is described in the Smart Access instructions.
Parameters 504/505/506/507 show which values have been
programmed via Smart Access. In unique cases, it is possible to adjust
the values via the CID.
Upon delivery from the factory, all parameter values are set to “255”, so
that the truck can be activated without any special Smart Access key.

Parameters
7510399-020 2012-10-03 6070557 815, 816

Smart Access, department
504 0 255 255 1 –
1–8
Smart Access, department
505
9 – 14
0 255 255*) 1 –
Smart Access, truck type

506 0 255 255 1 –
1–8
Smart Access, truck type
507 0 255 255 1 –
9 – 16
*)
After installation there is an upper functional limit at “63” as a
maximum of 14 departments may be defined. Values higher than “63”
must not be used.

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameters 504/505 specify to what department the truck belongs

within an installation:
Department Value P504
1 1
2 2
3 4
4 8
5 16
6 32
7 64
8 128
Department Value P505

9 1
10 2
11 4
12 8
13 16
14 32
Programming via Smart Access setup allows only one department

affiliation for a truck, but in unique situations parameters 504/505 can
be used to assign several departments to a truck. In such cases, the
department values for P504 and P505 are added separately.

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameters 506/507 specify the truck type from a list of types that
apply to a unique installation:
Truck type Value P506
1 1
2 2
3 4
4 8
5 16
6 32
7 64
8 128
Truck type Value P507

9 1
10 2
11 4
12 8
13 16
14 32
15 64
16 128
Only the value for one truck type must be used, even when the
programming is performed via the CID.
Note:
There is also a factory parameter “1001” that states the truck type. That
parameter has no connection to the Smart Access function. Nor has
the parameter pair 506/507 any connection to P1001.

Parameters
815, 816 6070557 2012-10-03 7510399-020
Example:
A company has nine different departments, where:
1 is incoming goods
2 is incoming goods inspection
8 is the spare parts department's high-bay warehouse
9 is goods out
Parameters 504/505, which determine to what department the truck
belongs, are given the values:
Dept. P504 P505

1 1 0
2 2 0
8 128 0
9 0 1
In the example's departments there are the following truck types:

1 – “Powered pallet trucks”
8 – “Reach trucks”
14 – VNA trucks for restocking the spare parts warehouse
15 – VNA trucks for picking orders
Parameters 506/507, truck types within the company, are given the
value:
Type P506 P507

1 1 0
8 128 0
14 0 32
15 0 64

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameters 508/509/512/513/514 – CID

configuration
This group of parameters is used to configure the CID with regard to
displays, buzzer and in which truck family it is fitted:
508 Display of load information 0 0 1 1 –
509 Buzzer activation 0 15 15 1 –
512 Truck family 0 0 0 1 –
513 Date format 0 0 1 1 –
514 Display of cab tilt information 0 0 1 1 –
Parameter 508 states if the CID is to show the weight of the load:
Value P508 Function:
The load’s weight is not
0
displayed
The load’s weight is
1
displayed
Parameter 509 states which operations will cause the CID's buzzer to
sound:
Operations that
The value which is
activate the CID's
added to P509
buzzer
Blocking symbol active 1
Parameter value is
2
entered
Safety pedal and option
4
buttons are used
The CID's buttons are
8
used
Example 1:
The buzzer is to be switched off – Normally P509 is programmed with
the value ‘0’.
Example 2:
The buzzer will sound when the option buttons or the CID’s buttons are
pressed – “4 + 8 = 12”.

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 512 must always have the value ‘0’ for this truck. This
parameter automatically specifies the type of truck for which the
program has been created.
Parameter 513 specifies how the CID displays the date:
Value P513 Display
0 yyyy-mm-dd
1 dd-mm-yyyy
Parameter 514 specifies whether the CID is to display the cab tilt
information.

The information is not
0
displayed
The information is
1
displayed

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 510/511 - Height pre-selector

Parameter 510 is used to enter the operator's option to program the
height pre-selection and parameter 511 specifies how many truck
aisles and lift heights that can be programmed.
510 Operator access 0 0 1 1 –
Height preselector, number of
511 1 7 8 1 –
aisles
Parameter 510:
CAN Service key is required for
0
height programming
The operators can themselves
1
program the height preselector
Parameter 511:
Value P511 Aisles Heights/aisle
1 1 200
2 2 100
3 4 50
4 5 40
5 8 25
6 10 20
7 20 10
8 40 5
Note:
To start up the function, see parameter 1103.
For other adjustment of the height preselector, see parameters 371 to
379.

Parameters
Service parameters, General Function Unit GFU
815, 816 6070557 2012-10-03 7510399-020
5.7 Service parameters, General

Function Unit GFU
Par. Description
551 GFU input control of MCU output
552 GFU input control of MCU output, selection of input
553 GFU input control of MCU output, selection of output
554 GFU input control of travel speed
555 GFU input control of travel speed

Parameters
General factory parameters
7510399-020 2012-10-03 6070557 815, 816
5.8 General factory parameters

Warning!!
Risk of personal injury and material and property damage.
All factory parameters affect the truck's configuration and
performance.
Changes may only be made by individuals who have undergone
parameter setting training and who can provide evidence of having a
good knowledge of how the truck is affected in the event of changes to
the factory parameters and how changes to factory parameters are
made.
Note:
Changes to the factory parameters are registered in the truck's
software. The registration indicates the time of the change and the
person who performed it.
5.8.1 Overview
General factory parameters are used to specify the truck type and how
the truck is configured. Some of the parameters can only be specified
with a single value.
Par. Description
1001 Truck type
1002 Drive motor
1003 Pedal type
1004 Steering servo
1005 Pump motor
1006 Pump type
1007 Lever activation
1008 Mast type
1009 Type of height indication
1010 Type of weight indication

Parameters
815, 816 6070557 2012-10-03 7510399-020
5.8.2 Description
Parameter 1001 - Truck type
The type of truck that the programme should adapt operation data for is
set using this parameter.
1001 Truck type 0 0 5 1 –
Value P1001 Configuration

0 Unknown truck type
1 1 = RRE140
2 2 = RRE160
3 3 = RRE180
4 4 = RRE200
5 5 = RRE250
Parameter 1002 - (Drive motor)

Specifies the size of drive motor that the programme should adapt the
operator data for.
1002 Drive motor 0 0 1 1 –

0 Small
1 Large
Parameter 1003 – Pedal type

Specifies the type of accelerator pedal that the program should adapt
the operation data to.

1003 Pedal type 0 0 1 1 –

0 Accelerator pedal
Direction switch on
1
accelerator pedal

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 1004 - Steering servo

Specifies the size of steering servo that the programme should adapt
the operator data for.
1004 Steering servo 0 0 1 1 –

0 Small
1 Large
Parameter 1005 - Pump motor

Specifies the size of pump motor that the programme should adapt the
operator data for.
1005 Pump motor 0 0 1 1 –

0 Small
1 Large
Parameter 1006 – Hydraulic pump

Specifies the size of hydraulic pump that the programme should adapt
1006 Hydraulic pump 0 0 1 1 –

0 Small
1 Large

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 1007 – Activation of hydraulic levers

Parameter 1007 specifies how many hydraulic functions will be
activated and the number of levers that are connected to the
electronics. This means that these are controlled safely.
Note:
For other settings, see parameters 301 - 332

1007 Lever activation 0 0 4 1 –

0 Lift, reach
1 Lift, reach, Aux1
2 Lift, reach, Aux1, Aux2
3 Lift, reach, Aux1, Aux2, Aux3
Lift, reach, Aux1, Aux2, Aux3,
4 Aux4 (fifth lever with button
depressed)
Parameter 1008 – Mast type

Specifies the mast type the program should adapt the operator data to.
1008 Mast type 0 0 2 1 –

0 1.6t
1 2.0t
2 2.5t

Parameters
7510399-020 2012-10-03 6070557 815, 816
Parameter 1009 – Height indication

Specifies the type of height indication that the programme should adapt
Type of height
1009 0 0 1 1 –
indication

0 No height indication
Height indicator
1
(pulse transducer)
Parameter 1010 - Weight indication

Here, the range within which the weight indication is performed and
within which the program must perform the weight measurement is
specified.
Type of weight
1010 0 0 1 1 –
indication

0 Base: Free lift range
Full: Free lift range and
main lift range
1
(requires pressure
sensor in both ranges)

Parameters
Factory parameters, activation of options
815, 816 6070557 2012-10-03 7510399-020
5.9 Factory parameters, activation of

options
Warning!!
Risk of personal injury and material and property damage.
All factory parameters affect the truck's configuration and
performance.
Changes may only be made by individuals who have undergone
parameter setting training and who can provide evidence of having a
good knowledge of how the truck is affected in the event of changes to
the factory parameters and how changes to factory parameters are
made.
Note:
Changes to the factory parameters are registered in the truck's
software. The registration indicates the time of the change and the
person who performed it.
5.9.1 Overview
Par. Description
1101 Support arm brake
1102 Inverted steering.
1103 Height preselector
1104 Cab tilting
1105 Door switch
1106 LID
1107 Lift height limitation
1108 Travel alarm 1
1109 Direction indicators
1110 Automatic cantering of sideshift
1111 Automatic fork tilting to horizontal position
1112 Travel alarm 2
1113 Max. travel speed 14km/h
1114 OTP: Prevention of lifting/lowering of the forks
1115 OTP: Travel speed reduction - steering angle
1116 OTP: Travel speed reduction - extension of reach carriage
1117 OTP: Reach speed reduction – fork height and load
1118 OTP: Speed reduction - main lift range
1119 GFU
1120 Quadruple mast
1121 MEWP
Special for selecting travel direction switch hand/foot using
1122
GFU
1123 Drive wheel centred at start-up
Parameters for activating options can only have the values

‘0’ – Option not activated

Parameters
7510399-020 2012-10-03 6070557 815, 816
‘1’ – Option activated.

If an option is activated, it may require the corresponding equipment on
the truck. Certain options also affect other parameters

Parameters
815, 816 6070557 2012-10-03 7510399-020
Parameter 1115 (Steering angle)

This parameter reduces the truck travel speed depending on the
steering angle.
OTP steerangle
km/h
14
12
10
8
6
4
2
0 °
0 5 10 15 20 25 30
Travel speed dependent on steering angle.

A - Platform = Pink line, B - Platform = blue dashed line.
At start-up, hunting for steering reference is performed to make sure
the truck has acquired drive wheel positioning information. This causes
the truck to always start with the drive wheel set to the 0º position.
Parameter 1116 (Extended mast)

This parameter reduces the truck travel speed depending on the
position of the reach carriage. The more the carriage is extended, the
lower the travel speed. The weight of the load is also taken into
consideration. When the reach carriage is completely retracted, the
travel speed is (at most) 14 km/h; it is then linearly reduced according to
the diagram below.
km/h OTP reach lenght

14
12
drive wheel
10 direction
8
fork direction
6
4
2
0 kg
0 500 1000 1500
Travel speed dependent on reach carriage extension. Loads over 1500
kg results in travel speed of 6 km/h (when reach carriage is completely
extended)
Drive wheel direction = Pink line, Fork direction = Blue line

Parameters
7510399-020 2012-10-03 6070557 815, 816
If the truck has remained unpowered, calibration of the home position

must be performed. Until this has been completed, the truck will
interpret the reach carriage as positioned in the fully extended position.
Parameter 1117 (Weight of load and fork height)

When this parameter is activated, the reach carriage extension speed
is reduced depending on the weight of the load and the lift height (see
picture below). The speed is only reduced for reach movements.
OTP reach speed
100%
90%
80%
70%
60%
Allowed
command
50 %
40%
30%
20%
2500
10% 500 0
7500
0% mm
0
10000
200
400
6 00
800
100 0
12 00
1400
12500
160 0
1800
2000
22 00
2400
kg
Parameter 1118 (Main lift range)

This parameter reduces the truck travel speed to 6 km/h when the forks
are in the main lift range.

Parameters
815, 816 6070557 2012-10-03 7510399-020
5.9.2 Description
Required Also affects

Par. Description Comment
equipment parameter
On activation, checks on the
Left
cables and brakes are
[Q16]/X131:39
1101 Support arm brake – performed from the MCU,
Right
which could give an error code
[Q17]/X131:12
if they are not present.
1102 Inverted steering. – – For Japan only
Also requires the option
1103 Height preselector [B38]/X503:2 371 – 379, 510, 511
height indicator
355, 514, operator
Also requires the truck to be an
1104 Cab tilting – parameters that end
E-model.
with number 6
1105 Door switch – 116, 202 For cold-storage cab only
1106 LID [P6] – –
1107 Lift height limitation [B39]/X503:8 380 – 393 –
1108 Travel alarm 1 [P7]/X131:23 105, 114 Horn
Left:
[P12]/131:8 Also requires
1109 Direction indicators –
Right: P1103 = ‘0’
[P13]/X131:35
[B41]/X503:9
Automatic centering Also requires the truck to be
1110 [B47]/X131:19/ –
of sideshift equipped with sideshift
131:32
Automatic fork tilting [B40]/X503:3, Also requires the truck to be
1111 –
to horizontal position [B5]/X130:16 equipped with fork tilt
1112 Travel alarm 2 [P5]/X131:36 106, 115 Warning lamp
Max. travel speed Also requires
1113 – –
14km/h P1101 = ‘1’
OTP: Prevention of
1114 lifting/lowering of the – 347, 348 –
forks
OTP: Travel speed
1115 reduction - steering [B59] – –
angle
OTP: Travel speed
1116 reduction - extension – – –
of reach carriage
OTP: Reach speed
1117 reduction – fork – – –
height and load
OTP: Speed Replaced by parameter 214
1118 reduction - main lift – – beginning with software
range package –006
1119 GFU – – –

Parameters
Factory parameters, calibration
7510399-020 2012-10-03 6070557 815, 816
5.10 Factory parameters, calibration

Note:
All calibration parameters are set via the CID's calibration functions
and must not be changed via the parameter menus.
Defau Incre
Par. Description Min. Max. Unit Comment
lt ment
1252 Free lift, up -200 0 200 5 mA –
1253 Free lift, down -200 0 200 5 mA –
1254 Main lift, up -200 0 200 5 mA –
1255 Main lift, down -200 0 200 5 mA –
Calibration of reach
1256 -200 0 200 5 mA –
mast, out
Calibration of reach
1257 -200 0 200 5 mA –
mast, in
1259 Ergo cab, tilt up -200 0 200 5 mA –
1260 Ergo cab, tilt down -200 0 200 5 mA –
Specifies the flow in % when
the free lift valve should close
Flow on upward during lift transition from free
1261 15 30 40 1 %
transition lift to main lift. For smooth
transition between the two
mast sections.
Specifies the flow in % when
the main lowering valve
should close during lowering
Flow during downward
1262 15 30 40 1 % transition from main lift to free
transition
lift. For a smooth transition
between the two mast
sections
Specifies what value
1264 Fork tilt 0 degrees -60 0 60 1 0.1° corresponds to 0 degrees on
forks
The total length of the reach
movement (in mm), so that the
1265 Reach length 120 564 840 12 mm
movement can be dampened
at the end positions
Weight 1 calibration in free lift
1266 Weight calibration 1 -300 0 300 5 kg
range
Reference weight 2 in free lift
1267 Reference weight 2 400 1000 3000 5 kg
range
Weight 2 calibration in free lift
range
1271 Free lift, height reference 100 800 1500 2 mm –
1272 Main lift, height reference 0 30 100 2 mm –
1273 Free lift height 0 3000 6000 2 mm –
1274 Max. lift height 0 0 15000 10 mm –
Calibration of reach mast
1275 -400 0 400 5 mA –
out, valve fully open

Parameters
815, 816 6070557 2012-10-03 7510399-020
Defau Incre
lt ment
Calibration of reach mast
1276 -400 0 400 5 mA –
in, valve fully open
Weight 1 calibration in main lift
range
Reference weight 2 in the free
1278 Reference weight 2 500 1000 3000 5 kg
lift range
Weight 2 calibration in main lift
1279 Weight calibration 2 -600 0 600 kg
range
1280 Reach offset 0 0 100 12 mm –
1281 Pulse length, free lift 15000 19930 25000 1 mm
1282 Pulse length, main lift 15000 19930 25000 1 mm
Indicates the value the sensor
1283 MEWP 0 angle X -100 0 100 1 0.1
has with the position 0
Indicates the value the sensor
1284 MEWP 0 angle Y -100 0 100 1 0.1 has with the position 0
Calibration of hydraulic
1351 32767 0 -32767 1 – –
lever 1
1352 32767 0 -32767 1 – –
lever 1
1353 32767 0 -32767 1 – –
lever 2
1354 32767 0 -32767 1 – –
lever 2
1355 32767 0 -32767 1 – –
lever 3
1356 32767 0 -32767 1 – –
lever 3
1357 32767 0 -32767 1 – –
lever 4
1358 32767 0 -32767 1 – –
lever 4
1359 32767 0 -32767 1 – –
lever 5
1360 32767 0 -32767 1 – –
lever 5
1361 32767 0 -32767 1 – –
lever 5
1362 32767 0 -32767 1 – –
lever 5
1363 32767 0 -32767 1 – –
lever 5
1364 32767 0 -32767 1 – –
lever 5
1365 32767 0 -32767 1 – –
lever 5

Parameters
7510399-020 2012-10-03 6070557 815, 816
Defau Incre
lt ment
1366 32767 0 -32767 1 – –
lever 5
1367 32767 0 -32767 1 – –
lever 5
1368 32767 0 -32767 1 – –
lever 5
1369 32767 0 -32767 1 – –
lever 5
1370 32767 0 -32767 1 – –
lever 5
1371 32767 0 -32767 1 – MEWP
lever 5
1372 32767 0 -32767 1 – MEWP
lever 5
1381 32767 0 -32767 1 – MEWP
lever 5
1382 32767 0 -32767 1 – MEWP
lever 5

Parameters
815, 816 6070557 2012-10-03 7510399-020

Installation
Transporting the truck
7510399-020 2012-10-03 6070557 815, 816
6 – Installation
6.1 Transporting the truck

There are two ways to transport the truck when the battery is not
installed.
Method 1
When the truck is to be transported over long distances you should use
a fork lift truck with the following lift capacity:
Load RRE 140– RRE 180– RRE 250

RRE 160 RRE 200
Load centre distance (Tp) 800 900 900
Weight without battery and 1600 2000 2100
mast
Tp
Insert the forks under the support arms and lift as illustrated in the dia-
gram.
Method 2
To move the truck over short distances, you can use an extension cable
from an adjacent battery.

Installation
Initial operation
815, 816 6070557 2012-10-03 7510399-020
6.2 Initial operation

DANGER!
Risk of centre of gravity shifting.
Due to the weight of the mast, the battery must be in position in the
truck before the mast is fitted.
6.2.1 Tool
6.2.2 Battery
Placing the battery
Check that the battery is of the correct weight as shown on the truck's
identification plate. The weight of the battery affects the truck's stability
and braking capacity.
DANGER!
Battery weight that is too low results in a deterioration in stability
The battery weight must conform to the details specified on the truck
identification plate.
1. Supply the truck with power from an external source.
2. Activate the parking brake.
3. Retract the mast to its innermost position.
4. Pull the handle at the bottom on the right in front of the operator
seat to release the battery lock.
5. Extend the reach carriage.
6. Switch off the truck.
7. Lift the new battery in.
8. Lock the battery.
9. Connect the battery cut out connector to the battery.
10. There is a risk that the battery cables will be crushed between the
battery and the battery wall. The wiring harness must lie in an 'S' to
the battery from the cable arm to the battery connector according to
the picture.
11. Start the truck.
12. Retract the reach carriage to its innermost position. Make sure the
battery catch engages in the battery lock. A sharp metallic sound
will be heard confirming that locking has occurred.

Installation
Initial operation
7510399-020 2012-10-03 6070557 815, 816
DANGER!
Risk of battery falling.
If the truck tips the battery may fall out if the battery catch is not
locked.
Check that the battery catch is locked.
DANGER!
Risk of battery falling.
When replacing a battery, there is a danger of it slipping and falling.
Always use an approved lifting device to lift the battery and use a bat-
tery yoke that suits the battery.
Battery parameters
Information about setting up the battery parameters according to
“14.6.1 Configuration menu” .
6.2.3 Mast, fitting

Fitting the mast according to“16.1.5 Placing the mast on the truck” .
6.2.4 Parameters on initial operation

Full calibration of the functions is described in section “13.3 Parameter
settings”.
Load indicator
The load indicator must be calibrated for each truck. Incorrect load cal-
ibration can result in incorrect speed and brake force limits and the load
indicator on the CID/LID giving the wrong indication.
Weight indicator, type Parameter no.

1016
Base version, measurement only on free lift 0
Full measurement 1
Can be combined with the LID (Load Indication Display) (option) and
then height information is displayed on the LID.

Installation
Initial operation
815, 816 6070557 2012-10-03 7510399-020
Ergo cabin
When the cabin is not in its very lowest position, there is a reduction in
speed (4 km/h), acceleration (30%) and automatic braking (30%) to
give gentler driving.
.
Ergo function Parameter no.

6 355
Height above floor level when the Ergo 1000
cabin begins to tilt
The forks height when the Ergo cabin 500
begins to tilt down
Cold store cabin

When the cabin door is not shut, the truck is braked by the motor until it
stops.
This is optional if the truck is to be driven (2.5 km/h) with the door open
or not.
.
Door open action (cold store cabin) Parameter no. 116

Disable operation (driving) 0
Speed limited to 2.5 km/h 1

Installation
Initial operation
7510399-020 2012-10-03 6070557 815, 816
6.2.5 Parameters for optional equipment

Height measurement (option)
Parameter 1009 sets the type of height measurement the truck is to
have.
Can be combined with the LID (Load Indication Display) (option) and
then height information is displayed on the LID.
Height measurement, type Parameter no.

344 1009
Base version, only position sensors — 0
Full measurement (option) 1 1
Travel speed limitation, height-dependent

Requires the full height measurement option. Limits travel speed when
the forks are above a certain predetermined height.
Speed reduction for a selectable Parameter no.

height 209 210
Height limit for speed reduction mm —
Speed limitation above selected height — km/h
Travel speed limitation, reach movement dependent

Limits travel speed when the mast is extended beyond a given prede-
termined millimetre limit.
Speed reduction for a selectable Parameter no.

reach movement length 211 212
Reach movement length for speed limita- mm —
tion
Speed limitation beyond a selected limit — km/h

Installation
Initial operation
815, 816 6070557 2012-10-03 7510399-020
Travel speed limitation, parameter-dependent

Configured and activated using a service parameter.
Select speed (parameter 205–207) and height limitation (parameter
395–397). Can be combined or used separately.
Input signal 1 Input signal 2 Input signal 3

Parameter no. Parameter no. Parameter
no.
205 395 206 396 207 397
Deacti- 100 0 100 0 100 0
vated
Activated 1-99 1-1500 1-99 1-1500 1-99 1-
1500
Collision sensor (BT)

The values in parameters 110 and 111 must be adapted to match the
truck application.
Collision sensor, functional opera- Parameter no.

tion 110 111 112
Deactivated 0 0 —
Activated, not possible to restart the truck 1–99 1–99 0
without collision PIN code
Activated, restart of truck without collision 1–99 1–99 1
PIN code possible
6.2.6 Test driving

Installation
Initial operation
7510399-020 2012-10-03 6070557 815, 816
This page is intentionally left blank.

Installation
Initial operation
815, 816 6070557 2012-10-03 7510399-020

Maintenance
Introduction, maintenance
7510399-020 2012-10-03 6070557 815, 816
7 – Maintenance
7.1 Introduction, maintenance

To maintain a high level of truck safety and to minimise downtime, all
the points specified in the service programme must be carried out.
The intervals specified are those meeting the truck manufacturer's
requirements for a truck – RRE140/160/180/200/250 – used in
standard applications for approximately 1,000 operating hours/year.
The local operating environment may require service intervals that
differ from those specified.
The hour meter is the instrument primarily used for determining when
servicing is to be carried out.
To maintain truck safety, only spare parts approved by the truck
manufacturer may be used for servicing and repairs.
During the truck's warranty period: If repairs/servicing have been
carried out by non-authorised personnel, or if non-approved spare parts
are used, the truck warranty ceases to be valid.
Note:
At each service, the truck must be checked to ensure normal function
and safety. Such checks are to be performed in accordance with the
instructions for daily care in the operator's manual.

Maintenance
Safety precautions for maintenance work
815, 816 6070557 2012-10-03 7510399-020
7.2 Safety precautions for maintenance

work
Only personnel trained in servicing and repair of this type of truck are
authorised to carry out service and repair activities.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Always keep the service work site clean. Spilled oil and water will
make the floor slippery.
• Never wear loose objects or jewellery when working with the truck
DANGER!
Short-circuiting/Burn injury.
When working on the electrical system on the truck, there is a risk of
short-circuiting/burn injury if metal objects come into contact with
live electric parts.
Remove wristwatches, rings and other metal objects beforehand.
• Always disconnect the battery connector when carrying out
maintenance or repair work on the truck unless otherwise stated in
this service manual.
• Always disconnect the battery connector before opening the covers
of the drive unit and the electrical system.
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system
• Use paper or a stiff piece of cardboard when checking for possible
oil leaks. Never use your hand.
• Bear in mind that the oil in the drive unit or the hydraulic system can
be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Allow the truck to cool down before changing the oil.
• Only fill the hydraulic system with new and clean oil
DANGER!
The hydraulic system can be damaged.
If the oil is contaminated, the hydraulic components will suffer
damage.
Always use new, clean oil in the hydraulic system.
• Store and dispose of used oil in accordance with local directives
• Do not flush solvents, etc. used for cleaning into drains that are not
intended for this purpose. Follow applicable local regulations with
regard to disposal.
• Disconnect the battery when welding on the truck

Maintenance
Safety precautions for maintenance work
7510399-020 2012-10-03 6070557 815, 816
Note:
The battery could be damaged.
When welding using an electric welding unit, welding current may
enter the battery.
Because of this, be sure to disconnect the battery.
• Prior to welding or grinding on painted surfaces, be sure to remove
the paint at least 100 mm around the welding/grinding area by using
sandblasting equipment or paint remover
DANGER!
Harmful gases.
Heated paint gives off harmful gases.
Remove paint 100 mm around the welding/grinding location.

Maintenance
Checks for cracks
815, 816 6070557 2012-10-03 7510399-020
7.3 Checks for cracks

The aim of an inspection is to discover any damage, crack, deformation
or similar that may impair safety. The individual performing the checks
must be a trained service technician.
7.3.1 Visual inspection

1. Clean the surfaces to be inspected, ensure adequate lighting.
2. The surfaces are to be subjected to a careful visual inspection for
cracks and, if necessary, a non-destructive crack indication check.
See section "7.3.2 Crack detection".
3. If a crack has been identified, contact the service organisation of
the truck manufacturer for further information.

Maintenance
Checks for cracks
7510399-020 2012-10-03 6070557 815, 816
7.3.2 Crack detection

Crack detection with liquid penetrants
1. Clean around the area in question (type Bycotest C10).
2. Apply penetrant (type Bycotest RP20).
3. Penetration time 20 min.
4. Wipe away penetrant with remover.
5. Apply developer (type Bycotest D30A).
6. Development time approx. 10 min.
7. Crack detection.
8. Etch a horizontal line at the tip of the crack (see illustration of the
principle below) to know far it must be ground out during repair.
Crack detection with magnetic yoke

1. Clean around the area in question.
2. Apply the magnetic yoke.
3. Apply magnetic particle liquid (type Bycotest C101).
4. Inspect with a UV lamp.
5. Etch a horizontal line at the tip of the crack (see illustration of the
principle below) to know far it must be ground out during repair.

Maintenance
Periodic maintenance
815, 816 6070557 2012-10-03 7510399-020
7.4 Periodic maintenance
7.4.1 Every 500 B-hours/180 days
7120.1
7120.2
7120.3
3370.1
5110.1
5110.2
5110.3

Maintenance
7510399-020 2012-10-03 6070557 815, 816
Position Component Type of work Work to be carried out

5110.1 Battery Check Open all of the battery cell plugs and
check the electrolyte level. This should be
10-15 mm above the top edge of the cell
plates. Top up as needed.
5110.2 Battery Check Check that none of the power cable
connections to the battery, truck and
charger are damaged or have overheated.
5110.3 Battery Check Visual check to ensure that the battery cell
and terminal protectors are undamaged.
7120.1 Masts Check Visual check of wear to lifting chains, chain
bolts, chain mountings and chain
sprockets
7120.2 Masts Check Adjustment of lifting chains, check the
tightening torque of lock nuts and inspect
the cotter pins.
7120.3 Masts Lubrication Lifting chains:
3370.1 Parking Check Play in non-braked position
brake

Maintenance
815, 816 6070557 2012-10-03 7510399-020

Together with 500-hour service
0340.1
0620.1
0350.2 0350.1
3370.1
0340.2
3180.1
3180.2
3180.3 2550.1
0840.1
0390.5
0390.2
0390.4
0390.9 0390.1
0390.10
0390.6

Maintenance
7510399-020 2012-10-03 6070557 815, 816
Perform 500-hour service together with the following 1,000-hour

service:

0000 Chassis Check Check for visible damage or cracks. See section
"7.3 Checks for cracks".
0340.1 Hood Check Check the hood locking function
0340.2 Hood Lubrication Hood hinges
0350 Support arms Check Check for visible damage or cracks. See section
0350.1 Support arms Lubrication Beam contact surfaces for reach carriage rollers
0350.2 Support arms Check Check wear and attachment of the mechanical reach
carriage stops
0390.1 Battery Check Visual check of wear to battery locking catch
compartment
0390.2 Battery Lubrication The locking pin for the battery catch
compartment
0390.4 Battery Lubrication Support arm/roller bed sliding surfaces
compartment
0390.5 Battery Check Roller bed locking (Option)
compartment
0390.6 Battery Check Wear to the roller bed sliding blocks (Option)
compartment
0390.9 Battery Check Inspect the sliding surfaces in the offloading
compartment mechanism
0390.10 Battery Lubrication The sliding surfaces in the offloading mechanism
compartment
0620.1 Operator Check Operator's seat mounting and adjustment functions
compartment
0840.1 Chassis Check Tilt stop wear and sealing
2550.1 Gear Lubrication Gear rim (after careful cleaning)
2550.2 Gear Oil change To be changed after the first 1000h, with no further
change after that.
3180.1 Wheel brake Check Brake disc wear
3180.2 Wheel brake Adjustment Play in non-braked position
3180.3 Wheel brake Check Braking force
3370.1 Parking Check Play in non-braked position
brake

Maintenance
815, 816 6070557 2012-10-03 7510399-020
7130
7110.1
4310.1
7130.1
5590.2
5590.3
5110.8
6600.2
7400.1
5000.4
5430.1
5430.2
3550.2
7190.2 7190.1
6660.1
6120.2
7190.4 7190.7
7190.5 7190.8
3530.1
3530.2
3530.3

Maintenance
7510399-020 2012-10-03 6070557 815, 816

3530.1 Wheels Cleaning Remove strings, dirt, etc.
3530.2 Wheels Check Tread depth wear
3530.3 Wheels Check-tighten Wheel bolts (140 Nm)
3550.2 Wheels Check Tread wear
4310.1 Steering wheel Check Mounting and locking
module
5000.4 Electrical system Check Emergency operation functions, and check that the
breaker on the fuse box releases the parking brake
5110.8 Battery Check Connection of the battery connector to the copper
bars
5430.1 Electrical system Check Wear and damage to copper bars
5430.2 Electrical system Check-tighten Copper bar mounting and connections
5590.2 Electrical system Check Wear to the mast wiring harness
5590.3 Electrical system Check Restrictions (strain) on mast wiring harness
6120.2 Hydraulic system Check Wear to hoses in reach carriage and mast
6600.2 Hydraulic system Check The mounting of the hydraulic cylinders
6660.1 Hydraulic system Lubrication Tilt cylinder bearing
0000.2 Chassis Lubrication Tilting cab hinge bearing
7100 Masts Check Check for visible damage or cracks. See section
7110.1 Masts Lubrication Rattle plate and mast beams
7130 Fork carriage Check Check for visible damage or cracks. See section
7130.1 Fork carriage Check Check the functionality and wear of the tilt stop.
7190 Reach carriage Check Check for visible damage or cracks. See section
7190.1 Masts Check-tighten Mast fixing points, upper and lower
7190.2 Masts Check Eccentric ring position in the upper mast fixing -
should not have rotated
7190.4 Reach carriage Adjustment Play of guide rollers
7190.5 Reach carriage Lubrication Guide rollers
7190.7 Reach carriage Adjustment Eccentric rollers
7190.8 Reach carriage Lubrication Eccentric rollers
7400.1 Forks Check Check for visible damage or cracks. See section

Maintenance
815, 816 6070557 2012-10-03 7510399-020
0390.13
0390.14
5110.7
5110.9
0000.2
5000.3
3370.2
0390.12
3550.1
0390.11
7190.3
0390.7
2550.2
0390.3 5000.2

Maintenance
7510399-020 2012-10-03 6070557 815, 816
Perform 500-hour and 1000-hour services together with the

following 2000-hour service:

0000.2 Chassis Check Securing devices for wiring harness
0390.3 Battery Check-tighten Battery locking catch fastening device
compartment
0390.7 Battery Check Bearing for battery rollers
compartment
0390.11 Battery Check Battery changing function
compartment
0390.12 Battery Check Wear to battery cover
compartment
0390.13 Battery Check Wear to finger guard lock plunger (Ergo)
compartment
0390.14 Battery Lubrication Lock plunger and its contact surfaces
compartment (Ergo)
3550.1 Wheels Check Rotation and abnormal noise from bearing
5000.2 Electrical Check The mounting of the electric panel
system
5110.7 Battery Check Force required to disconnect the battery
connector
5110.9 Battery Check Wear to battery tray guiding elements
7190.3 Reach Check Wear to and bearings of reach carriage
carriage guide rollers


2550.2 Drive gear Check-tighten The gear mounting bolts in the chassis
3370.2 Parking Check Braking force
brake
5000.3 Electrical Check-tighten Power cables for motor controls
system

Maintenance
815, 816 6070557 2012-10-03 7510399-020
5200.1
0640.1
5110.4
5110.5
5110.6 6140.1
1700.1
5390.1
5590.1
5000.1

Maintenance
7510399-020 2012-10-03 6070557 815, 816


6140.1 Hydraulic Replacement Oil filter and air filter
system
7.4.6 Annual status inspection

0640.1 Operator Check Functions relating to controls, steering
compartme wheel, brake, pedals, horn and emergency
nt switch off
1700.1 Motors Check-tighten Power cable connections. Torque
tightening.
5000.1 Electrical Cleaning Electric panel:
system
5110.4 Battery Check Measure the battery fluid density with an
acid density meter
5110.5 Battery Check Measure the battery temperature at the
centre of the battery
5110.6 Battery Cleaning Remove excess fluid from the battery tray
5200.1 Electrical Check Wear and damage to the truck's displays
system
5390.1 Electrical Check Wear to wiring harness
system
5590.1 Electrical Check Wear and damage to wiring harness,
system including
protective cover, in reach carriage

Maintenance
Maintenance instructions
815, 816 6070557 2012-10-03 7510399-020
7.5 Maintenance instructions
7.5.1 Cleaning and washing

Cleaning and washing the truck is an important factor in maintaining
truck reliability.
• Carry out general cleaning and washing each week.
Note:
Risk of damage to the electrical system.
Disconnect the battery before washing by pulling out the battery
connector.
High-pressure washers
High-pressure washers may only be used on metal surfaces.
Under no circumstances may high-pressure washers be used in the
truck's motor compartment.
When using a high-pressure washer, the jet must be directed in such a
way that it does not damage electric cables, electric sensors, hydraulic
hoses or decals.
Lifting chains, piston rods and end pieces of hydraulic cylinders, ball
and roller bearings – including those that are fully enclosed – must not
be exposed to the jet, as there is a risk that water may penetrate and
cause corrosion.
After washing with a high-pressure washer, all the truck bearings and
chains must be lubricated/greased as specified in the maintenance
instructions.
Degreasing agents
When using degreasing agents, only environmentally-friendly cold
degreasing agents may be used, such as those that are designed for
general vehicle cleaning and do not damage paintwork, plastic
components, cables, hydraulic hoses or decals.
Cleaning the truck exterior

• Remove rubbish, etc. from the wheels daily
• Degreasing agents can be used as needed, in line with the previous
section.
• Rinse off loose dirt using warm water.
Note:
Seizure, corrosion.
Risk of damage to mechanical parts.
Once washed, the truck should be lubricated as set out in the
maintenance instructions.

Maintenance
7510399-020 2012-10-03 6070557 815, 816
Cleaning the chain

If a chain is very dirty, replacement is recommended.
Dirty chains should be cleaned before being lubricated, e.g. by washing
with a solvent such as diesel or petrol.
The chain must be blown dry using compressed air and lubricated
directly after cleaning.
Note:
Exercise care with degreasing agents as these can contain abrasives.
Cleaning the motor compartment

• Cover the electric motors, contacts and valves before washing.
Note:
Risk of damage to the electrical system.
Electrical components must not be washed with high-pressure
washers.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose dirt using warm water.
Electrical components
• Blow electric motors clean with compressed air.
• Clean electric panels, electronic cards, contactors, connectors,
magnetic valves, etc. with a rag moistened with water and a suitable
detergent.
Note:
Risk of damage to electrical components.
Do not break off any warranty seals on the electronic card.

Maintenance
815, 816 6070557 2012-10-03 7510399-020

Troubleshooting
Abbreviations used in this section
7510399-020 2012-10-03 6070557 815, 816
8 – Troubleshooting
8.1 Abbreviations used in this section

ACH (AC Hydraulic) Pump Control (T2)
ACT (AC Traction) Travel Control (T1)
CID Central Information Display (A1)
EPS (Electronic Power Steering) Steering Servo (A2)
FCU Fork Control Unit
GFU General Function Unit (A8)
LID Load Information Display (P6)
MCU Main Control Unit (A5)
8.2 Truck help functions
8.2.1 Error log menu

Description
The error log displays a list of the last 20 errors logged.
Five errors are listed directly on the menu. The log number, date and
error code are displayed for each error. The selected error is
highlighted by means of a box that can be moved up or down the list
using the arrow keys. When the selection approaches the top or
bottom of the list, the menu rolls the list on, to display more errors if
there are any.
Access
i

Troubleshooting
Truck help functions
815, 816 6070557 2012-10-03 7510399-020
8.2.2 Error information menu

Note:
The error information menu is mainly intended for software
development and shows detailed information about the logged error.
Description
The error information menu displays more detailed information relating
to the logged error.
The error code (3:180) is shown on the left in the window. Beneath it are
the log date (080409) and time (12:57) when the error occurred.
The window also contains logged information relating to the error.
Only five values are displayed at a time. Use the arrow keys to access
additional values.
Access
8.2.3 Diagnostic screens

Note:
Please note that the updating frequency for data is slow, once a
second.
Access
1–17/

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
State 1 – Voltage from the control console levers

State 1 displays the voltage from the levers and the travel direction
selector on the control panel. The value is displayed in volts to 2
decimal places.
No. CID signal

1 X505:2 Lift/lowering lever
2 X505:11 Reach movement lever
3 X505:17 Tilt lever
4 X505:3 Sideshift lever
5 X505:12 Fork spread lever
6 X505:4 Travel direction selector.
7 X505:6 —
8 X505:15 —
9-10 Not used

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
State 2 – Digital signals from the truck control to

CID
State 2 displays 20 digital signals from the truck controls to the CID.
No. CID signal

1 X504:13 Steering pulse transducer 1 A
2 X504:4 Steering pulse transducer 1 B
3 X504:11 Steering pulse transducer 2 A
4 X504:2 Steering pulse transducer 2 B
5 X503:6 Free
6 X505:5 Horn
7 X503:2 Options: Height preselector
8 X503:8 Options: Height preselector override
9 X503:3 Options: 0-position tilt
10 X503:9 Options: 0-position sideshift
11 X503:4 Options: Extra function 5th lever
12 X503:10 Cab tilt (E-model)
13 X503:5 Free
14 X503:11 Free
15 X504:10 Free
16 X504:1 Free
17 X505:14 (Multi/Single Keying)
18 X503:12 Free
19 X504:16 Emergency switch off (ESO)
20 X504:7 Status - key relay

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
State 3 – Voltage from control/sensor to MCU

State 3 displays the voltage to the MCU from 10 analogue controls and
sensors on the truck. The value is displayed in volts to 2 decimal
places.
No. MCU signal

1 X130:2 —
2 X130:16 Fork tilt indicator
3 X130:30 Options: Hydraulic pressure, main lift
[M2]
4 X130:3 Hydraulic pressure, free lift [M]
5 X130:17 Accelerator pedal
6 X130:31 Safety pedal
7 X130:4 Brake pedal, signal 1
8 X130:18 Brake pedal, signal 2
9 X130:32 Power consumption
10 X130:5 Battery voltage +

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
State 4 – Digital input signals to MCU

State 4 displays 25 digital input signals to the MCU.
No. MCU signal

1 X130:10 Cabin tilt, upper position
2 X130:24 Cabin tilt, lower position
3 X130:38 Pulses: Reach carriage sensor 1 [B26]
4 X130:11 Pulses: Reach carriage sensor 2 [B27]
5 X130:25 Steering angle, 180 degrees
6 X130:39 Mast lowering mode A
7 X130:12 Main lift height A (with height indicator)/
Mast near bottom position (without height
indicator)
8 X130:26 Main lift height B
9 X130:40 Free lift height A
10 X130:13 Free lift height B
11 X130:27 Mast lowering mode B
12 X130:41 Seat switch
13 X131:2 Forks below 1 m (with height indicator)/
Forks near top of mast (without height
indicator)
14 X131:16 Options: Travel direction pedal, drive wheel
direction
15 X131:30 Options: Travel direction pedal, fork
direction
16 X131:3 Free
17 X131:17 Options: Speed limitation 1/Max lift height 1
20 X131:18 Options: Sideshift, left
21 X131:32 Options: Sideshift, right
22 X131:5 Emergency switch off (ESO)

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
23 X131:19 Options: Key

24 X131:33 (Production test)
25 X131:6 Key signal in

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
State 5 – Digital output signals from MCU

State 5 displays 18 digital output signals from the MCU.
No. MCU signal

1 X131:20 Parking brake
2 X131:34 Chassis fan
3 X131:7 Main contactor
4 X131:21 Extra (Aux) hydraulic function valve 2
[Q12]
5 X131:35 Options: Flashers, right
6 X131:8 Options: Flashers, left
7 X131:22 Free
8 X131:36 Travel alarm 2 (Warning lamp)
9 X131:9 Fan for transistor regulators
10 X131:23 Travel alarm 1
11 X131:37 Extra (Aux), direction A [Q8]
[Q14]
[Q15]
[Q18]
15 X131:11 Extra (Aux), direction B [Q9]
16 X131:25 Horn
17 X131:39 Support arm brake, left
18 X131:12 Support arm brake, right

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
State 6 – PWM output signals from MCU

State 6 displays 10 pulse modulated (PWM) output signals from the
MCU. The value is shown to 2 decimal places.
No MCU signal Unit

1 X131:26 V Main lift, Lift [Q2]
2 X131:40 V Main lift, Lower [Q4]
3 X131:13 V Reach movement, In [Q6]
4 X131:41 V Reach movement, Out [Q7]
5 X131:39 V Support arm brake, left
6 X131:12 V Support arm brake, right
ACH signal
7 K1:10 A Free lift, Lift [Q3]
8 K1:2 A Free lift, Lower [Q5]
ACT signal
9 K1:10 A Cabin tilt, up [Q11]
10 K1:2 A Cabin tilt, down [Q21]
State 7 – FCU (not used)
State 8 – FCU (not used)
State 9 – GFU (not used)
State 10 – GFU (not used)

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
State 11 – Temperature signals

State 11 shows a total of 5 temperature signals in the truck The value is
displayed in degrees Celsius.
No. Temperature
1 ACT motor temperature
2 ACT cooler plate temperature
3 ACH motor temperature
4 ACH cooler plate temperature
5 EPS motor temperature
State 12 – Voltage levels

State 12 displays 6 different voltage levels in the truck. The value is
displayed in volts to 2 decimal places.
No. Voltage
1 MCU battery voltage
2 15 V external voltage
3 5 V external voltage
4 ACH battery voltage
5 ACT battery voltage
6 EPS battery voltage
7-10 Free

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
State 13 – Travel information

State 13 displays travel information.
No. Unit
Travel speed, target m/s
Travel speed, actual m/s
A Accelerator V
B1 Brake pedal V
B2 Brake pedal V
1 Main contactor
2 ACT power stage activated
3 Safety pedal/door switch
4 Seat switch
5 Parking brake enabled
6-8 Not used

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
State 14 – Steering information

State 14 displays steering information.
No. Unit
Position, target °
Position, actual °
Steering speed, target rpm
Steering speed, actual rpm
S1 Steering command %
S2 Steering command %
1 MCU reference sensor
2 EPS reference sensor
3 Target drive wheel direction
4 Target fork direction
5 Steering command reversed
6-8 Not used

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
State 15 – Lift/lowering information

State 15 displays lift/lowering information.
No. Unit MCU signal

FH Height, free lift mm
MH Height, main lift mm
H Height, total (displayed) mm
S Lifting/lowering speed mm/s
L Lift/lowering lever %
P Requested hydraulic pump rpm
speed
Basic version, height indicator (parameter 1009 = 0)
1 Mast lowered pos. A X130:39
2 Mast lowered pos. B X130:27
3
4 Mast near to lowered pos. X130:12
5 ACH activated
6
7
8 Forks near to mast top X131:2
Full height indication (parameter 1009 = 1)
1 Mast lowered pos. A X130:39
2 Mast lowered pos. B X130:27
3
4
5 ACH activated
6
7
8 Free lift, height reference X131:2

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
Stage 16 – Reach movement information

State 16 displays reach movement information.
No. Unit
R Actual reach movement length mm
PAR Parameter 1265, maximum reach movement mm
length
L Reach movement lever V
P Requested hydraulic pump speed rpm
1 Reach carriage sensor 1 [B26]
2 Reach carriage sensor 2 [B27]
3-8 Not used

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
Stage 17 – Hydraulic information

State 17 displays hydraulic information.
No. Unit
FT Fork tilt, angle 0.1°
L1 Lever aux 1 V
L2 Lever aux 2 V
L3 Lever aux 3 V
P Requested hydraulic pump speed rpm
1 Ergo cabin, upper position
2 Not used
3 Sideshift sensor, left-hand side
4 Sideshift sensor, right-hand side
5 Ergo cabin, lowered position
6-8 Not used

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
State 18 – VNA (not used)
State 19 – Pressure sensor for free and main lifts

State 19 will show weights, pressures and voltages for free and main
lifts.
No. Signal Function: Unit

FW X130:3 Weight measured by sensor [B4] kg
FP X130:3 Pressure that actuates sensor [B4] bar
FV X130:3 Voltage from sensor [B4] mV
MW X130:30 Weight measured by sensor [B6] kg
MP X130:30 Pressure that actuates sensor [B6] bar
MV X130:30 Options: Voltage from sensor [B6] mV

Troubleshooting
Initial troubleshooting
7510399-020 2012-10-03 6070557 815, 816
8.3 Initial troubleshooting

Begin
troubleshooting
CID lit? No Troubleshooting

without indications
Yes
Catch Yes Troubleshooting using

symbol catch symbol
displayed?
No
Error code Yes Troubleshooting using

displayed? error codes
No
Troubleshooting
without indications

Troubleshooting
Troubleshooting using catch symbol
815, 816 6070557 2012-10-03 7510399-020
8.4 Troubleshooting using catch

symbol
Symbol Cause Tips

The forks have reached their maximum Check that parameter 1274, which defines
height and further lifting movement the mast's lift height, is correctly set.
required.
Options: Speed reduced via parameter Check the status of the MCU inputs:
controlled input signals to the MCU.
X131:4 CID diagnostic screen 4/pos 19
Function reactivation The activation sequence for a required

function is not correct.
The MCU does not know if the seat If the indication is intermittent, this may be
switch [B49] is affected. due to gaps in the cable connections or
the sensor's mechanical mounting.
If the indication is shown constantly, check
that the MCU's digital input DI12 switches
status when the chair is loaded, CID
diagnosis screen 4/pos 12.
1. If the input becomes low, the sensor's

function and the wiring harness must be
checked for any break in conductors 27,
40 and 83.
2. If the input is constantly high, the
sensor's function and the wiring harness
must be checked for short circuiting
between conductors 27 and 83.
3. If there is a voltage at input X130:41
when the seat is not loaded, but the input
status shows this, the MCU must be
replaced.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
Symbol Cause Tips

Perform the control sequence in the right
The control sequence was performed in order.
the wrong order.
If the indication is intermittent, this may be
or due to gaps in the cable connections or
The MCU does not detect that the safety mechanical fault in the sensor.
pedal [B31] is actuated. If the indication is shown constantly, check
that the signal from the safety pedal
changes status when the seat is loaded;
CID diagnostic screen 3/pos 6.
Normal values are:

approx 1.5 V when the pedal is free
approx 3.5 V when the pedal is depressed
fully.
If the value on the diagnostic screen
does not change:
• replace the pedal
• Update the truck's software.
• Replace the MCU.
If the value on the diagnostic screen
changes:
• Update the truck's software

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
Symbol Cause Tips

ACT or ACH signals that the The truck has been used more intensively
temperature exceeds 85°C. than its maximum specification. Allow the
truck to cool.
The G3 fan does not work:
– Fan testing can be done using the CID's
service functions
– Controlling the fan, MCU output DO9,
can be checked via CID diagnostic screen
5, pos 9.
The motor control cooling element is dirty

and must be cleaned.
If there is not 48 V between [G3:1] and
[G3:2]: Check the wiring harness and the
MCU.
If there is 48 V between [G3:1] and [G3:2]:
Check the fan
The MCU detects that the emergency Check that the emergency switches are
switch off, ESO, is depressed. not pressed.
Check that fuse F60 is intact.
Check that the MCU's digital input DI22
switches status when the emergency
switch is operated, CID diagnostic screen
4/pos 22.
If the input does not change status, the

emergency switch function and the wiring
harness must be checked for any break in
conductors 20 and 22.
If there is voltage at input X131:5,
conductor 21, when the emergency switch
off button is not pressed, but the input
status shows this, the MCU must be
replaced.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
Symbol Cause Tips

The hour recorder reading to the next Carry out service and reset parameter 101
service has reached 0. to the agreed service interval.
The forks height cannot be determined Operate the mast throughout the entire
with certainty, either within the free or free lift area and as far within the main lift
main lift area. area that sensors [B46] and [B57] change
status.
Normally occurs when the truck is
energized and the mast is positioned in CID diagnostic screen 4, pos 6 [B46] and
the main lift area. 11 [B57]:
Applicable combinations are:

[B46] [B57]
Main lift in bottom position: ‘1’ ‘0’
Main lift raised: ‘0’ ‘1’
If the signals do not correspond with the
mast's position, the switches may be
confused.
CID diagnostic screen 4, pos 13:
The indication for [B58] changes when

[B58] is affected by the reference rail.
[B58] affected by the reference rail: 1.
Further troubleshooting can be done
according to the separate catch symbols
for free or main lift.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
Symbol Cause Tips

The forks height cannot be established Lift or lower the mast so that [B58] passes
with certainty in the free lift area. the reference rail.
Only using the height measurement. If the indicator is not extinguished when
the sensor passes the upper edge of the
Normally occurs when the truck is
reference bar, check that the MCU's digital
energized and the mast is positioned in
input DI13 switches status, CID diagnosis
the free lift area.
screen 4/pos 13.
If the input changes status

– Check for pulses from sensor [B18], CID
4/pos 9 and 10.
– Check the mechanical propulsion of the
free lift's pulse transducer [B18]
– There may also be a fault in the MCU's
software or hardware.
If the input does not change status, check
that:
– the reference rail is not deformed and
that the distance to the sensor is max 6.5
mm
– There is 48 V between [B58:1] and
[B58:3], conductors 27 and 30
– no breaks between [B58:2] and
[X131:2], conductor 141
– no short circuit between [B58:2] and
conductor 27 or 30.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
Symbol Cause Tips

The forks height cannot be established If the forks are raised, lower them fully so
with certainty in the main lift area. that [B58] is affected by the reference rail.
Attempt to raise the forks so far that the
Only using the height measurement.
main lift area ought to start.
If main lift is not activated, the mechanical
propulsion of the free lift's pulse
transducer [B18] must be checked.
If the main lift is activated, the mechanical
propulsion of the main lift's pulse
transducer [B19] must be checked, CID
diagnostic screen 4/pos 7 and 8.
.
The reach carriage position can not be 1. Retract the reach carriage fully.
established with certainty.
2. Release the joystick and then request
Only as an option. a new retraction of the reach carriage
so that the function works
continuously.
3. Once the pressure has increased, and
a certain time has elapsed, set the
reach carriage position to 0 mm.
4. If the home position calibration cannot
be done in the normal operating mode,
test the same procedure under
"Emergency operation."
5. If the symbol is not extinguished,
check both reach carriage sensors
[B26] and [B27]: pos 3 and 4.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
Symbol Cause Tips

Main lift not in bottom position Speed reduction is due to the truck being
driven with the main lift above the bottom
position.
Check that sensors [B46] and [B57] are
correctly connected, CID's diagnostic
screen 4, pos 6 [B46] and 11 [B57]:

[B46] [B57]
If the signals do not correspond with the
mast's position, the switches may be
confused.
Door open. Close door
Only cold store cab. If the indication is shown constantly, check
that the signal from the safety pedal
switches status when the door is closed,
CID diagnosis screen 3/pos 6
Normal values are:

0 V with the door open
In the vicinity of the battery voltage with
the door closed.
If the signal does not change status:
– Check the distance between the sensor
and the activator, max distance 6 mm
– Check the cable between [B31:2] and
[X130:31]
– Replace sensor [B31]
– Replace the MCU
If the signal changes status:
– Update the MCU's software
– Replace the MCU

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
Symbol Cause Tips

Ergo cabin tilted Max speed 4 km/h, which can be adjusted
downwards using parameter 203, cannot
With cab tilt only
be exceeded with the cab tilted.
Check that the sensor [B28] is activated in
the downward tilted mode = ‘1’, CID's
diagnostic screen 4, pos 2:
Fork movement stopped The truck's speed will not allow the forks
to be operated.
With OTP only
Is shown when there are errors when 1. It could be that the lever was released
auto-calibrating. early or the forks did not travel to a
mechanical stop.
Lift up the forks and try again.

Troubleshooting
Troubleshooting using error codes
815, 816 6070557 2012-10-03 7510399-020
8.5 Troubleshooting using error codes

The first digit of the error code identifies the subsystem where the error
code has arisen.
Troubleshooting using
error codes
Error Yes
code CID, warnings and errors
1.xxx?
No
Error
Yes MCU and miscellaneous
code
warnings and errors
2.xxx?
No
Error Yes
code Drive system error
3.xxx?
No
Error Yes
code Hydraulic system error
4.xxx?
No
Error Yes Steering system,

code
warnings and errors
5.xxx?
No
Error Yes GFU, warnings

code and errors
8.xxx?
No
Troubleshooting
without
indications

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
The first digit of the three-digit error code indicates the severity of the
error and how the truck is affected/responds when the error occurs.
.
Code Error category/action taken

number
n:0nn Caution. Generally an information code. No action to
be taken on the truck.
n:1nn Warning. Some functions may be disabled or
reduced. See the specific error code to see what
action has been taken.
n:2nn Error. All parts of the hydraulic system are disabled.
See the specific error code to see what action has
been taken.
n:3nn Error. The truck is braked by the motor and/or the
support arm brake and/or the parking brake until it
comes to a halt. It is not possible to drive. The
steering may be disabled if there is a steering error.
To see what action has been taken, see the specific
error code.
n:4nn Error. The truck is braked by the plug braking until it
stops. Once the truck has stopped, or after 5
seconds, the relays for the main power supply and
key are switched off.
n:5nn Critical error.
Main contactor and key relay opens.
The error codes are subdivided into smaller categories based on the
last two digits of the code (see below).
Error code, type of error

Code Description
number
n:n00–n09 Miscellaneous error codes.
n:n10–n19 CAN-related error codes
n:n20–n39 Error codes related to specific units.
n:n40–n59 Error codes for short-circuited output data.
n:n60–n79 Error codes for output data from open electrical
circuits
n:n80–n99 Faulty signals from sensors.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
8.5.1 CID, warnings and errors
Indicator. Cause Tips

1.003 Minor software version Update the truck's software to the latest
incompatibility. available version.
The software versions in the MCU and
CID do not match each other.
The MCU does not support some of the
functions used by the CID, or vice versa.
1.004 Incompatibility in the display Update the truck's software to the latest
software. available version.
The software versions of the MCU and
1.010 CAN 1 communication warning. 1. Check that CAN 1 is intact in terms of
wiring harness, final resistance and
The CID CAN module has received too
contacts.
many error messages.
2. Disconnect the battery. Check that the
resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID and
DHU.
1.120 LID sending invalid status. Update the truck's software to the latest
available version.
LID blocked.
1.121 No message received from the LID. 1. Check that CAN 1 is intact in terms of
LID blocked.
contacts.
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID.
1:412 LID communication warning. 1. Check that CAN 1 is intact in terms of
LID blocked.
contacts.
[X41:4] is 54 – 66 ohm.
3. Deactivate by setting parameter 1106
= 0 and disconnecting LID

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

1.431 External +5 V is outside the permitted 1. Disconnect the joysticks, buttons and
range. sensors connected to [X505:1] one at
a time and check if the error code
disappears.
2. Check the CID's internal wiring
harness.
3. Replace the CID.
1:500 Software error 1. Update the truck's software to the
latest available version.
1.501 CID has detected an error in the Update the truck's software to the latest
MCU's program execution. available version.
1.503 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
1.504 The software for CID and MCU are not 1. Update the software for CID, MCU and
compatible. other units to the latest available
versions.
Not possible to log in.
2. Check that the software
are compatible.
1:507 The software for CID and MCU are not Update the truck's software to the latest
compatible. available version.
1:508 The software for LID and MCU are not Update the truck's software to the latest
- compatible. available version.
1:509
LID do not match each other.
functions used by the LID, or vice versa
1.510 Communication error – CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 – 66 ohm.
3. Deactivate and disconnect LID, DHU
and collision sensor. Activate and then
connect them one by one to find out
which unit gives rise to the
communication error.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

1.512 Communication disturbance – CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 – 66 ohm.
1.514 MCU or CID has not received a 1. Check that CAN 1 is intact in terms of
– response within 70 ms via CAN1. wiring harness, final resistance and
1.516 contacts.
[X41:4] is 54 – 66 ohm.
1.520 Internal +5 V is outside the permitted Replace the CID.
range.
1.540 Key relay [K20] – Break in the control 1. Check that there is no break in the
circuit coil of the control circuit,
2. Check the contacts [X131] and [X504]
the relationship between [K20:A1] –
[X131:5] as well as [K20:A2] –
[X504:17].
3. Replace the CID [A1].
1.580 Key relay [K20] – Contacts welded 1. Check the key relay's function and that
there is no relationship between
[K20:1] and [K20:2].
2. Check for the presence of a short
circuit that may cause improper supply
of [X504:7], e.g. from [X504:16],
[X504:17] and [X504:18].
3. Replace the CID [A1]

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

1.581 Key relay [K20] does not close Check if the CID's input [X504:7] switches
status when the key relay is used, CID's
If the input does not change status:

• Check that fuse [F74] is intact.
• Check the key relay's function and that
there is a relationship between [K20:1]
and [K20:2] when the relay is drawn.
• Check that conductor 26 from the key
relay to the fuse box and conductor 28
from the fuse box to the CID input
[X504: 7] are intact.
• Replace the CID.
If the input changes status:
• Update the CID's software.
• Replace the CID [A1].

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
8.5.2 MCU and other warnings and errors

2:001 Error in the error log 1. Delete the error log
2. Update to the latest software
2:002 The MCU is programmed using Download or adjust the parameters to
standard values for parameters. correspond with the truck model and
equipment.
2:003 MCU memory error. 1. Make a backup of truck parameters.
Backup data, hour recorder and error log 2. Update to the latest software.
may be affected.
3. Check parameters and hour recorder.
4. Copy the truck configuration from CID
to MCU.
2:004 Error in check sums of backup data. 1. If MCU or CID has been changed,
copy the truck configuration from the
Normally shown after replacing MCU or
MCU or CID unit which has not been
CID.
replaced to the new unit.
2. Make a backup of truck parameters.
3. Update to the latest software.
4. Check parameters and hour recorder.
2:005 Hour recorder reading to service = 0. Carry out servicing and reset the S
counter using TruckCom.
2:006 Error log buffer full. Shows that errors which would normally
be logged in the error log may have been
No indication, logged only.
lost.
2:007 MCU's internal memory full 1. Report the error to the manufacturer.
2. Restart the truck.
3. If the error persists, update the truck's
software to the latest available
version.
2:008 Application time. Set when the application (20ms) takes
No indication, logged only. longer than 17 ms.
1. Rectify the error code that occurred in
direct conjunction with this error code.
2. Report the error to the manufacturer.
2:009 Tick time. Set when tick time (1.25 ms) takes longer
No indication, logged only. than 1.10 ms.
1. Rectify the error code that occurred in
direct conjunction with this error code
2. Report the error to the manufacturer.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

2:010 Communication disturbance – CAN 1. 1. If the CAN key is connected: Try using
a CAN-key with a later production
MCU has received too many incorrect
date.
telegrams.
2. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 – 66 ohm.
2:011 Communication disturbance – CAN2. 1. Check that CAN 2 is intact in terms of
MCU has received too many incorrect
contacts.
telegrams.
[X130:22] is 54 – 66 ohm.
3. Disconnect EPS, ACT and ACH. Then
2:021 Not correctly logged out by the truck 1. The truck was not switched off
correctly. The battery was
disconnected before the truck was
logged out.
2:022 The MCU does not have the same 1. The code is not displayed, only added
software it had when last started up. to the error log to show that the
software has been updated.
Shown when the software has been
updated.
2:101 Incorrect truck type. Use TruckCom to save parameter values.
Factory parameters not loaded. If the MCU has been replaced:
• Enter the truck's parameter list.
• Check parameter “1001 – Truck type”, if
it is not correct, all parameters must be
checked.
• Copy the truck configuration from CID
to MCU

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

2:102 Height preselector - Stop height error. 1. Lifting: check/adjust parameters 371,
373 and 375.
2. Lowering: check the calibration of the
valves for free lowering and main
lowering. Check/adjust parameters
372, 374, and 376.
3. Adjust parameter 377.
2:103 Lifting height limiting. If the truck is equipped with height
indication, activate this using factory
Lifting height limiting is activated and
parameter 1009 = 1.
height measurement is deactivated.
If the truck does not have height
indication, deactivate the lifting height
limiting using parameter 1107 = 0.
2:104 Height preselector If the truck is equipped with height
indication, activate this using factory
Lifting height preselector is activated
parameter 1009 = 1
and height measurement is deactivated
If the truck does not have height
indication, deactivate the lifting height
preselector using parameter 1103 = 0
2:105 More than 80% difference between Check parameter 113.
current consumption measured by
B-version: 280
MCU and
The measured power consumption of E-version: 335
the ACT/ACH (>2 sec. @ >200 A).
No reduction/blocking of the truck's
functions.
2:106 Collision locking. If parameter 112 = 0: Use the special PIN
code to reset the collision sensor.
A collision value exceeding those set via
parameters 110 and 111 has been If parameter 112 = 1: Restart the truck to
detected. reset the collision sensor.
The truck can only be driven at reduced
speed

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

2:141 Digital output DO9 – short circuit. 1. Check that conductor X131:9,
conductor 33, has not short circuited
with conductor 27.
2. Check that fan G3 is not short
circuited.
3. Check that cables and contacts are
undamaged.
4. Check output DO9 via the CID's
2:161 Digital output DO9 – break. 1. Check that there is no break in

conductor X131:9, conductor 33 and
conductor 27 leading to fan G3.
undamaged.
3. Check output DO9 via the CID's
2:180 No contact with the shock sensor. 1. If the truck is not equipped with a
collision sensor, set parameter 110 = 0
and 111 = 0.
undamaged.
3. Replace [B90]
2:401 Internal programme error 1. Report the error to the manufacturer.
version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

2:403 The permitted time for reading 1. Report the error to the manufacturer.
analogue
signals has been exceeded.
version.
2:420 Battery voltage under 33.6 V. 1. Check the battery voltage.
2. Check that the battery cable is
undamaged and free from oxidation.
3. Check that the voltage between
[X130:19] and [X130:32] corresponds
to the measured battery voltage.
4. Replace the MCU.
2:421 Battery voltage over 72 V. 1. If the error code occurs in association
with strong motor braking directly after
charging: Log out/log in.
2. If the error code occurs during plug
braking during normal driving:
Check all power cabling between the
battery and transistor regulator for
breaks, poorly tightened screws/nuts
and oxidation.
2:431 +5 V for external sensors under +4.9 If the error code is shown at the same time
V. as error code 2:433, the troubleshooting
must begin with this.
1. Make sure that no short circuit or other
high load is present in the sensor [B4],
safety pedal or pedal unit for speed
and braking.
2. Check the wiring harness of the above
components.
3. Replace the MCU and check the
function of the sensor [B4], safety
pedal and pedal unit for speed and
braking.
2:432 +5 V for external sensors over +5.1 V. 1. Check that there is no short circuit
between conductor 55 and any
conductor with voltage higher than
5 V, e.g. battery voltage.
2. Check the function of
– Sensor [B4]
– Safety pedal
– Pedal unit for speed and brakes.
3. Replace the MCU.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

2:433 +15 V for external sensors under +12 1. Check that there is no short circuit or
V. high load in sensors [B18] and [B19].
2. Check the wiring harness of the above
components.
3. replace the MCU and check the
function of sensors [B18] and [B19].
2:434 +15 V for external sensors over +16.5 1. Check that there is no short circuit
V. between conductor 29 and any
conductor with voltage higher than
15 V, e.g. battery voltage.
2. Check the function of sensors [B18]
and [B19].
3. Replace the MCU.
2:435 Internal +7.5 V under +7 V. Replace the MCU.
2:436 Internal +7.5 V over +8 V. Replace the MCU.
2:501 Check sum error, parameters 1. Restart the truck.
2. Change one parameter in each
category (operator, service,
manufacturer, calibration) to create a
new check-sum. Start the truck. Then
switch off and reset all values.
3. Replace the MCU.
2:502 Serious software error, MCU. 1. Report the error to the manufacturer.
version.
2:503 error in check sum, factory 1. If MCU or CID has been changed,
parameters. copy the truck configuration from the
MCU or CID unit which has not been
Normally shown after replacing MCU or
replaced to the new unit.
CID.
2. Make a backup of truck parameters.
3. Update to the latest software.
4. Check factory parameters.
2:504 Only one of the CID and the MCU is in 1. Log off and make the truck without
emergency driving mode. voltage for approx 1 minute.
2. Restart the truck and log in again.
2:505 MCU has detected an error in the Update the truck's software to the latest
CID's program execution. available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

2:507 The truck is disabled. Contact your local manufacturer
representative or the manufacturer for
All functions disabled.
reactivation of the truck.
2:510 Initialisation error – CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 – 66 ohm.
3. Deactivate, disconnect and reconnect
the units from CAN1 individually to find
the device giving rise to the
initialisation error.
2:511 Initialisation error – CAN 2. 1. Check that CAN 2 is intact in terms of
contacts.
[X130:22] is 54 – 66 ohm.
2:512 Communication disturbance – CAN 1. 1. Check that CAN 1 is intact in terms of
contacts.
[X41:4] is 54 – 66 ohm.
2:513 Communication disturbance – CAN 2. 1. Check that CAN 2 is intact in terms of
contacts.
[X130:22] is 54 – 66 ohm.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

2:514 Login error – DHU. Check that parameter 503 corresponds to
the truck's equipment:
1. Check that it is possible to connect
TruckCom to the DHU.
If it is possible to connect them, check
the DHU's configuration.
2. Check that the DHU's green LED is lit.
If the LED is not lit: Check the DHU's
supply voltage. The battery voltage
between [A82:1] and [A82:8].
If there is battery voltage: Replace
the DHU.
contacts: Disconnect the battery.
Check that the resistance between
[A82:2] and [A82:3] is 54 – 66 ohm.
2:523 Discharge current over 800 A. Check parameter 113:
B-version: 280
E-version: 335
2:531 Internal +5 V under +4.9 V. Replace the MCU.

2:532 Internal +5 V over +5.5 V. Replace the MCU.
2:533 Internal +15 V under +14.25 V. Replace the MCU.
2:534 Internal +15 V over +15.75 V. Replace the MCU.
2:537 Internal supply for digital outputs Replace the MCU.
under 9.7 V.
2:538 Internal supply for digital outputs over Replace the MCU.
12 V.
2:540 Short circuit in output for main 1. Check that the coil of the main
contactor [Q10]. contactor is not short-circuited.
2. Check that there is no short circuit in
connection [X131:7], wire 31.
3. Replace the MCU and check the
function of the main contactor.
2:555 Valid time for start-up exceeded. 1. Check that fuse [F73] is intact.
2. Check that the wiring harness and
contacts are intact and correctly
attached.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

2:556 Valid time for shut-down exceeded. 1. Turn off the truck by disconnecting the
battery.
2. Restart the truck and log in.
2:560 Break in output for main contactor 1. Check that there is no break in the
[Q10]. main contactor's coil.
2. Check that there is no break between
connection [Q10:A2] and [X131:7],
wire 31.
3. Check that there is a battery voltage
between [Q10:A1] and B-.
If there is not battery voltage.
• Check that the emergency switches are
not pressed.
• Check that fuse F60 is intact
4. Log in to emergency travel mode to
reset the status of the main contactor.
5. Check the function of the main
contactor.
6. Replace the main contactor.
7. Replace the MCU.
2:580 Main contactor [Q10] – Contacts 1. Check the main contactor's function
welded and that there is no relationship
between [Q10:1] and [Q10:2].
2. Check that there is no short circuit that
can cause improper supply to
[X131:5].
2:581 Main contactor [Q10] – Activated but 1. Check fuse [F71]
the MCU is unaware of this.
2. Check the main contactor's function
and that there is a relationship
between [Q10:1] and [Q10:2].
3. Check that there are no breaks in
conductor 8 between the main
contactor and the fuse panel, as well
as conductor 23 between the fuse
panel and [X131:15].

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

2:582 Key relay input status not the same 1. Check fuse [F74]
between MCU and CID
2. Check that conductor 28 from fuse
No software 260038-012 [F74] to MCU input [X131:6] is intact.
3. Check that conductor 28 from fuse
[F74] to CID input [X504:7] is intact.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
8.5.3 Drive system error

3:080 Safety pedal active for more than Check input A6 via CID diagnostic screen
20 minutes. 3, pos 6:
The signal should be approx. 3.5 V with

the pedal depressed and approx. 1.5 V
with it released.
If the signal does not change:
• Check that the wiring harness and
contacts are undamaged.
• Replace the safety pedal [B31].
If the signal changes:
• Log off and disconnect the battery for
approx 1 minute.
• Connect the battery, log on and check
that the error indication has
disappeared.
• Update the truck's software to the latest
available version.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

3:081 Seat switch active for more than Check input DI12 via CID diagnostic
20 minutes. screen 4, pos 12:
The signal should read '1' when the seat is

loaded and '0' when the seat is unloaded.
If the signal does not change:
• Check that the wiring harness and
contacts are undamaged.
• Replace the seat switch [B49].
If the signal changes:
• Log off and disconnect the battery for
approx 1 minute.
• Connect the battery, log on and check
that the error indication has
disappeared.
available version.
3:082 Motor temperature sensor open or 1. check that the wiring harness and
short-circuited contacts are intact and correctly
connected.
2. Use the special tool kit to replace the
temperature sensor [B1]
3:142 Short circuit in the left support arm 1. Check that the resistance of the brake
brake. coil [Q16] is between 44 and 52 ohm.
Max. speed limited to
9 km/h.
3:143 Short circuit in the right support arm 1. Check that the resistance of brake coil
brake. [Q17] is between 44 and 52 ohm.
9 km/h.
3:162 Break in the left support arm brake. 1. Check that the resistance of the brake
coil [Q16] is between 44 and 52 ohm.
9 km/h.
3:163 Break in the right support arm brake. 1. Check that the resistance of brake coil
[Q17] is between 44 and 52 ohm.
9 km/h.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

3:180 Safety pedal output voltage Check that safety pedal output voltage is
incorrect. within the interval 1.5 V to 3.5 V. CID
If the output voltage is outside these

limits:
• Check that the voltage is between 4.5 V
and 5.5 V between [B31:1] and [B31:3].
• Check that there is no break, short
circuit or incorrect voltage supply to
[X130:31], conductor 84.
If the output voltage is within limits, but
that changes when the pedal is
operated:
• Replace the pedal [B31].
available version.
3:201 MEWP joystick not calibrated 1. Calibrate the joystick
2. Check the activation of the hydraulic
levers with parameter 1007.
3:300 Faulty reversing brake. 1. Check the battery charge status. If the
battery is fully charged when the plug
The truck is braked using the
braking is applied strongly, this may be
mechanical brake and driving is
the cause of the error.
disabled.
2. Check the battery cables and their
connections.
3. Check the three phase connections
between the motor and the ACT.
4. Replace the ACT.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

3:305 Motor temperature over 180°C. 1. Check that the resistance in the drive
motor's temperature sensor is
The truck is braked by the plug braking
between 550 ohms and 650 ohms. At
until it stops.
150°C the resistance should be 600
ohm.
2. Check that the motor compartment fan
works and that the ventilation
openings are not blocked.
3. Check that the drive motor is not
damaged.
3:314 The MCU or ACT has not responded 1. Check fuse [F73].
– via CAN2 within 70 ms.
3:315
The truck is braked by the plug braking wiring harness, final resistance and
–
until it stops. contacts. Disconnect the battery.
3:316
[X130:8] and [X130:22] is 54 – 66
ohm.
3. Check that the ACT's green LED is lit
constantly.
If the LED is not lit:
• Check that the ACT has a supply
voltage of 48 V between [K1:9] and [B-].
• Replace the ACT.
If the LED is lit:
3:320 ACT – Voltage for motor supply Check
– outside specified limits.
1. Fuse F71
3:322
2. Fuse F1
until it stops.
3. That the main contactor [Q10] is
closed and that the contacts are not
burned.
4. That the wiring harness between the
battery and the ACT are complete and
not oxidised.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

3:323 Overcurrent – ACT. Check
The truck is braked by the plug braking 1. That the battery voltage is correct
until it stops. when connected to the ACT.
2. That the battery harness is
undamaged and there is no
connection between B+ and
B-.
3. That the motor cables are undamaged
and there is no relationship between
them or with B-.
4. The motor windings' resistance to the
motor yoke, there should be no
connection.
5. Test using a new motor controller. If
the error persists, the fault is probably
an internal motor problem. Replace
the motor and refit the old controller.
3:325 The ACT's cooling element is over Check that the cooling fan for the ACT
125°C. and ACH is working normally. CID Service
function:
until it stops.
If the fan is working normally:

• Clean the ACT's heat sink and
associated ducts. If the error returns the
fault is probably an internal ACT
problem.
If the fan does not work normally:
• If there is not 48 V between [G3:1] and
[G3:2]: Check the wiring harness and
the MCU.
• If there is 48 V between [G3:1] and
[G3:2]: Check the fan

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

3:328 Short circuit in the ACT, the drive Check
motor or the motor cables.
1. That the motor cables are undamaged
The truck is braked by the plug braking and there is no short circuit between
until it stops. them or with B-.
2. The motor windings' resistance to the
connection.
3. Test using a new motor controller. If
an internal motor problem. Replace
the motor and refit the old controller.
3:329 Measurement/Calibration error in the 1. Log off and make the truck without
ACT's current measurement. voltage for at least one minute.
The truck is braked by the plug braking 2. Restart the truck and log in again
until it stops.
3. Check the wiring harness between the
motor and the ACT.
If the fault persists:
3:331 The ACT's internal 5 volts is outside Check
the specified limits. • Fuse F73
The truck is braked by the plug braking • Battery voltage [ACT K1:9] and B-.
until it stops. If the voltage deviates from battery
voltage:
• Check that cable 27, between the fuse
panel and the ACT, is undamaged and
that the connections are not oxidised.
If the voltage is the same as battery
voltage:
3:332 Error at upstart Check fuse F73 and that ACT is showing
a green light.
ACT did not respond during upstart
If the ACT does not display the light, then
replace the ACT.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

3:333 The ACT's internal 15 volts is outside Check
The truck is braked by the plug braking • Battery voltage [ACT K1:9] and B-.
until it stops. If the voltage deviates from battery
voltage:
panel and the ACT, is undamaged and
voltage:
3:380 Break or short circuit in the speed Loosen the sensor and remeasure [B11:1]
sensor [B11]. and [B11:4], ‘1’ = + and ‘4’ = -. The
resistance should be approx 160 kohm.
Max travel speed is reduced to 10.5km/
h. If the resistance measurement
suggests a break/short circuit in the
sensor:
• Replace the sensor.
If the resistance measurement
excludes a break/short circuit:
• Check conductors “10” and “11”,
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
any break/short circuit.
If the conductors are undamaged:
3:381 Loss of one channel in the speed Disconnect the sensor and remeasure
sensor [B11:1] and [B11:4], ‘1’ = + and ‘4’ = -. The
sensor:
[B11:1]/[K1:11] and [B11:4]/[K1:6], for

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

3:382 No current or earth to speed sensor. Loosen the sensor and remeasure [B11:1]
and [B11:4], ‘1’ = + and ‘4’ = -. The
sensor:
[B11:1]/[K1:11] and [B11:4]/[K1:6], for
3:385 The voltage from the accelerator Check that accelerator output voltage is
pedal [B32] is outside the specified within the interval 0.25 V to 4.75 V. CID
limits. diagnostic screen 3, pos 5:
Driving is blocked and the truck is
braked to a stop with plug braking.

limits:
circuit or incorrect feed to [X130:17],
conductor 87/GY.
operated:
• Download new software to the MCU. If
this involves an update, the software for
the CID must also be changed.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

3:387 The voltage from the brake pedal Check that brake pedal, signal 1, output
[B32], signal 1, is outside the voltage is within the interval 0.25 V to
specified limits. 4.75 V. CID diagnostic screen 3, pos 7:

limits:
conductor 85/WH.
operated:

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

3:388 The voltage from the brake pedal Check that brake pedal, signal 2, output
[B32], signal 2, is outside the voltage is within the interval 0.25 V to
specified limits. 4.75 V. CID diagnostic screen 3, pos 8:

limits:
conductor 86/BK.
operated:

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

3:389 Too large discrepancy between both Check that both the brake pedal signals'
brake pedal signals. output voltages follow each other and that
one is inverse to the other.
V = brake pedal's output voltage,

Δpos = Brake pedal depression
CID diagnostic screen 3, pos 7 and 8:
If the output voltage does not change

normally:
• Check that there is no poor relationship
or faulty supply of [X130:4], conductor
85/WH and [X130:18], conductor 86/
BK.
If the output voltage changes normally:

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

3:390 The voltage from the travel direction Check that the travel direction selector
selector [B36] is outside the specified output voltage is between 0.25 V and
limits. 4.75 V when the selector is moved to the
respective end positions. CID diagnostic
screen 1, pos 6:

limits:
and 5.5 V between [A6:1] and [A6:4].
conductor 94/GY.
that changes when the selector is
operated:
• Replace PCB A6 with sensor.
• Update the truck's software to the
3:440 Output to parking brake is short- 1. Check that solenoid [Q1] has the
circuited] correct voltage, 48 V
2. Check output [X131:20]
3:460 Output to parking brake is short- 1. Check that solenoid [Q1] has the
circuited] correct voltage, 48 V
2. Check output [X131:20]
3:461 Output to parking brake is defective. 1. Check that the parking brake is
The parking brake is not activated activated when you are stationary and
when required. depressing the pedal
2. Check that the solenoid gets 48 V and
that wiring harness and connectors
are not damaged or loose.
3. Replace the MCU
3:500 Unknown ACT error. 1. Update the truck's software to the
2. Replace the ACT.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

3:520 ACT start-up error. Check that the ACT's green LED is lit
constantly.
• Check fuse [F73].
• Check that the ACT has a supply
If the LED is lit:
• Check that CAN 2 is intact in terms of
contacts. Disconnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
3:540 Short circuit in parking brake circuit. 1. Check that the resistance in the
parking brake coil is ~32 ohm.
2. Check that conductor 95, [X131:20],
does not receive a faulty 48 V supply.
3. Replace the MCU.
3:560 Break in the parking brake circuit. Make sure that the brake is released using
the emergency release switch [S133].
If the brake is released in an
emergency:
• Check that the contact [X131] is intact
and that conductor 95 is undamaged.
If the brake cannot be released:
• Check that the resistance in the parking
brake coil is ~32 ohm.
• Check that there is 48 V at [Q1:1],
towards B- and that conductor 27 is
undamaged.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
8.5.4 Hydraulic system error

4:080 Motor temperature sensor open or 1. Check that the wiring harness is intact
short-circuited and correctly fitted.
2. Replace the temperature sensor. Use
the special tool.
4:100 Side-shift override is activated, but • If the option automatic side-shift to
automatic side-shift to middle middle position is installed, activate the
position is not available. function using parameter 1110.
Side-shift override requires that the • If the option automatic side-shift to
automatic side-shift to middle position middle position is not installed,
option is installed and activated. deactivate the function using parameter
368.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:180 No pulses from the main lift height 1. Check that hydraulic valve Q2 is open.
sensor during lifting/lowering.
Service function:
Lifting blocked.
+ +
2. Check the height sensor's mechanical

drive.
3. Check that inputs [X130:12] and
[X130:26] swap status when the
sensor rotates. If the main lift's
movement is blocked, the sensor's
mechanical drive is released and the
sensor is turned by hand.
CID diagnostic screen 4, pos 7 and 8:
If the inputs change status:

available version.
If the inputs do not change status:
• Check that there is 15 V between
[B19:1] and [B19:4]. If there is not 15 V,
conductors 29 [X130:37] and 30
[X130:20] must be checked. If these are
intact: Replace the MCU.
• Check that conductors 75, [X130:12]
and 76 [X130:26] are intact.
• Replace the height sensor [B19].
4. Replace the valve unit.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:181 Measured height deviates by more Check:
than ±30 mm when the main lift's • that inputs [X130:12] and [X130:26]
reference sensor is affected. swap status when the height sensor
Lifting blocked. rotates. If the main lift's movement is
blocked, the sensor's mechanical drive
is released and the sensor is turned by
hand.
• The reference sensors' inputs.
CID diagnostic screen 4:
[B19]: pos 7 and 8.
[B46]: pos 6, ‘1’ = Not in main lift zone.
See also CID diagnostic screen 15.

If the inputs [X130:12] and [X130:26] do
not change status:
(cont.)

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

(cont.) 4:181 If inputs [B46]/[X130:39] and [B57]/
[X130:27] do not change status:
• Check that the distance between the
sensors and the mast beam does not
exceed 6.5 mm.
• Check that there is a voltage between
[B46:1]/[B46:3] and [B57:1]/[B57:3].
• Check that conductors 73/[X130:39]
and 139/[X130:27] are intact.
If all the inputs change status normally:

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:182 No pulses from the free lift height 1. The load on the forks may exceed the
sensor on lift/lowering. lifting capacity.
Lifting blocked. 2. Check the height sensor's mechanical
driving.
3. Check that hydraulic valve Q3 opens.
Service function:
+ +
4. Check that inputs [X130:40] and

[X130:13] swap status when the
sensor rotates. If the free lift's
CID diagnostic screen 4,
pos 9 and 10:
If the inputs change status:

If the inputs do not change status:

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:183 Measured height deviates by more Check:
than ±30 mm when the free lift's • that inputs for [B18], [X130:40] and
reference sensor is passed. [X130:13] swap status when the height
Lifting blocked. sensor rotates. If the free lift's
• The reference sensors' inputs.
[B18]: pos 9 and 10.
[B58]: pos 13, ‘1’ = Forks under 1 m.
See also CID diagnostic screen 15.

If the inputs [X130:40] and [X130:13] do
not change status:
(cont.)

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

(cont.) 4:183 If [B58]/[X131:2] does not change
status when the sensor leaves the
reference rail:
• Check that the reference rail is not
deformed and that the distance
between the sensor and the rail does
not exceed 6.5 mm.
• Check that there is battery voltage
between [B58:1] and [B58:3]:
• Check that conductor 141/[X131:2] is
intact.
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:184 Lifting/lowering speed excessively Check the lifting and lowering speeds
high. CID diagnostic screen 15, pos S
Lifting and lowering movement blocked.
The lifting and lowering speeds should be

maximum
650 mm/s. If the speed is above 1000
mm/s, the fault code is generated.
If the speed is too high:
• Reduce the speed using parameter 341
for lifting or 342 for lowering.
If the speed is correct:
• Check the pulse sensor.
If an error indication arises when
lifting:
• Calibrate the free and main lifting valves
[Q3] and [Q2] respectively.
+ +1
and
+ +3
If an error indication arises when

lowering:
• Calibrate the free and main lowering
valves [Q5] and [Q4] respectively.
+ +2
and
+ +4
Calibrate the maximum opening points of
the free and main lowering valves [Q5]
and [Q4].
(cont.)

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

(cont.) Lifting/lowering speed excessively If the error indication persists
high. after calibration/adjustment:
4:184
Lifting and lowering movement blocked. • Check that there is 15V between
[B18:1] and [B18:4] and between
[B19:1] and [B19:4]. If there is no 15V,
conductors 29 [X130:37] to [B18:1] and
30 [X130:20] to [B18:4], as well as 29
[X130:37] to [B19:1 and 30 [X130:20] to
[B19:4] must be checked.
• If the conductors are intact: Replace the
MCU.
• Check that conductors 130/[X130:40],
131/[X130:13], 75/[X130:12] and 76
[X130:26] are intact.
• Replace the MCU
4:185 The free lift's reference sensor does Check that the input for [B58] switches
not change status as expected. status when the reference sensor passes
the upper edge of the reference bar, CID's
Lift/lowering speed reduced.
diagnostic screen 4, pos 13, ‘1’ = Forks
under 1 m.
If [B58]/[X131:2] does not change

reference rail:
not exceed 6.5 mm.
intact.
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:186 The main lift's reference sensor does Check that the input for [B46] and [B57]
not switch status as expected. changes status when the main lift leaves/
reaches it's lowest position, CID
diagnostic screen 4:
If inputs [B46]/[X130:39] and [B57]/

exceed 6.5 mm.
[B46:1]/[B46:3] and [B57:1]/[B57:3].
available version.
4:187 Invalid lifting height. Check that parameter 1274, which defines
the mast's lift height, is correctly set.
The forks estimated height is lower than
the lowest possible level - including
tolerance of 150 mm - or 50 mm above
the maximum lifting height according to
parameter 1274.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:188 Invalid signal combination from the Check the status of the cabin tilt sensors
cabin tilt sensor. [B29] and [B28], CID's diagnostic screen
4, pos 1 and 2:
Cabin tilt blocked.

[B29] [B28]
Cab fully tilted down: ‘1’ ‘1’
Cab in the tilt area: ‘1’ ‘0’
Cab fully tilted up: ‘0’ ‘0’
Where the [B29] = ‘0’ and [B28] = ‘1’
exists:
• The sensors were mixed up when
reconnecting after repairs.
[B28:1]/[B28:3] and [B29:1]/[B29:3].
If the diagnostic screen only shows
valid combinations:
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:189 Pressure sensor error – Load sensor. 1. Check that parameter 1010 is correctly
set.
The truck assumes max load. P = 25
MPa (250 bar) 2. Check that the output voltage is min
0.3 V without load and max 4.7 V with
full load from the pressure sensor [B4],
CID's diagnostic screen 3, pos 4:
If the voltage at any time is outside the

specified limits:
• Check that the voltage is 5 V between
[B4:3] and [B4:1].
intact.
• Replace the pressure sensor [B4].
available version.
If the voltage is within the specified
limits:
available version.
(cont.)

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

(cont.) Pressure sensor error – Load sensor. 4. Check that the output voltage is min
0.3 V without load and max 4.7 V with
4:189 The truck assumes max load. P = 25
full load from the pressure sensor [B6],
MPa (250 bar)
CID's diagnostic screen 3, pos 3:

specified limits:
• Check that voltage is 5 V between
[B6:3] and [B6:1].
intact.
• Replace the pressure sensor [B6].
available version.
limits:
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:190 Faulty signal shift from free lift Check that the input for [B58] switches
reference sensor status when the reference sensor passes
the upper edge of the reference bar, CID's
diagnostic screen 4, pos 13, ‘1’ = Forks
Applicable for height measuring under 1 m.
If [B58]/[X131:2] does not change

reference rail:
not exceed 5 mm.
intact.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:192 Faulty signal combination from the Check the status of the main lift sensors
main lift sensor at the lowest height. [B46] and [B57], CID diagnostic screen 4,
pos 6 and 11:

[B46] [B57]
If any of the signals do not change
status as expected:
exceed 6.5 mm.
• Check that each sensor has a supply
voltage: Battery voltage between
[Bxx:1] and [Bxx:3].
• Check conductor 73/[X130:39] for [B46]
and 139/[X130:27] for [B57].
• Replace sensors that do not change
status.
If the signal combinations are valid:
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:193 Signal missing from the reach If the reach carriage moves:
carriage's sensor. • Check the status of the reach carriage
Reduced reach movement. sensor, CID's diagnostic screen 4:
• [B26]/[X130:38] and [B27]/[X130:11]:
pos 3 and 4.
If an input does not change status:

• Check the distance between the sensor
and the ruler, max 6 mm.
• Check that there is a battery voltage
between [B2x:1] and [B2x:3]:
• Check conductors 78/[X130:38] and 79/
[X130:11].
• Replace sensors that do not change
status.
If the reach carriage does not move:
• Check that the reach carriage is not
blocked mechanically.
• Calibrate valves [Q6] and [Q7].
• Replace the main valve block if
calibration is not possible.
available version.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:194 Missing signal from the main lift No signal even though the main lift sensor
sensor at the lowest height. indicates that the the mast is in the lowest
position.
Lift/lowering speed reduced
1. Check that the input for [B46] and
Not applicable for height measuring
[B57] changes status when the main
lift leaves/reaches it's lowest position,
If inputs [B46]/[X130:39] and [B57]/

• Check that the sensors haven't been
mixed up
exceed 5 mm.
[B46:1]/[B46:3] and [B57:1]/[B57:3].
2. Check that the input for [B33]/
[X130:12] changes status when the
mast reaches the bottom position. The
CID's diagnostic screen 4, pos 7, ‘1’ =
Mast in bottom position.
(cont.)

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

(cont.) Missing signal from the main lift If input [B33]/[X131:12] does not
sensor at the lowest height. change status:
4:194
Lift/lowering speed reduced • Check that the reference rail is not
Not applicable for height measuring between the sensor and the rail does
not exceed 5 mm.
intact.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:195 Mast separation error The mast is still separated when the forks
are 1.5 metres below the max. free lift
height or 0.6 metres from the ground.
1. Calibrate the main lowering valve.
2. Calibrate the mast separation
3. Check the shims of the mast
4. Check that the input for [B46] and
[B57] changes status when the main
lift leaves/reaches it's lowest position,
If inputs [B46]/[X130:39] and [B57]/

• Check that the sensors haven't been
mixed up
exceed 5 mm.
[B46:1]/[B46:3] and [B57:1]/[B57:3].
5. Check that the input for [B33]/
[X130:12] changes status when the
mast reaches the bottom position. The
CID's diagnostic screen 4, pos 7, ‘1’ =
Mast in bottom position.
(cont.)

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

(cont.) Mast separation error If input [B33]/[X131:12] does not
change status:
4:195
not exceed 5 mm.
intact.
4:200 Unknown ACH error. 1. Download new software to the ACH. If
this involves an update, the software
for the MCU, the CID and other units
may also need to be changed.
2. Replace the ACH.
4:201 Levers for hydraulic functions not 1. Calibrate the hydraulic levers.
calibrated
2. Check the activation of the hydraulic
Hydraulic movements blocked levers with parameter 1007.
4:205 Motor temperature over 180°C. 1. Check that the resistance in the pump
motor's temperature sensor is
Hydraulic movement blocked
between 550 ohms and 650 ohms. At
150°C the resistance should be 600
ohm.
2. Check that the motor compartment fan
works and that the ventilation
openings are not blocked.
3. Check that the pump motor is not
damaged.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:214 The MCU or ACH has not responded 1. Check fuse [F73].
– via CAN2 within 70 ms.
4:216
Hydraulic movement blocked wiring harness, final resistance and
contacts. Disconnect the battery.
[X130:8] and [X130:22] is 54 – 66
ohm.
3. Check that the ACH's green LED is lit
constantly.
• Check that the ACH has a supply
• Replace the ACH.
If the LED is lit:
4:220 ACH – Voltage for motor supply Check
– outside specified limits. • – Fuse F71
4:222 • – Fuse F3
• – That the main contactor [Q10] is
closed and that the contacts are not
burned.
• – That the wiring harness between the
battery and the ACH are complete and
not oxidised.
4:223 Overcurrent – ACH. Check
Hydraulic movement blocked • – That the battery voltage is correct
when connected to the ACH.
• – That the battery wiring harness is
undamaged and there is no relationship
between B+ and B-.
• – That the motor cables are
undamaged and there is no relationship
between them or with B-.
• – The motor windings' resistance to the
relationship.
• – Test using a new motor controller. If
an internal motor problem. Replace the
motor and refit the old controller.
4:224 ACH - Error at start-up. Check.
ACT did not respond during start-up • – Fuse F73
• – That a green light is lit on the ACH

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:225 The ACH's cooling element is over Check that the cooling fan for the ACT
125°C. and ACH is working normally. CID Service
function:

– Clean the ACH heat sink and associated
ducts. If the error returns the fault is
probably an internal ACH problem.
• There is a voltage to the fan, replace the
fan.
• There is no voltage to the fan, check the
fan's wiring harness. If the wiring
harness is intact: replace the MCU.
4:228 Short circuit in the ACH, the pump Check
motor or the motor cables. • That the motor cables are undamaged
Hydraulic movement blocked and there is no short circuit between
them or with B-.
• The motor windings' resistance to the
connection.
• Test using a new motor controller. If the
error persists, the fault is probably an
internal motor problem. Replace the
motor and refit the old controller.
4:229 Measurement/Calibration error in the • Log off and make the truck without
ACH's current measurement. voltage for at least one minute.
Hydraulic movement blocked • Restart the truck and log in again.
4:231 The ACH's internal 5 volts is outside Check
Hydraulic movement blocked • The battery voltage [ACH K1:9] and B-.
If the voltage deviates from battery
voltage:
box and the ACH, is undamaged and
voltage:

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:233 The ACH's internal 15 volts is outside Check
Hydraulic movement blocked • The battery voltage [ACH K1:9] and B-.
If the voltage deviates from battery
voltage:
box and the ACH, is undamaged and
voltage:
4:240 Short circuit in the circuit for raising 1. Check that conductor 36,
the free lift [Q3]. [ACH:K1:10], does not receive a faulty
48 V supply.
Lifting blocked.
2. With the truck de-energised and fuse
F73 removed: Check that the
resistance in the coil to valve [Q3] is
approx. 24 ohm, [ACH:K1:10] towards
fuse holder [F73].
3. Replace the ACH.
4:241 Short circuit in the circuit for lowering 1. Check that conductor 35, [ACH:K1:2],
the free lift [Q5]. does not receive a faulty 48 V supply.
Lowering of forks in the free lift zone is 2. With the truck de-energised and fuse
blocked. F73 removed: Check that the
fuse holder [F73].
3. Replace the ACH.
4:242 Short circuit in the circuit for tilting 1. Check that conductor 64, [ACT:K1:10],
the cabin upwards [Q11]. does not receive a faulty 48 V supply.
Upward tilting of cabin blocked. 2. With the truck without power and fuse
approx 24 ohm, [ACT:K1:10] towards
fuse holder [F73].
3. Replace the ACT.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:243 Short circuit in the circuit for function 1. Check that conductor 65, [X131:21],
AUX2 [Q12]. does not receive a faulty 48 V supply.
AUX functions are blocked. 2. With the truck de-energised and fuse
approx 64 ohm, [X131:21] towards
fuse holder [F73].
3. Replace the MCU.
fuse holder [F73].
3. Replace the MCU.
fuse holder [F73].
3. Replace the MCU.
fuse holder [F73].
3. Replace the MCU.
4:247 Short circuit in the circuit for tilting 1. Check that conductor 41, [ACT:K1:2],
the cabin downwards [Q21]. does not receive a faulty 48 V supply.
Tilting of cabin blocked. 2. With the truck without power and fuse
fuse holder [F73].
3. Replace the MCU.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

AUX, direction A [Q8]. does not receive a faulty 48 V supply.
fuse holder [F73].
3. Replace the MCU.
AUX, direction B [Q9]. does not receive a faulty 48 V supply.
AUX blocked. 2. With the truck de-energised and fuse
fuse holder [F73].
3. Replace the MCU.
4:250 Short circuit in the circuit for raising 1. Check that conductor 59, [X131:26],
the main lift [Q2]. does not receive a faulty 48 V supply.
All hydraulic functions blocked. 2. With the truck de-energised and fuse
approx. 24 ohm, [X131:26] towards
fuse holder [F73].
3. Replace the MCU.
4:251 Short circuit in the circuit for lowering 1. Check that conductor 58, [X131:40],
the main lift [Q4]. does not receive a faulty 48 V supply.
All hydraulic functions blocked. 2. With the truck de-energised and fuse
fuse holder [F73].
3. Replace the MCU.
4:252 Short circuit in the circuit for the 1. Check that conductor 61, [X131:41],
reach carriage's “Out” movement does not receive a faulty 48 V supply.
[Q7].
2. With the truck de-energised and fuse
Reach carriages movement blocked. F73 removed: Check that the
fuse holder [F73].
3. Replace the MCU.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:253 Short circuit in the circuit for the 1. Check that conductor 60, [X131:13],
reach carriage's “In” movement [Q6]. does not receive a faulty 48 V supply.
Reach carriages movement blocked. 2. With the truck de-energised and fuse
fuse holder [F73].
3. Replace the MCU.
4:260 Break in the circuit for raising the free 1. With the truck de-energised and fuse
lift [Q3]. F73 removed: Check that the
Lifting blocked.
fuse holder [F73].
2. Replace the ACH.
4:262 Break in the circuit for tilting the 1. With the truck without power and fuse
cabin upwards [Q11]. F73 removed: Check that the
Upward tilting of cabin blocked.
fuse holder [F73].
2. Replace the ACT.
4:263 Break in the circuit for function AUX2 1. With the truck without power and fuse
[Q12]. F73 removed: Check that the
fuse holder [F73].
2. Replace the MCU.
fuse holder [F73].
2. Replace the MCU.
fuse holder [F73].
2. Replace the MCU.
fuse holder [F73].
2. Replace the MCU.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:267 Break in the circuit for tilting the 1. With the truck without power and fuse
cabin downwards [Q21]. F73 removed: Check that the
Tilting of cabin blocked.
fuse holder [F73].
2. Replace the MCU.
4:268 Break in the circuit for function AUX, 1. With the truck without power and fuse
direction A [Q8]. F73 removed: Check that the
AUX blocked.
fuse holder [F73].
2. Replace the MCU.
4:269 Break in the circuit for function AUX, 1. With the truck without power and fuse
direction B [Q9]. F73 removed: Check that the
AUX blocked.
fuse holder [F73].
2. Replace the MCU.
4:270 Break in the circuit for raising the 1. With the truck without power and fuse
main lift [Q2]. F73 removed: Check that the
All hydraulic functions blocked.
fuse holder [F73].
2. Replace the MCU.
4:272 Break in the circuit for the reach 1. With the truck without power and fuse
carriage's “Out” movement [Q7]. F73 removed: Check that the
Reach carriages movement blocked.
fuse holder [F73].
2. Replace the MCU.
4:273 Break in the circuit for the reach 1. With the truck without power and fuse
carriage's “In” movement [Q6]. F73 removed: Check that the
Reach carriages movement blocked.
fuse holder [F73].
2. Replace the MCU.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:280 Input signal from joystick lift/lower Check that the output voltage is min 0.3 V
outside specified limits. and max 4.7 V in each position, from
joystick [B20], CID's diagnostic screen 1,
Lifting/lowering blocked.
pos 1:

specified limits:
• Check 5 V between [B20:1] and
[B20:2].
• Check that cable 50/BK is intact,
[B20:3] to [X505:2].
• Replace the joystick [B20].
limits:
available version.
4:281 Input signal from joystick reach Check that the output voltage is min. 0.3 V
outside specified limits. and max. 4.7 V in each end position, from
joystick [B21], CID diagnostic screen 1,
Reach movement blocked.
pos 2:

specified limits:
• Check that there is 5 V between [B21:1]
and [B21:2].
• Check that cable 51/BN is intact,
[B21:3] to [X505:11].
limits:
available version.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:282 Input signal from joystick tilt outside Check that the output voltage is min. 0.3 V
specified limits. and max. 4.7 V at each end position, from
Tilt movement blocked.
pos 3:

specified limits:
and [B22:2].
• Check that cable 52/OG is intact,
[B22:3] to [X505:17].
limits:
available version.
4:283 Input signal from joystick AUX1/ Check that the output voltage is min. 0.3 V
sideshift outside specified limits. and max. 4.7 V in each end position, from
AUX1/sideshift blocked.
pos 4:

specified limits:
and [B23:2].
• Check that cable 53/YE is intact,
[B23:3] to [X505:3].
limits:
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:284 Input signal from joystick AUX2/fork Check that the output voltage is min. 0.3 V
spreading outside specified limits. and max. 4.7 V in each end position, from
AUX2/fork spreading blocked.
pos 5:

specified limits:
and [B24:2].
• Check that cable 54/GN is intact,
[B24:3] to [X505:12].
• Replace the joystick[B24].
limits:
available version.
4:285 Break or short circuit in the speed Loosen the sensor and remeasure [B12:1]
sensor [B12]. and [B12:4], ‘1’ = + and ‘4’ = -. The
sensor:
[B12:1]/[K1:11] and [B12:4]/[K1:6]], for

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:286 Input signal from the fork incline If the truck is not equipped with a fork
angle sensor [B5] outside the incline angle sensor:
specified limits.
Check that parameter 1111 = ‘0’.
If the truck is equipped with a fork
incline angle sensor:
Check that the output voltage is min 0.3 V
and max 4.7 V for angle sensor [B5], CID's

specified limits:
• Check the voltage is 48 V between
[B5:1] and [B5:3].
• Check that conductor 74/[B5:2] to
[X130:16] is intact.
• Replace angle sensor [B5].
the CID and other units must also be
changed.
limits:
available version.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

4:287 Invalid combination of input signals If the truck is not equipped with centre
from sideshift position sensors [B47]. positioning of the forks side shift:
All hydraulic functions blocked. • Check that parameter 1110 = ‘0’.
If the truck is equipped with centre
positioning of the forks sideshift:
• Check the status of both signals from
the sideshift sensor, CID's diagnostic
screen 4, pos 20 & 21:
If both signals = ‘0’ (invalid

combination):
• Check 48 V between [B47:1] and
[B47:4].
[X131:18] and conductor 112/[B47:3] to
[X131:32] are intact.
• Replace sideshift position sensor.
available version.
If both signals display “01”, “10” or
“11” (valid combinations):
available version.
4:288 The speed sensor has lost the signal Check
All hydraulic functions blocked. • That the wiring harness is intact and
correctly fitted.
• Replace the sensor [B12]
4:289 All AUX functions are blocked Check
• That the wiring harness is intact and
correctly fitted at X131:33
•

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

4:520 ACH start-up error. Check that the ACH's green LED is lit
constantly.
• Check fuse [F73].
• Check that the ACH has a supply
If the LED is lit:
• Replace the ACH
• Check that CAN 2 is intact in terms of
contacts. Disconnect the battery. Check
that the resistance between [X130:8]
and [X130:22] is 54 – 66 ohm.
4:561 Short circuit in the circuit for lowering 1. With the truck without power and fuse
the free lift [Q5]. F73 removed: Check that the
fuse holder [F73].
2. Replace the ACH.
4:571 Break in the circuit for lowering the 1. With the truck without power and fuse
main lift [Q4]. F73 removed: Check that the
fuse holder [F73].
2. Replace the MCU.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
8.5.5 Steering system, warnings and errors

5:010 The steering servo's CAN module has 1. Check that CAN 2 is intact in terms of
– received or sent too many faulty wiring harness, final resistance and
5:011 telegrams. contacts. Disconnect the battery.
[X130:8] and [X130:22] is 54 – 66
ohm.
2. Update the truck's software to the
3. Replace the steering motor.
4. Replace the MCU.
5:035 The temperature of the steering servo Check that the chassis cooling fan is
exceeds 68°C. working normally. CID Service function:

– Clean the steering servo heat sink and
fan. If the error returns, the fault is probably
an internal steering servo problem.
• There is a voltage to the fan, replace the
fan.
• There is no voltage to the fan, check the
fan's wiring harness. If the wiring
harness is intact: replace the MCU.
5:080 The steering sensor [B59] has no Check
contact • That the wiring harness and connector
are intact and correctly fitted.
• Replace the steering sensor [B59].
5:081 The steering sensor [B59] has no Check
contact • That the wiring harness and connector
are intact and correctly fitted.
• Replace the steering sensor [B59].
5:135 Risk of thermal overcurrent in the 1. Check that there are no objects
steering servo. blocking the steering movement.
The indication is shown from 80% up to 2. Check that the steering gear is not
100%. At 100% the indication switches jammed or blocked by dust, thread or
over to error code 5:325. contaminants.
Travel speed limited to 3. Replace the steering servo.
max. 8 km/h.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

5:181 Signal from the steering angle sensor 1. Check the mechanical fastening of
– 180° incorrect. steering angle sensor [B17].
5:184
Travel speed limited to 2. Check the routing of the wiring
max. 8 km/h. harness at the steering angle sensor
[B17]. The harness must lie according
to Fig 1. The wiring harness must not
be routed as shown in Fig 2, as there is
a risk of the connector coming loose.
Fig 1. Fig 2.
3. Compare with the direction arrows
and check that the signal from the steering

angle sensor changes status twice for
every complete turn of the steering wheel,
If the signal does not change status:

between [B17:1] and [B17:3].
[X130:25] is intact and does not receive
a faulty 48 V supply.
• Replace the steering angle sensor.
available version.
If the signal changes status:

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

5:185 Reference search. 1. Check that parameter 1115 is set to
- correspond with the truck's equipment.
Only optional
5:186
2. Check the reference sensor, [B59],
function, CID diagnostic screen 14,
pos 2:
3. Check that there is 12 V between

[B59:1] and [B59:3]:
If there is 12 V:
Check the distance between the sensor
and the reference plate.
Check that conductor 211 between
[B59:2] and [X901:11] is intact.
Replace the reference sensor [B59].
If there is not 12 V:
• Check that conductors 203/[X901:3] to
[B59:1] and 212/[X901:12] to [B59:3]
are intact.
• Replace the steering servo.
5:300 The power steering does not react as 1. Restart the truck.
& expected.
2. In the error log/list: Check other
5:304
Driving is disabled and the truck is simultaneous error codes.
If there are other error codes, correct
these before continuing with
troubleshooting.
3. Check the steering servo's wiring
harness.
4. Replace the steering servo.
5:301 Power steering power stage fault. 1. Check fuse [F72].
Driving is disabled and the truck is 2. Check that there is a battery voltage
braked to a stop with plug braking. between conductors 250/[X901:8] +
[X901:16] and 40/[X901:7] +
[X901:15].

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

5:302 The MCU cannot transfer the Update the truck's software to the latest
parameters to the steering servo. available version.
Driving is disabled and the truck is
5:303 The steering servo does not respond 1. Check fuse [F64] and [F72].
on start up.
Driving is disabled and the truck is between conductors 250/[X901:8] +
braked to a stop with plug braking. [X901:16] and 40/[X901:7] + [X901:15]
as well as between conductors 9/
[X901:6] and 40/[X901:7] + [X901:15].
3. Check there is approx 60 ohm in the
wiring harness for CAN2 at [X901:2]
[X901:10].
5:320 The steering servo's supply is less 1. Check the battery voltage.
than 24 VDC.
2. Check fuse [F64] and [F72].
between conductors 250/[X901:8] +
[X901:16] and 40/[X901:7] + [X901:15]
[X901:6] and 40/[X901:7] + [X901:15].
5:325 Thermal overcurrent in the steering 1. Check that there are no objects
servo, 100% of permitted value. blocking the steering movement.
Driving is disabled and the truck is 2. Check that the steering gear is not
braked to a stop with plug braking. jammed or blocked by dust, thread or
contaminants.
5:326 The steering servo's power stage is If the truck is used where the ambient
under -40°C or over +85°C. temperature is within specified
temperature limits:
braked to a stop with plug braking. Check that the motor compartment fan is
working normally. CID Service function:
5:335 Internal error in the steering servo. Replace the steering servo.
–
5:336

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

5:380 Supply error – Steering sensor 1. Check that there is 5 V between [B13:1]
and [B13:4].
braked to a stop with plug braking. If there is 5 V:
Replace the CID.
• Check that conductors 42/[504:14] to
[B13:1] and 45/[X504:5] to [B13:4] are
intact.
• Check 5 V between [X504:14] and
[X504:5].
5:381 Supply error – Steering sensor 2. Check that there is 5 V between [B13:5]
and [B13:8].
Replace the CID.
[B13:5] and 45/[X504:5] to [B13:8] are
intact.
[X504:5].
5:382 Abnormal pulse frequency from the 1. Check that the CID inputs from the
steering sensor. steering pulse sensors are stable, CID
diagnostic screen 2, pos 1 – 4:
2. Check that conductors

43/[X504:13] to [B13:3],
44/[X504:4] to [B13:2],
47/[X504:11] to [B14:7] and
48/[X504:2] to [B14:6] are intact.
3. Replace the steering sensor.
4. Replace the CID.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816

5:383 Interruption in pulse series from 1. Check that all the CID inputs from the
steering sensors 1 and 2. steering pulse sensors change status
when the steering wheel is turned, CID
diagnostic screen 2, pos 1 – 4:
2. Check that conductors

43/[X504:13] to [B13:3],
44/[X504:4] to [B13:2],
47/[X504:11] to [B14:7] and
48/[X504:2] to [B14:6] are intact.
3. Replace the steering sensor.
4. Replace the CID.
5:384 Supply error – Steering sensors 1 and • Check that there is 5 V between [B13:1]
2 and [B13:4] and between [B13:5] and
[B13:8].
[B13:1] and 45/[X504:5] to [B13:4] are
intact.
[X504:5].
[B13:5] and 45/[X504:5] to [B13:8] are
intact.
[X504:5].

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020

5:414 The MCU or steering servo has not 1. Check fuse [F64] & [72].
– responded via CAN2 within 70 ms.
5:416
The truck is braked by the plug braking wiring harness, final resistance and
until it stops. contacts. Disconnect the battery.
[X130:8] and [X130:22] is 54 – 66
ohm.
between conductors 250/[X901:8] +
[X901:16] and 40/[X901:7] + [X901:15]
[X901:6] and 40/[X901:7] + [X901:15].
5:421 The power steering's direct voltage is 1. Check whether there are other,
above 72 V. simultaneous error codes being
stored. If there are, correct these
before continuing with
until it stops.
troubleshooting.
5:422 Short circuit in the steering servo Replace the steering servo.
until it stops.
5:435 Internal error in the steering servo. Replace the steering servo.
–
5:438
until it stops.
5:500 Unknown steering servo error. 1. Update the truck's software to the
5:501 The steering servo has detected an Make a back up copy of the truck's
error in the MCU. parameter settings and update all
software.
5:509 Steering manoeuvre without request. Replace the steering servo.

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
8.5.6 GFU, warnings and errors
Indicato Cause Tips

r.
8:001 The software in the MCU and GFU do 1. Update the software to the latest
not match each other. version.
The MCU does not support some
functions in the GFU, or vice versa.
8:010 To many faulty transmissions, CAN to 1. Disconnect the battery. Check that the
GFU resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
2. Deactivate and disconnect GFU.
8:220 Communication to GFU is stopped by 1. Disconnect the battery. Check that the
the software in the GFU or the MCU resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
8:411 The MCU or GFU has not responded 1. Disconnect the battery. Check that the
– via CAN2 within 70 ms. resistance between [X41:3] and
8:412 [X41:4] is 54 – 66 ohm.
until it stops. 2. Deactivate and disconnect GFU.
3. Replace the GFU.
8:430 Faulty VDD V 1. Replace the GFU.
until it stops.
8:431 Erroneous external fault + 5V 1. Check wiring harness

The truck is braked by the plug braking 2. Check external loads as well as for
until it stops. faulty sensors. When checking,
disconnect each one in turn, and
check if there is any voltage.
8:432 Erroneous + 7,5V 1. Replace the GFU.
until it stops.
8:433 Erroneous internal fault + 15V 1. Replace the GFU.
until it stops.
8:434 Erroneous external fault + 15V 1. Check wiring harness
The truck is braked by the plug braking 2. Check external loads as well as for
until it stops. faulty sensors. When checking,
disconnect each one in turn, and
check if there is any voltage.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
Indicato Cause Tips

r.
8:435 Faulty Ug V 1. Replace the GFU.
until it stops.
8:436 Faulty AD V 1. Replace the GFU.
until it stops.
8:500 The software in the MCU and GFU do 1. Update to the latest software
not match each other.
8:501 The software in the MCU and GFU do 1. Update to the latest software
not match each other.
8:510 To many faulty transmissions, CAN to 1. Disconnect the battery. Check that the
GFU resistance between [X41:3] and
[X41:4] is 54 – 66 ohm.
8:520 No reply when initiating GFU 1. Check that the wiring harness is not
damaged, and that all pins are
correctly connected.
2. Check the fuses.

Troubleshooting
Troubleshooting without indications
7510399-020 2012-10-03 6070557 815, 816
8.6 Troubleshooting without indications
8.6.1 Mechanical brake (3000)

Error Cause Tips
Brake does not release Voltage too low. Check the truck battery. Charge if
necessary.
Break in voltage supply. Check wiring harness to the brake.
Restart the truck.
Too much play. Adjust the play.
Worn friction disc. Replace the friction disc.
Coil defective. Replace the brake.
Too little play. Adjust the play.
Brake does not brake Voltage remains when truck Check the truck battery and its
is switched off. connections.
Grease on friction surfaces. Replace the friction disc and
readjust the play.
Uneven braking effect Voltage too low. Check the truck battery. Charge if
necessary.
8.6.2 Steering (4000)

Error Cause Tips
No steering manoeuvre Error in steering sensor 1. Replace the steering sensor
when the steering wheel is [B13]. [B13].
turned.
2. Check that all the CID's inputs
from the steering pulse sensors
switch status when the steering
wheel is turned, CID's diagnostic
screen 2, pos 1 – 4:

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
8.6.3 Telescopic forks
Error Cause Tips

The forks run in and The hydraulic hoses are incorrectly Connect the hydraulic hoses
out unevenly connected
The four hoses are not the same
length
Dirt between inner and outer forks Remove the dirt
Leakage at the piston seal Replace the piston seal
The distribution valve is damaged Replace the distribution valve
The forks move Leak in the regulator valve Check as below
without the levers
being operated
The forks are leaking Couplings are leaking Correct fitting or replace
oil couplings
The cylinder head seal is damaged Replace the cylinder head seal
The fork is worn Immediately remove the forks
from the truck
The forks move The regulator valve/pump is worn Check as below
fitfully during Insufficient flow
extension and
retraction
One of the outer The bolt is broken or loose Replace or tighten the bolt with
forks does not retract Loctite 542
The fork tips are no One of the forks has been overloaded Remove the forks from the
longer at the same and has become permanently truck
height deformed Check as below
Too great a tolerance The outer forks are worn or have been Replace the outer forks
between the inner overloaded, resulting in the underside
and outer fork of the outer forks becoming
permanently deformed

Troubleshooting
7510399-020 2012-10-03 6070557 815, 816
8.6.4 Log on was normal, but one or several

functions cannot be used
Error Cause Tips
The truck cannot be The brake does not release The brake pedal must be
driven in any direction. completely released in order to
start driving.
~0.5 V,
If the diagnostic screen shows
pos 8: ~4.5 V when the brake that the brake is not completely
pedal is completely released: released, 7: > ~1 V and 8: < ~4
V, the brake pedal may have
mechanically seized in the
partly or completely depressed
position.
The function automatic The values from sensor [B5] are Check that [B5] is connected
fork tilt to horizontal incorrect correctly.
position does not work. Incorrectly configured hydraulic Check that the hydraulic valves
valves. are configured correctly.
Cab tilt not functioning Due to variations in the setting of Shim out the switch.
correctly. the ergo-cab’s position against the
lower part, the cab switches can be
too far from their sensing area.
When the cab is tilted, it is turned Adjust the cab, using the two
from the battery and the sensor screws at the tilt joint.
looses contact with the cab. This is
due to a poorly adjusted machine
housing at the tilt joint.

Troubleshooting
815, 816 6070557 2012-10-03 7510399-020
This page has been deliberately left blank

Frame/Chassis 0000
General
7510399-020 2012-10-03 6070557 815, 816
9 – Frame/Chassis 0000
9.1 General
The truck chassis consists of a base plate with support arms. The bat-
tery compartment and motor and cab brackets are then fitted to the
chassis. The lifting mast and moving reach mast are not part of the
chassis.
9.2 Motor hood (0340)
9.2.1 Opening the motor compartment

RRE 140-RRE 250
To open the motor compartment:

• Move the seat to its forward position.
• Loosen the screw (8 mm Allen screw) beside the operator's seat and
swing the hood out.
To close the motor compartment:

• Swing the hood in and tighten the screw.
See section “9.4.1 Cab tilting RRE 140 – 250 Ergo”.for access to the
motor compartment on Ergo trucks.

Frame/Chassis 0000
Motor hood (0340)
815, 816 6070557 2012-10-03 7510399-020
Replacing the motor hood

1. Open the motor compartment. See section “9.2.1 Opening the mo-
tor compartment”.
2. Remove the operator's seat. See section “9.4.1 Operator's seat
(0620)”.
3. Loosen the four clamps holding the wiring harness that runs to the
operator's seat.
4. Lift the hood off the hinges.
5. Replace the hood and reassemble in reverse order.
Adjustment of motor hood

After replacing the motor hood it must be adjusted to ensure that the
hood and the outsides of the machine housing line up.
1. This can be done with the aid of shims on the hood's hinges
2. If the hood sits slightly high, the plate by the lock can be raised us-
ing shims so that the plate is at the correct level

Frame/Chassis 0000
Motor hood (0340)
7510399-020 2012-10-03 6070557 815, 816
3. To ensure the hood is in line at the front edge, adjust it using stud
bolts (4 mm socket head) locked with nuts (13 mm spanner).

Frame/Chassis 0000
Battery compartment components (0390)
815, 816 6070557 2012-10-03 7510399-020
9.3 Battery compartment components

(0390)
9.3.1 Adjusting the battery bed

Fit and adjust the tray as shown in the illustration below:
b
c
1. Push in the tray so that the hook (B) hooks onto the locking device
(A).
2. Adjust so that there is no play between the tray and the drive part
using the adjuster screw (C).
3. Tighten the union to torque 189 Nm.
4. Test to check that the battery mechanism functions correctly.

Frame/Chassis 0000
Operator's cab (0500)
7510399-020 2012-10-03 6070557 815, 816
9.4 Operator's cab (0500)
9.4.1 Cab tilting RRE 140 – 250 Ergo

Make sure there is sufficient room for the tilted cab before you start
servicing work. Also make sure there is no risk of the cab accidentally
being tilted back during servicing.
DANGER!
Risk of tipping.
The truck can tip if the battery is removed when the truck is tilted to
the service position.
Never remove the battery from the truck.
On trucks with low lift heights – extend the mast so that the finger
guards and panel are made accessible when tilting up. Check also that
the cab does not catch the mast, hose reel or other parts on the truck.
When carrying out servicing in the motor compartment, you should tilt
the cab all the way up and over into its service position. This tilting proc-
ess is only possible with the service key inserted and the truck in serv-
ice mode.
To tilt the cab to its service position:
1. Insert the service key and put the truck into service mode.
2. Select the cab tilt position.
3. When the cab is tilting up you must stand beside it in a position
where there is no danger of being crushed.
4. Move the fork lift lever back in a single motion and hold it in place
until the cab is fully tilted.
5. Once the cab's centre of gravity passes its centre of rotation (at ap-
proximately 45°), the cab drops slowly into its service position.
DANGER!
Cab dropping!
The cab drops slowly when tilted beyond 45°.
Ensure nobody/nothing is close to the cab when tilting.
To tilt the cab to its normal position:
Make sure that nobody is working in the motor compartment when tilt-
ing the cab back.
DANGER!
Risk of crushing.
There is a very high risk of injury if anyone is working in the motor
compartment when tilting the cab back.
Make sure that nobody is working in the motor compartment when
tilting.
1. Shift the fork lift hydraulic lever forward until the cab stops in its nor-
mal position.
2. Exit service mode and remove the service key.

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
9.3.1 Cab windows (0530)

Fitting a window
1. Fit the rubber strip around the window.
2. Place a piece of cord in the strip’s groove
3. Lubricate the rubber strip with water and some washing-up liquid.
4. Fit the window in the frame.

5. Fit it into position using the cord.
Note!
Handle the glass window carefully to avoid breakages and stresses,
and prevent direct contact with steel surfaces.

Frame/Chassis 0000
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This page is intentionally left blank

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
9.3.2 Cab door (0550)

Disassembly of the door lock
×n ×n
s s
Step 2, s: T20, n: 16. Step 3, s: T30, n: 2.
×n ×n
s s
Step 5, s: T30, n: 1.
Step 7, s: T30, n: 4.
×n
Max
s mm
Step 9, s: 4 mm, n: 4. Step 11.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
Tools required
• Torx key T20
• Torx key T30
• 4 mm Allen key
Method
1. Open the door.
2. Remove the screws that hold the door panel in position, 16 × T20.
3. Remove the screws for the handle bracket, 2 × T30.
4. Remove the bracket
5. Remove the screw for the door indicator, 1 × T30.
6. Remove the door panel and handle.
7. Remove the screws that secure the lock handle, 4 × T30.
8. Remove the lock handle.
9. Remove the screws, 4 × Allen 4 mm, and remove the lock.
10. Reassemble in reverse order.
11. Check that the lock mechanism works correctly and that the
distance between the sensor [B31] and the screw for the door
indicator is max. 6.5 mm.

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
Disassembly of the lock device
×n
s
Step 1. Step 2, s: T20, n: 2.
×n ×n
s mm
s mm
Step 3, s: 19 mm, n: 1. Step 4, s: 4 mm, n: 3.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
Tools required
• Torx key T20
• Spanner 19 mm
• Spanner 18 mm
• Allen key 4 mm
Method
1. Pull contact [B31] apart.
2. Remove the screws that secure the close-proximity switch and
remove it, 2 × T20.
3. Disassemble the lock pin.
4. Remove the screws that secure the bracket, 3 × Allen 4 mm.
5. Remove the bracket, shim and nut plate.

Frame/Chassis 0000
Operator compartment (0600)
815, 816 6070557 2012-10-03 7510399-020
9.4 Operator compartment (0600)
9.4.1 Operator's seat (0620)

The operator's seat is available with back rests in two different heights.
Both versions can be ordered with:
• Cloth upholstery
• Cloth upholstery with heater
• PVC upholstery with heater.
Disassembling the entire seat

1. B version: Push the seat as far as it will go to the front and open
the motor compartment, E version: Tilt up the cab.
2. In the motor compartment, disconnect the switch [X47] that con-
trols the electric seat functions.
3. Push the seat all the way to the back and loosen the front screws
securing the chair to the chassis. Then push the seat all the way to
the front and loosen the two rear screws.
×n
s mm
Step 3:
s = 6 mm, n = 2 × 2
4. Lift out the old seat. Set the new seat to the “Maximum front” posi-
tion, and fit it into place.
5. Secure the two rear screws, push the seat to the rearmost position,
then secure the two front screws.
6. Connect the new seat switch [X47] to the chassis harness.
7. B version: Push the seat as far as it will go to the front and close
the motor compartment, E version: Tilt down the cab.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
Replacing the seat switch

On “E version” trucks, for better access push the seat as far as it will go
to the front.
On “B -version" trucks, when opening the motor compartment the seat
folds down.
1. Loosen the two screws securing the cover over the seat back rest
×n
s
Step 1: s = T25, n = 2
2. Raise the cover and disconnect the switch.
3. Loosen the two screws securing the sensor.
×n
s
Step 3: s = T10, n = 2
4. Screw the new sensor into place
5. Connect the cable
6. Hook the cover into place and secure it with screws.

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
Replacing the back rest

The back rest is secured to the seat frame with three hooks. The upper
hook of the three hooks serves to secure the back rest using a spring,
which is attached to the frame. When the back rest is in the correct po-
sition, the spring interlocks with the hook.
1. Push the seat as far to the front as possible.

2. Use the thumb and push the back rest locking spring backwards,
and use the other hand at the same time to take hold of the lower
edge of the back rest and lift it up.
Back rest locking spring

3. If the seat has a heater, disconnect the switch [X63], and then con-
nect the new back rest [X63] before assembling the back rest.
4. Align the three hooks of the back rest in the seat frame, and push
the back rest down until the locking spring interlocks with the hook.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
Replacing the chair seat

1. Remove the back rest as instructed in “Replacing the back rest”.
2. If the seat has a heater, then disconnect the switch [X62].
3. Loosen the two screws at the back of the seat.
×n
s
Step 3: s = T25, n = 2
4. Push the seat forwards until it comes loose from the frame.
5. Align the new seat and push it backwards, then downwards until
the two screw holes at the back become aligned with the two
threaded holes.
6. Secure the seat with two screws.
7. If the seat has a heater, then connect the terminal [X62].
8. Reinstall the back rest as instructed in “Replacing the back rest”.
Replacing the seat heater switch
1. Remove the back rest as instructed in “Replacing the back rest”

until the switch becomes easily accessible.
2. Use a screwdriver or similar to push down the upper locking lip of
the switch while simultaneously pulling out the switch.
3. Disconnect the switch cables and then connect the new switch.
4. Push the new switch into place in the cover opening, and make
sure the switch locking lips catch the cover.
5. Reinstall the back rest as instructed in “Replacing the back rest”.

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
9.4.2 Cab heating/ventilation (0630)

Replacing the air filter on the cold store cabin:
The air filter is situated under the cover as depicted in the picture below.
The filter should be replaced at least once a year.
1. Unscrew the four screws (Torx 25) and remove the cover.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
2. Unscrew the three screws (Torx 20) and remove the plate covering
the filter
3. Remove the filter.

4. Replace the filter and reassemble in reverse order.
Removing the fan and heater

1. Unscrew the four screws (Torx 25) and remove the cover.
2. Unscrew the three screws (Torx 20) and remove the plate and the
air filter

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
3. Unscrew the 6 screws and remove the cover.
4. Disconnect the cabling (1) and loosen the nuts securing the + -
connections on the contactors.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
5. Unscrew the two screws (Torx 20) securing the cassette, and pull
it out.
6. Loosen the screws (Torx 20)

7. Disconnect the five connections on the heater.
8. Remove the outer clamp.
9. Remove the heating unit.

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
To remove the fan, proceed as follows.

1. Remove the rim.
2. Unscrew the ten screws holding the fan.
3. Disconnect the connector.

4. Remove the fan.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
Replacing the potentiometers
1. Unscrew the four screws and remove the cover.
3 mm
2. Disconnect the cables

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
3. Loosen the nuts securing the potentiometers.
13 mm
4. Remove the potentiometers.

5. Reassemble in reverse order. When reassembling the knobs, be
sure to set them to the right positions. In the detent position where
a click is heard, the knobs are off.

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
9.4.3 Internal fittings (0680)

The interior of the operator compartment consists of interconnected
panels that are tightly locked together, as well as to the cab chassis.
Most of the panels are held in place without the use of screws or snap
fasteners, but to remove the panels they must be dealt with in
sequence.
1. Remove screw (a) on the right of the tiller arm and remove the pan-
el.
2. For the next panel, remove screw (b) located in front of the tiller
arm. This panel is also fixed in place by a snap fastener (c). Re-
move the entire panel.
a
b
3. The remaining panels can now be removed one by one in se-

quence, without the use of tools.
4. Reassemble in reverse order

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020
9.4.4 Disassembling/assembling the floor

plate, B version 0680
1. Open the motor compartment. See section “9.2.1 Opening the mo-
tor compartment”.
2. Unscrew the two screws in the footboard and lift the footboard
away.
×n
s mm
Step 2: s = 8 mm, n = 2
3. Disconnect the safety pedal and accelerator/brake pedal terminal
[X39] next to the hydraulic oil tank.
4. Unscrew the two remaining screws securing the floor plate.
×n
s
Step 4: s = T30, n = 2

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
5. Lift out the floor plate and pedal as a single assembly.

6. Align the floor plate in the correct position.
7. Secure the floor plate with two screws.
– M6×16 shoulder screw at the pedal assembly
– M6×20 screw at the pump motor.
×n
s
Step 7: s = T30, n = 2
t. = 9.6 Nm
8. Clean the floorboard screws, apply a light coat of oil and screw
them into the floorboard.
×n
s mm
Step 8: s = 8 mm, n = 2
t. = 47 Nm

Frame/Chassis 0000
Safety equipment (0800)
815, 816 6070557 2012-10-03 7510399-020
9.5 Safety equipment (0800)
9.5.1 Checking the overhead guard (0810)

1. Prepare the truck for servicing.
2. Check the following for cracks and secure mounting:
- casing (c)
- fine-mesh guard (b) (option)
- transparent top (a) (option)
- protective grating (d) (option).
a

Frame/Chassis 0000
7510399-020 2012-10-03 6070557 815, 816
9.5.2 Adjusting the tilt stops (0840)

1. Park the truck on a level surface.
2. Measure the distance between the tilt stop and the floor (max. 15
mm).
3. If the distance between the tilt stop and the floor is greater than this,
the distance of the stops must be adjusted.
4. Lift up the rear edge of the truck using a jack and place a wooden
block under the support arms to prevent the truck from tipping over.
5. Remove the screws (d), tilt stop (c) and shims (b).
6. Insert shims so that the distance between the tilt stop and the floor
is as close to 15 mm as possible. The distance must not exceed 15
mm.
a
b
c d
Max.
15 mm

Frame/Chassis 0000
815, 816 6070557 2012-10-03 7510399-020

Motors 1000
Motor sensors
7510399-020 2012-10-03 6070557 815, 816
10 – Motors 1000
10.1 Motor sensors

Switch off the truck and remove the battery connector when working on
motors.
10.1.1 Temperature sensor

A working temperature sensor mounted inside the motor should give a
resistance reading as shown in section“8.5 Troubleshooting using error
codes” .
The temperature sensor mounted outside gives a resistance reading as
shown in section “8.5 Troubleshooting using error codes” .
It is impossible to replace the temperature sensor in the motor winding.
In the event of a fault with the temperature sensor, an external temper-
ature sensor should be retrofitted.

Motors 1000
Motor sensors
815, 816 6070557 2012-10-03 7510399-020
Retrofitting an external temperature sensor

1. The temperature sensor can be mounted to the right or left of the
terminal block, depending on which side is easiest to access and
the length of the cable from the new sensor.
2. Scrape the surface clean where the new temperature sensor is to
be mounted.
W
V
3. Place the temperature sensor as shown in the illustration.

4. Apply plastic steel over the sensor. Ensure that the entire sensor is
covered by the plastic steel.
5. Secure the plastic steel and sensor with masking tape and allow to
harden.
6. Remove the masking tape. The temperature sensor should now be
fixed in place and covered entirely by the plastic steel.
7. Remove the ferrite block from the old sensor and mount it on the
cable for the new sensor.
8. Remove the contact from the broken sensor, which is attached to
the motor.
9. Place the new sensor contact in the old bracket and connect it to
the wiring harness.
10. Fasten the old contact and its wiring harness using a cable tie so it
cannot damage anything.
10.1.2 Replacing the motor speed sensor

1. Remove the screw (a) (5 mm Allen screw) and withdraw the sen-
sor.
2. Loosen the cable clamp (b) (3 mm Allen screw).
3. Loosen the sensor cable connection (c) from the motor by pushing
a in the locking pin on the rear of the contact.
b 4. Reassemble in reverse order. Tightening torque 6 Nm.

Motors 1000
Pump motor (1710)
7510399-020 2012-10-03 6070557 815, 816
10.2 Pump motor (1710)
10.2.1 General
The pump motor is integrated with the hydraulic pump.
This section contains instructions for bearing replacement and shaft
seals.
For removal of the pump motor from the truck, removal of the hydraulic
pump, and refitting of these, See section “15.2 Hydraulic unit (6100)”..
The pump motor dismantled

Motors 1000
Pump motor (1710)
815, 816 6070557 2012-10-03 7510399-020
10.2.2 Replacing the bearing on the pump

motor
Dismantling the pump motor
Motor without pump
1. On the stator (b) and the N (e) and D-shield (drive end) (a), mark
where these are located in relation to one another.
2. Unscrew the four screws (g) holding the power terminal block (h) in
the N-shield.
3. Remove the four long screws (c) (6 mm Allen screws).
4. Remove the pulse transducer (d) (5 mm Allen screw) from the N-
shield and loosen the cable clamp (f) (3 mm Allen screw).
e
d
c
f
b g
h
a
5. Lift out the N-shield (e) and spring washer (j).

Motors 1000
Pump motor (1710)
7510399-020 2012-10-03 6070557 815, 816
6. Remove the seal (n) and locking ring (m) from the armature shaft.
s 7. Lift the armature (k) out of the stator (b).
k 8. Remove the D-shield (a) from the stator.
9. Remove the locking ring (o) and stay ring (p).
o 10. Remove the bearings (s, q) from the armature and the D-shield us-
ing a puller.
p
q

Motors 1000
Pump motor (1710)
815, 816 6070557 2012-10-03 7510399-020
Reassembling the pump motor

Ensure all parts are intact and clean before assembly.
o
1. Place a bearing (q) in the D-shield (a).
p 2. Place the stay ring (p) and locking ring (o) in the D-shield (a).
q 3. Place the stator (b) in the D-shield in line with the markings made
during dismantling.
4. Push the bearing (s) onto the armature shaft.
5. Place the armature in the D-shield.
6. Slide the locking ring (m) onto the armature shaft.
7. Fit the seal (n) using the assembly device.
NOTE
Always use a new seal when fitting the armature shaft.
8. Fit the spring washer (j) and N-shield (e).
9. Secure the four screws (g) holding the power terminal block (h) in
the N-shield.
e
10. Fit the four long screws (c) - tightening torque 15 Nm.
11. Place the pulse transducer (d) in the N-shield and attach the cable
clamp (f).
j e
d
c
f
b g
h
a
12. Attach the pulse transducer's connector unit in the bracket under
the power terminal block.

Motors 1000
Steering motor and steering unit (1730)
7510399-020 2012-10-03 6070557 815, 816
10.3 Steering motor and steering unit

(1730)
10.3.1 General
The steering motor can turn the drive unit through 360°.
This section contains instructions for steering motor replacement.
10.3.2 Layout of the flange holes
b
a
View from the underside of the steering motor.
a: Mounting,
b: Steering,
c: Threaded M10 holes

Motors 1000
Steering motor and steering unit (1730)
815, 816 6070557 2012-10-03 7510399-020
10.3.3 Removing the steering motor from the

truck
1. Open the motor compartment.See section “9.2.1 Opening the mo-
tor compartment”.
2. Disconnect the connector unit from the steering motor. The con-
nector unit is locked with a catch (arrow) that must be pressed out
before the connector unit can be undone.
3. Remove the three fixing screws (8 mm Allen screws) on the steer-

ing motor.
4. Remove the motor. The motor bracket has a guide pin (a) that can
jam when removing the motor. Use M10 screws as a puller in the
threaded holes if the motor gets jammed.
10.3.4 Fitting the steering motor in the truck

1. Clean the guide pin hole in the motor bracket and fit the motor.
Tightening torque 45 Nm.
2. Connect the connector unit for the steering motor and press the
locking catch in.

Motors 1000
Fan motor/fan (1740)
7510399-020 2012-10-03 6070557 815, 816
10.4 Fan motor/fan (1740)
10.4.1 General
There are two fans in the truck's motor compartment. One fan cools the
motors' frequency converter and the other ventilates the entire motor
compartment.
This section contains instructions for fan replacement.
10.4.2 Replacing the frequency converter

cooling fan
Standard truck
tor compartment”.
2. Remove the foot step and the floor and pedals. See section
“9.4.4 Disassembling/assembling the floor plate, B version 0680”.
Ergo truck
tor compartment”.
2. Remove the covers covering the MCU and the traction and lift tran-
sistor regulators.
3. The top cover (a) can be lifted off without any tools (snap fastener).
4. The cover on the fan exhaust is screwed on with three screws (b)
(12 mm Allen screws).
a

Motors 1000
815, 816 6070557 2012-10-03 7510399-020
5. Disconnect the cooling fan wiring harness.

6. Remove the screw (c) (10 mm hexagonal screw) holding the cool-
ing fan's mounting bracket.
7. Remove the cooling fan (d).
8. Fit the new cooling fan. Ensure the two pins in the cooling fan's
mounting bracket engage with the vibration dampers (e) in the
cooling block.
c
d
e
Standard model
Ergo model
9. Screw the cooling fan into place.

10. Connect the wiring harness.
11. Refit any covers or the floor.

Motors 1000
7510399-020 2012-10-03 6070557 815, 816
10.4.3 Replacing the motor compartment

cooling fan
tor compartment”.
2. Disconnect the cooling fan wiring harness (c).
3. Remove the screws (a) (6 mm Allen screws) holding the cooling fan
and air duct in place.
4. Remove the cooling fan from the air duct - 4 slotted-head screws
(b).
5. Fit the new cooling fan.
6. Screw the cooling fan into place.
a b
a c

Motors 1000
Drive motor (1760)
815, 816 6070557 2012-10-03 7510399-020
10.5 Drive motor (1760)
10.5.1 General
The drive motor is integrated with the drive gear to form a complete
drive unit that can be steered through 360°.
This section contains instructions for drive motor replacement, disman-
tling/assembly of the drive motor, and bearing replacement.
The drive motor dismantled

Motors 1000
Drive motor (1760)
7510399-020 2012-10-03 6070557 815, 816
10.5.2 Removing the drive motor from the

truck
Tools
Lifting eye V11-1258 (M12x20 mm)

tor compartment”.
W
V
2. Disconnect the power cables from the drive motor.

13 mm
×3
3. Undo the connector units for the temperature sensor and pulse
W
V
transducer.
4. Undo the brake line connector unit.

Motors 1000
Drive motor (1760)
815, 816 6070557 2012-10-03 7510399-020
5. Remove the six screws (6 mm Allen screws) holding the drive mo-
W
tor in place.
V
6. Remove the cap from the centre of the parking brake (2.5 mm Allen
screws).
7. Attach the lifting eye V11-1258 (M12x20 mm) to the drive motor
shaft.
8. Carefully lift the motor straight up; paying attention to the splines on
the output shaft of the motor. The motor weighs approximately 40
kg.
NOTE!
Risk of spline damage.
The splines on the end of the motor are easily damaged.
Be careful when lifting out the motor.

Motors 1000
Drive motor (1760)
7510399-020 2012-10-03 6070557 815, 816
10.5.3 Dismantling the drive motor

1. Remove the parking brake,See section “12.2.4 Removing the park-
ing brake from the truck”..
2. On the stator (b) and the N (f) and D-shield (drive end) (a), mark
where these are located in relation to one another.
3. Remove the pulse transducer (d) and loosen the cable clamp (g).
4. Unscrew the four screws (h) holding the power terminal block (j) in
the N-shield.
5. Remove the two locking rings (e) from the motor shaft.
6. Remove the long screws (c).
e
d
g
c
h
b
j
7. Lift the N-shield and the armature (k) out of the stator.

Motors 1000
Drive motor (1760)
815, 816 6070557 2012-10-03 7510399-020
8. Pull the N-shield off the armature using a standard puller.

9. Remove the locking ring (m).
10. Push the ball bearing (n) out of the N-shield.
11. Use a light tap to carefully remove the drive-end shield (a) from the
stator (b).

Motors 1000
Drive motor (1760)
7510399-020 2012-10-03 6070557 815, 816
10.5.4 Cleaning
The motor should be cleaned dry, preferably by vacuuming it. Do not
wash the motor in water.
The insulation resistance on a cleaned and dry motor should be in
excess of 1 G ohm under cool conditions.

Motors 1000
Drive motor (1760)
815, 816 6070557 2012-10-03 7510399-020
10.5.5 Assembling the drive motor

Ensure all parts are intact and clean before assembly.
1. Using standard tools, insert a new ball bearing (m) in the N-shield.
2. Fit the locking ring (n).
3. Position the D-shield (a) against the stator (b) in line with the mark-
ings.
m NOTE!
If the original parts are being used, the stator (b) and the D-shield
(drive end) (a) should have their relative mounting positions clearly
n
marked, as in the illustration.
4. Insert the armature shaft into the bearing and fit the locking rings
(e) on the armature shaft.
5. Insert the armature (k) with the N-shield into the stator.

Motors 1000
Drive motor (1760)
7510399-020 2012-10-03 6070557 815, 816
6. Insert the screws for the power terminal block (h) and tighten.
7. Insert and tighten the long screws (c) - tightening torque 15 Nm.
8. Refit the speed sensor (d) along with its wiring harness (g).
9. Replace the contact in the holder under the power cables.
10. Fit the parking brake, See section “12.2.5 Installing the parking
brake in the truck”.”.
e
d
g
c
h
b
j

Motors 1000
Drive motor (1760)
815, 816 6070557 2012-10-03 7510399-020
10.5.6 Fitting the drive motor in the truck

1. Lubricate the splines on the output shaft of the motor with Klüber-
plex BEM34-132 (226158).
2. Attach a lifting eye to the shaft end of the motor and lift the motor
into place in the truck, paying attention to the splines on the shaft
end.
3. Turn the motor shaft if the motor output shaft does not engage with
the gearbox.
4. Secure the motor. Tightening torque 25 +4/–2 Nm.

5. Connect the power cables on the motor - tightening torque 20 Nm.
6. Connect up the connector units for the sensor and brake.
7. Fit the cap in the centre of the parking brake (2.5 mm Allen screws).

Motors 1000
Drive motor (1760)
7510399-020 2012-10-03 6070557 815, 816

Motors 1000
Drive motor (1760)
815, 816 6070557 2012-10-03 7510399-020

Drive gear 2000
General
7510399-020 2012-10-03 6070557 815, 816
11 – Drive gear 2000
11.1 General
The drive gear is integrated with the drive motor and brake to form a
complete drive unit which can be steered through 360°.
d e c
a: Oil filler plug, b: O-ring, c: Lower cap, d: Drain plug,
e: Screw for lower cap (8 each)
11.2 Repair- and serviceability
Action Level Remarks

Checking the oil Service See “11.3.1”
level.
Oil change Service See “11.3.2”
Sealing leaks Repairs See “11.3.3”
Replacing the drive Repairs See “11.3.4”
gear
Reconditioning Not Special training required
possible Special tools required

Drive gear 2000
Measures
815, 816 6070557 2012-10-03 7510399-020
11.3 Measures
Switch off the truck and pull out the battery connector when working in
the motor compartment and with the drive gear. When checking the oil
level and changing oil, you must turn the drive wheel to such a position
that the fill and drain plugs are accessible.
11.3.1 Checking the oil level.

1. Park the truck on level ground and block it so that it will not start
rolling.
×n 2. Carefully clean the area around the oil filler hole (a).
3. Loosen the oil filler plug. Remove the plug and the sealing ring.
4. Use a pump intended for oil changes, and refill with new gear oil.
s mm
The correct oil level is when the oil reaches the lower edge of the
Step 3: s = 6, n = 1
plug of the refilling hole.
5. Replace the plug of the refilling hole. Always use a new sealing
ring.
×n 6. Wipe off any excess oil from around the area of the refilling hole.
Note:
Remove any spilled oil using a suitable binder.
s mm
Step 5: s = 6, n = 1
Mv = 22 Nm

Drive gear 2000
Measures
7510399-020 2012-10-03 6070557 815, 816
11.3.2 Oil change

Note:
Handle the old oil in accordance with applicable environmental
regulations.
DANGER!
Risk of burn injuries!
If the truck has just been used, the oil can be very hot!
When draining the oil, it must be done so that no hot oil can come into
a contact with the skin or be absorbed by clothing.
rolling.
2. Carefully clean the area around the hole for refilling (a) and
×n draining (b) oil.

3. Remove the fender (a).
4. Place a container – RRE140/160: approx. 5 l, RRE 180/250
s mm approx. 6 l – to collect the oil under the drain plug hole.
Steps 4 & 5: s = 6, n = 1 5. Loosen the oil drain plug. Remove the plug and the sealing ring.
7. Allow all the oil to drain into the container.
8. Clean the magnet on the drain plug, replace the sealing washer
and screw back the plug.
×n 9. Use a pump intended for oil changes, and refill with new gear oil.
The correct oil level is when the oil reaches the lower edge of the
plug of the refilling hole.
s mm 10. Change the seal on the oil level plug (a) and fit it.
Steps 7 & 10: s = 6, n = 1 11. Wipe away any excess oil.
Mv = 22 Nm Note:
Oil refill table.

The amount of oil is also written on the drive gear identification plate.
Model Gear Volume

RRE 140-160 GK25 3.3 L
RRE 180-250 GK30 4.7 L

Drive gear 2000
Measures
815, 816 6070557 2012-10-03 7510399-020
11.3.3 Leakage from the bottom cap

rolling.
×n 2. Carefully clean the area around the hole for refilling (a) and
draining (b) oil.
3. Place a container – RRE140/160: approx. 5 l, RRE 180/250
s mm approx. 6 l – to collect the oil under the drain plug hole.
Steps 4 & 5: s = 6, n = 1 4. Loosen the oil drain plug. Remove the plug and the sealing ring.
6. Allow all the oil to drain into the container.
7. Loosen the screws (e) and remove the cap (c) from the drive gear.
×n
s mm
Step 7: s = 5, n = 8
8. Clean the magnet on the drain plug, replace the sealing washer
and screw back the plug.
×n 9. Replace the O-ring (b) on the cover.

10. Put a drop of oil on the bolts before fitting.
11. Screw on the cap, taking care not to damage the O-ring.
s mm
12. Fill the gearbox up with new oil as far as the upper oil level plug (a).
Steps 8 & 13: s = 6, n = 1
Mv = 22 Nm 13. Replace the seal on the oil level plug (a) and fit it.
14. Wipe away any excess oil.
Note:
×n
s mm
Step 11: s = 5, n = 8
Mv = 46 Nm

Drive gear 2000
Measures
7510399-020 2012-10-03 6070557 815, 816
11.3.4 Replacing the drive gear

Special tools
Lifting eye for motor
3 screws, M12x110 mm
Exposing the drive gear

1. Open the motor compartment.See section "9.2.1 Opening the
motor compartment".
2. Remove the fender (a) and the step plate (b).
×n
s mm
Step 2: s = 8, n = 6
3. Remove the fixing screw (arrow) for the floor and pedals.
4. Undo the connector units for the pedal harness (press the lugs of
the female contact together to undo the contact).
5. Remove the floor and pedals.
L
Removing a drive motor from the truck

See section "10.5.2 Removing the drive motor from the truck".
Removing a steering motor from the truck

See section "10.3.3 Removing the steering motor from the truck"..

Drive gear 2000
Measures
815, 816 6070557 2012-10-03 7510399-020
Removing the drive gear from the truck

1. Undo the locking nuts on the drive wheel.T
2. Use a jack to raise the truck by approximately 16 cm.

3. Support the truck:
4. Remove the drive wheel. See section "12.3.2 Removing the drive
wheel from the truck".
×n 5. Undo the six gear screws.
s mm
Step 6: s = 10, n = 6

Drive gear 2000
Measures
7510399-020 2012-10-03 6070557 815, 816
6. Place a block of wood, approximately 70×70 mm, under the gear.

7. Lower the truck so that the gear is resting on the block of wood.
8. Remove the screws holding the gear.

9. Raise the truck by 21 cm and chock up the truck.
10. Lower the gear onto the floor.
11. Extract the gear in a lying down position.
Note:
The gear weighs approx. 60 kg.

Drive gear 2000
Measures
815, 816 6070557 2012-10-03 7510399-020
Fit the drive gear back in the truck

1. Place the gear in a standing position on the floor under the truck.
2. Lower the truck over the gear.

3. Place three screws, M12x110 mm, in the fixing holes to hold the
gear in place.
4. Raise the truck and place spacers under the gear.

5. Lower the truck over the gear.
6. Screw the gear into place.
×n
s mm
Step 6: s = 10, n = 6
Mv = 97 Nm
7. Raise the truck and position the drive wheel. Fit the washers and
nuts and tighten the nuts by hand as hard as possible.
8. Lower the truck onto the wheel.

Drive gear 2000
Measures
7510399-020 2012-10-03 6070557 815, 816
9. Torque tighten the drive wheel nuts.
Placing the steering motor in the truck

×n See section "10.3.4 Fitting the steering motor in the truck".
s mm Placing the drive motor in the truck

See section "10.5.6 Fitting the drive motor in the truck".
Step 9: s = 19, n = 7
Mv = 130 Nm Concluding work
1. Screw the floor and pedals back into place. Join the connector unit
for the pedal harness.
2. Screw the fender back into place behind the drive wheel and foot
step.
×n 3. Function test the truck.
s mm
Step 2: s = 8, n = 6

Drive gear 2000
Measures
815, 816 6070557 2012-10-03 7510399-020

Brake and wheel 3000
Travel brake system (3100)
7510399-020 2012-10-03 6070557 815, 816
12 – Brake and wheel 3000
12.1 Travel brake system (3100)
12.1.1 Removing the support arm's multiple

disc brake
”See section “12.5.1 Removing the support arm wheel from the truck”.
12.1.2 Dismantling the multiple disc brake

e
d
c
g
b
1. Lift the brake from the support arm wheel.

2. Place the brake on a clean, dry workbench with the end plate (d)
uppermost.
Note!
Take care not to damage the components and wiring harness during
×n this and subsequent operations.
3. Undo and remove the socket head cap screws (e) and their wash-
ers.
s mm
4. Remove the aluminium end plate (d).
Step 3: s = 4, n = 6
Note!
Make a note of the number of shims (f) on each spacer (g).
5. Lift off the pressure plate (c) and the transmission clutch pack,
which consists of four outer discs (a) and three inner discs (b).
6. Remove the brass plate (h).

815, 816 6070557 2012-10-03 7510399-020
Inspection
1. Check the thickness of the discs.
The nominal thickness of a new disc = 2.0 mm.
Limit for wear = 1.4 mm.
2. When replacing discs:
Replace all inner and outer discs at the same time. Do NOT replace
individual discs.
3. Check that the discs are flat and that there is no damage to the
splines or recess.
4. Check the electrical resistance of the magnetic coil.
Nominally 47.7 ohms ± 10% at 20 °C.
Note!
The resistance can be measured with the brake/wheel fitted to the
truck.
Adjusting play
1. Disconnect the MCU connection and connect the brake to 48
V DC.
2. Check the amount of play, measurement A, with the brake en-

gaged.
Note!
Check play at two points simultaneously, with 180° between the
points.
3. Maximum permitted play = 2.25 mm.

7510399-020 2012-10-03 6070557 815, 816
4. Nominal play on a newly-adjusted brake should be 1.0 – 1.25 mm.

5. To adjust, remove the aluminium end plate.
6. Remove the shims (f) when adjusting due to wear, or add shims
when replacing with new discs.
Each shim is 0.127 mm thick.
7. Fit the aluminium end plate, connect to 48 VDC and check play.
8. Once play is within the nominal permitted limits, fit the brake to the
wheel and the wheel to the truck.
Assembling the multiple disc brake

1. Clean the parts carefully.
×n Note!
Use only a wire brush and dry cloth for cleaning.
2. Assemble the brake in reverse order.
s mm
3. Connect the brake to 48 V DC.
Step 2: s = 4, n = 6
4. Check play between the end plate and the pressure plate (brake
disengaged). Adjust play if necessary.
12.1.3 Installing the multiple disc brake in the

truck
1. Check that the brake engages and releases when intended. Con-
nect the brake to 48 V DC. Switch the power off and on.
j
2. Check that the play between the end plate (d) and the pressure
plate (c) is 1.0 – 1.25 mm with the power on (brake disengaged).
Play may need adjusting - see the section "Adjusting play".
Note!
Check play at two points simultaneously, with 180° between the
points.
3. Fit the brake into the support arm wheel. Make sure that the splines
of the inner discs are positioned correctly so that they reach the
splines on the wheel hub without being obstructed.
4. Fit the wheel to the support arm - see the section "Fitting the sup-
port arm wheel to the truck".
Make sure that the locking shoe (j) is seated correctly in its recess
in the support arm.
5. Connect the brake wiring harness (k) and check the braking func-
tion by pressing the brake pedal fully down.

815, 816 6070557 2012-10-03 7510399-020
12.1.4 Checking the wheel brake's brake

force
1. Raise the truck and support it using blocks so that the support arm
wheel is clear of the floor.
2. Check that the wheel rotates freely.
3. Connect the brake to 48 V DC.
4. Check that the wheel cannot turn.

Parking brake (3300)
7510399-020 2012-10-03 6070557 815, 816
12.2 Parking brake (3300)
12.2.1 General
The parking brake is a single-stage electromagnetic spring-assisted
brake which is activated when its magnetic coil is not powered.
DANGER!
The brake is a safety component. Do not interfere with the brake compo-
nents.
a
b
a. Fixing screws
b. Magnet housing
g
c. Pressure plate
d. Adjusting screws
e. Friction disc
f. Pressure plate (fixed)
h
g. Locking screws
h. Hub

815, 816 6070557 2012-10-03 7510399-020
12.2.2 Emergency release of the parking

brake
If the parking brake will not disengage due to some fault other than the
parking brake itself being broken, there is a power switch in the fuse
box under the truck's foot step which energises the parking brake
directly, even if the truck is not running.
DANGER!
Make sure that the truck cannot accidentally start to roll when the brake
is released.
If the parking brake does not work at all, it must be removed from the
truck. See section “12.2.4 Removing the parking brake from the truck”.
12.2.3 Checking the brake force

×n 1. Raise the truck so that the drive wheel is clear of the ground. See
section “3.3 Safe lifting”.
2. Open the motor housing covers. See section “9.2.1 Opening the
s mm motor compartment”.
Step 3: s = 2.5, n = 2 3. Remove the cap from the centre of the parking brake.
4. Insert the M12 bolt into the hole in the motor shaft (for lifting), and
screw in. Use a torque wrench and an M12 flange bolt, or a normal
bolt with a flat washer. The maximum length of the M12 bolt should
be 20 mm.
Torque wrench setting: 90 Nm.
Note!
Bolt grade must be at least 10.9.
5. Using the torque wrench, turn the motor shaft until the brakes are
released.
6. The brake force is too low if the brake is released before the torque
wrench starts to slip.
7. Adjust the brake play to the correct value. See section “ Adjusting
the air gap”.
8. Check the brake force once more using the torque wrench.
9. Replace the cap.
×n
s mm
Step 9: s = 2.5, n = 2

7510399-020 2012-10-03 6070557 815, 816
12.2.4 Removing the parking brake from the

truck
×n 1. Switch off the truck and open the motor compartment. See section
“9.2.1 Opening the motor compartment”.
2. Remove the electrical connection for the parking brake (arrow) that
s mm links it to the truck's electrical system.
3. Remove the screws (a) holding the parking brake in position on the
Step 3: s = 5, n = 3 motor. (The Allen key can be inserted through the holes in the
brake at each screw position.)
4. Remove the brake unit from the motor shaft. The spline sleeve (h)
can be taken out with the brake or can remain on the motor shaft.
.

815, 816 6070557 2012-10-03 7510399-020
Dismantling and checking for wear
×n
s mm
Step 1. Step 3, s: 4 mm, n: 3.

6
5
4
3
2
1
0
Step 4. Step 5. Step 6.
×n
s mm
Step 7. Step 8, s: 4 mm, n: 3, T: 9 Nm ±10 %.

7510399-020 2012-10-03 6070557 815, 816
Required tools
• 4 mm Allen key
• Sliding calliper
Procedure
1. Verify that the pressure disk has been mechanically relieved with
two M6×40 screws.
2. Place the brake assembly on a clean, dry work bench with the mag-
net housing facing downwards.
3. Loosen the locking screws, 3 × 4 mm socket head cap screws.
4. Remove the fixed pressure disk.
5. Remove the friction disk and verify that the thickness is minimum
10.5 mm.
6. Place the friction disk on the revolving pressure disk.
7. Place the fixed pressure disk on top of the friction disk, making sure
the locking screw holes are correctly positioned.
8. Secure the fixed pressure disk with 3 × 4 mm socked head cap
screws to a tightening torque of 9 Nm ±10%.
9. Adjust the air gap as follows.

815, 816 6070557 2012-10-03 7510399-020
Adjusting the air gap
Required tools Step 1.
×n
s mm
Step 2, s: 4 mm, n: 3. Step 3.
×n
s mm
Step 4, s: 4 mm, n: 3, T: 9 Nm ±10 %.
Step 5.

7510399-020 2012-10-03 6070557 815, 816
Required tools
• 11 mm spanner wrench
• 4 mm socket head sleeve
• 9 Nm torque wrench
• 0.3 mm and 0.4 mm feeler gauges
Procedure
1. Verify that the revolving pressure disk has been mechanically re-
lieved with two M6×40 screws.
2. Loosen the three locking screws until the adjustment screws can
be turned.
3. Adjust the air gap by turning the adjustment screws
– counter-clockwise to increase the air gap
– clockwise to reduce the air gap
4. Tighten the locking screws to a torque of 9 Nm ±10%.
5. If necessary, repeat the adjustment until a 0.3 mm feeler gauge can
be inserted, but not a 0.4 mm gauge. Measure the air gap between
the magnet housing of the brake assembly and the revolving pres-
sure disk after the locking screws have been tightened.

815, 816 6070557 2012-10-03 7510399-020
12.2.5 Installing the parking brake in the truck

1. Fit the key and hub (h) on the motor shaft.
2. Fit the brake on the hub.
a 3. Before fitting the brake, check that the friction disc is centred in re-
lation to the magnet housing.
- It may be necessary to apply 48 V DC to the magnetic coil to po-
b sition the friction disc correctly.
4. Insert the fixing screws (a) for the brake unit and tighten them.
5. Place the cap over the centre of the brake.
6. Check play between the magnet housing and the pressure plate
h with the brake fitted.
7. Connect the brake cable (arrow) to the truck’s electrical system.
8. Start the truck and release the parking brake.
9. Check that the friction disc rotates freely.
Cut the voltage and check that the pressure plate locks the friction
disc and that play is correct.
Note!
Do not hammer the friction disc onto the motor shaft, as this may
cause cracks in the brake disc, resulting in it breaking.
Push the friction disc onto the motor shaft instead.
×n
s mm
Step 4: s = 5, n = 3
T=17±1.7 Nm.
×n
s mm
Step 5: s = 2.5, n = 2
T=17±1.7 Nm.

Drive wheel (3530)
7510399-020 2012-10-03 6070557 815, 816
12.3 Drive wheel (3530)
12.3.1 General
To avoid heavy and uncomfortable lifting when changing the drive
wheel, you can use a board or a sheet of metal (or two, if the board or
sheet does not easily slide over the floor surface).
12.3.2 Removing the drive wheel from the

truck
1. Withdraw the battery cut-out connector.
2. Remove the fender by the drive wheel.
3. Raise the truck by approximately 1 cm. Remember to secure the
truck with blocks to prevent it dropping down onto its chassis if the
jack were to fail.
4. Turn the drive wheel so that the nuts are facing you. Apply an iron
bar against the gear rim, taking care not to damage the teeth.
5. Raise the truck so that a plank/sheet of metal can be pushed under
the drive wheel. This is then used to withdraw and insert the wheel
under the truck.
6. Undo the 7 nuts, and remove them along with the washers.
7. Pull the wheel away from the gear - the truck may need to be raised
slightly as you do this.
8. Once the wheel is on the plank, raise the truck by approximately 10
cm plus the thickness of the plank.
9. Using the plank, withdraw the wheel.
12.3.3 Installing the drive wheel on the truck

1. Roll the new wheel onto the plank and push the wheel and plank
under the truck.
2. Align the wheel holes so that they line up with the stud bolts.
3. Lower the truck while pushing the wheel in against the gear.
4. Lower the truck so that the stud bolts are level with the holes on the
wheel.
5. Push in the plank with the wheel so that the wheel is in the proper
position.
6. Fit the washers and nuts.
7. Tighten the wheel nuts - tightening torque 130 Nm.
8. Refit the fender by the drive wheel.

Wheel bolt (3530)
815, 816 6070557 2012-10-03 7510399-020
12.4 Wheel bolt (3530)

General
The wheel bolts on the drive gear are stud bolts threaded in the hub.
12.4.1 Replacing wheel bolts

1. Remove the drive wheel. See section “12.3.2 Removing the drive
wheel from the truck”.
2. Wheel bolts with damaged threads should be removed using a stud
bolt tool.
3. Broken wheel bolts:
• Method 1: Drill a hole in the centre of the bolt and screw out the bolt
using a screw extractor for M14 bolts.
• Method 2: If the bolt will not come loose using a screw extractor, the
bolt must be drilled out.
- Centre-punch the centre of the bolt; be precise when centring the
punch.
- Drill a pilot hole through the bolt using a 5 mm bit.
Drill out the bolt using an 11.5 mm bit.
- Try to remove the remains of the bolt using pliers or a similar tool.
If that does not work, remove the remains by clearing the thread
with a M14x1.5 tap.
4. Smear some LOCTITE 270 onto the thread of the wheel bolt.
Fit the new wheel bolt using the stud bolt tool.
Tightening torque: 80 Nm
5. Fit the drive wheel. See section “12.3.3 Installing the drive wheel
on the truck”.
6. Insert the battery cut-out connector.

Support arm wheel (3550)
7510399-020 2012-10-03 6070557 815, 816
12.5 Support arm wheel (3550)
12.5.1 Removing the support arm wheel from

the truck
1. Raise the truck and support it using blocks so that the support arm
wheel is clear of the floor.
2. Remove any guard (a) over the support arm wheel.
3. Remove the protective cover (b) over the cable to the braked sup-
port arm wheel and pull out the cable until the connector unit in the
support arm can be accessed. Undo the connector unit.
4. Unscrew the screw (e) 1 cm and tap it in so that the axle (c) is eject-
ed from the support arm.
5. Remove the screw (e) and screw an M16 screw into the axle (d)
and withdraw this from the support arm.
6. Remove the support arm wheel.
d e

815, 816 6070557 2012-10-03 7510399-020
12.5.2 Replacing a wheel bearing - braked

wheel (A)
1. Remove the spacer rings (n), (m) and locking rings (g, k).
2. Tap out the bearing (h) and axle (f).
3. Fit a new bearing on the axle (f).
4. Insert the locking ring (k) into the wheel.
5. Fit the bearing and axle in the wheel.
6. Fit the second locking ring (g).
7. Insert the spacer rings (n) and (m) in the wheel.
A
f
j
k
m
n

7510399-020 2012-10-03 6070557 815, 816
12.5.3 Replacing a wheel bearing - unbraked

wheel (B)
1. Remove the sealing rings (o, t) and locking rings (p, s).
2. Tap out the bearing (q) and axle (r).
3. Turn the wheel over and remove the other bearing (q).
4. Fit a new bearing on the axle (r).
5. Slide the locking ring (p) onto the axle outside the bearing.
6. Fit the bearing and axle in the wheel.
7. Insert the second bearing (q) into the wheel and slide the locking
ring (s) onto the axle.
8. Fit the washers (o, t) on the wheel.
B
o
p
q
q
r
s
t

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12.5.4 Fitting the support arm wheel to the

truck
1. Position the support arm wheel correctly in the support arm.
2. Insert axle (c) and (d) correctly into the support arm.
3. Insert the screw (e) and washer into the axle - tightening torque 83
Nm.
4. Braked wheels:
Connect the brake connector unit to the cable in the support arm.
Insert the connector unit into the support arm.
Replace the protective cover (b) over the cable.
5. Replace any guards (a, b) over the support arm wheel.
6. Lower the support arm and function-test the truck.
d e

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12.5.5 Wheel wear and tear
H H
Type mm Normal measure- Minimum measure-

ment, mm (H) ment, mm
Drive wheel D = 400 30 15
Drive wheel D = 350 30 15
Support arm wheel D = 25 12.5
350
Support arm wheel D = 25 12.5
300
Support arm wheel D = 20 10
265

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Electric steering wheel (4310)
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13 – Steering system 4000
13.1 Electric steering wheel (4310)
13.1.1 General
The steering wheel module has a pulse transducer fitted under the
steering wheel. The pulse transducer can be replaced without remov-
ing the operating console from the truck.
If the wiring harness inside the operating console needs to be replaced,
the entire operating console should be removed from the truck.
13.1.2 Replacing the pulse transducer on the

steering wheel module
1. Remove the four screws (a) (Torx 10) from the underside of the
steering wheel module.
2. Remove the bottom panel (b).
b 3. Remove the disc with the logo from the centre of the steering
wheel.
a 4. Remove the two screws (c) (Torx 20) and the washer (d).
5. Remove the steering wheel (e) and the spacer (f).
c
d
e
f
g
6. Undo the connector unit for the pulse transducer.
7. Remove the three screws (g) (Torx 20) holding the pulse transduc-
er (h) in place.
h
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13.1.3 Removing the operating console from

the truck
1. Expose the operating console by removing the screw (a) on the
right-hand side of the tiller arm and also the panel.
2. Remove the screw (b) for the other panel section, located in front of
the tiller arm. Remove the entire panel.
3. Undo the contact unit (c) by the wall.
d c
4. Remove the three screws (d) (Torx 30) holding the operating con-
sole in place and remove the operating console from the truck.

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13.1.4 Replacing the wiring harness in the

operating console
1. Remove the four screws (a) (Torx 10) from the underside of the
steering wheel module.
2. Remove the bottom panel (b).
3. Remove the two screws (c) (Torx 10) together with the pulse trans-
ducer.
4. Remove the top panel (d).
d
5. Undo the connector unit (e) by the transducer.

6. Remove the screws (Torx 25) and sleeve (g) by the steering wheel
module joint.
7. Unscrew the adjusting screw (f) all the way so that the steering
wheel module is free of the operating console.
e
f

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8. Prise the button (h) free of the operating console.

9. Remove the two screws (k) (Torx 10) and remove the casing (j)
from the operating console.
10. Remove the panel (m) (check for verification) from the operating
console.
DANGER!
Undo the springs carefully. Risk of personal injury.
j
k
h m
k
11. Remove the four screws (n) (Torx 15) and the cover (o).
12. Remove the screws (p) (Torx T25) and sleeve (q) by the joint for the
operating console's bracket.
13. Note how the cable is fixed in the operating console and then re-
move the cable.
p
q
14. Fit a new cable and reassemble in reverse order.

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13.1.5 Fitting the operating console in the

truck
1. Fit the operating console on the truck.
2. Tighten the three screws (d) (Torx 30) holding the operating con-
sole in place - torque 2 Nm.
3. Connect the contact unit (c) by the wall.
c
4. Refit the panels around the operating console.

Steering reference sensor (4350)
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13.2 Steering reference sensor (4350)

General
These instructions apply to the replacement of the steering reference
sensor [B17] located on the drive gear housing, up against the drive
motor.
When the sensor is to be replaced, disassemble the floor first. See
a
section “9.4.4 Disassembling/assembling the floor plate, B version
0680”.
13.2.1 Replacing the reference transducer

[B17]
The transducer does not need adjusting on replacement.
1. Remove the screw securing the old transducer (5 mm Allen screw).
2. Undo the connector unit for the transducer.
3. Fit the new transducer and screw it in tight.
4. Connect the wiring. The wiring should be routed as shown in Fig 1.
The wiring must not be routed as shown in Fig 2, as there is a risk
of the terminal coming loose.
Fig 1. Fig 2.
5. Refit the floor.

Steering bearings (4380)
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13.3 Steering bearings (4380)

If the steering bearing has to be replaced, remove the drive gear as per
the instructions - see the section "Replacing the drive gear".
13.3.1 Removing a steering bearing from the

drive gear
1. Undo the screws (a) and remove the steering bearing (b) from the
drive gear.
13.3.2 Fitting a steering bearing on the drive

gear
1. Apply Loctite 242 to the screws (a).
2. Using the screws (a), fit the steering bearing (b) on the drive gear.
Tightening torque 23 Nm.

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Electrical system 5000
Battery (5110)
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14 – Electrical system 5000
14.1 Battery (5110)
14.1.1 Battery recommendation

Exide gel batteries (e.g. Sonnenschein)
In BT's tests with Exide gel batteries, no recommendations were
obtained for parameter setting on any of BT's products.
BT does not therefore recommend these batteries.
Hawker Evolution gel batteries

After carrying out trials and tests, there are recommended parameter
settings for RRE with the Hawker Evolution gel battery. There are also
instructions for verifying and adjusting the set values.
These are the batteries that BT recommends.
There are clear guidelines on how to use Hawker Evolution gel
batteries.
- Evolution batteries are designed for low intensity use.
- Recommended use is one shift per day (a maximum of 8 hours).
- Weekly maximum is 6 days per week, with a limit on expected
service life of 1000 cycles.
- Maximum depth of discharge is 70%.
- The ambient temperature should be between +5°C and +35°C.
- The battery should be charged with a Hawker battery charger
complete with EZ control. Charging must be done according to
Hawker's instructions.
- The usual charging time is 12 hours.
- Equalising charging is required after 6 charging cycles.
- It is not permitted to store discharged batteries. The longest
permitted storage period is 2 months, but this must involve
charging once per month.

Battery (5110)
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14.1.2 Battery installation

Note:
Parameter no. 107 must always be checked and adapted to the battery
that is installed in the truck. The parameter settings depend on
battery type, truck type, battery size and the truck application.
Note:
Only change/install a battery that has the same weight as the original
battery. The weight of the battery affects the stability and braking
capacity of the truck. Information on the minimum permitted battery
weight is on the truck identification plate.
DANGER!
Battery weight that is too low results in a deterioration in stability
The battery weight must conform to the details specified on the truck
identification plate.
Replacement/installation of battery.
DANGER!
Always use an approved lifting device to lift the battery and use a
battery yoke that fits the battery.
1. Activate the parking brake.

2. Retract the mast to its innermost position.
3. Pull the handle at the bottom right in front of the operator's seat to
release the battery. The battery indicator on the instrument panel
lights up.
4. Extend the mast.

5. Switch off the truck.
6. Disconnect the battery connector and unhook the battery arm.
7. Release the catch on the side of the battery.

Battery (5110)
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Procedure without battery changing table

1. Lift out the discharged/old battery.
2. Insert the new battery.
.

4. Connect the battery connector on the battery.
battery and the battery wall. The wiring harness must lie in an 'S'
to the battery from the cable arm to the battery connector
according to the picture.
6. Retract the mast to its innermost position. Make sure the battery
catch engages in the battery lock. A sharp metallic sound will be
heard, confirming that locking has occurred.
Procedure with battery changing table

1. Connect the extension cables between the battery and the truck.
2. Release the catch on the side of the battery.
3. Slide out the discharged/old battery and move the truck.
4. Remove the extension cables.
5. Slide the new battery in past the catch.
7. Connect the truck's battery connector to the battery.
battery and the battery wall. The wiring harness must lie in an 'S' to
the battery from the cable arm to the battery connector according to
the picture.
9. Retract the mast to its innermost position. Make sure the battery
catch engages in the battery lock. A sharp metallic sound will be
heard, confirming that locking has occurred.

LID (5200)
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14.2 LID (5200)
14.2.1 Replacing the LID
1. Disconnect the wiring harness.

2. Undo the screw of the LID bracket (5 mm Allen screw) and remove
the LID.
3. Unscrew the bracket from the LID (Torx 25).
4. Install the new LID on the bracket.

5. Screw the bracket into the roof panel.
Note:
In order for the LID to be used, parameter 1106 must be activated.
LID (5200)
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14.2.2 Replacing the LID cold store cab
1. Disconnect the wiring harness.

2. Undo the two screws of the LID bracket (Torx 30) and remove the
LID.
3. Unscrew the bracket from the LID (Torx 25).

4. Install the new LID on the bracket.
5. Screw the bracket into the roof panel.
Note:
In order for the LID to be used, parameter 1106 must be activated.

Replacing pedals (5300)
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14.3 Replacing pedals (5300)
14.3.1 Accelerator and brake pedal

DANGER!
The accelerator and brake pedal are closed units and must not be
opened. If the pedal is not working properly, replace the pedal.
Opening up the unit may constitute a safety risk.
1. Switch off the truck and pull out the battery connector.
2. Loosen the connector unit from the pedal unit (a).
a
3. Remove the pedal's mounting screws (Allen 5 mm) (Torx T30)

4. The accelerator and brake pedal can be replaced individually.
When the pedal unit has been removed, separate the pedals.
6. Tightening torque 2Nm.
14.3.2 Safety pedal

2. Loosen the connector unit from the pedal unit (b).
3. Open up the pedal by loosening the locking heel in the front edge of
the pedal using a screwdriver.
4. Remove the pedal's mounting screws (Allen 5 mm) for ergo and
(Torx T30) for Std if the pedal is to be changed.
5. If the spring is to be changed, open up the pedal using a
screwdriver. Remove the broken spring and fit a new one.

Control console (5510)
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14.4 Control console (5510)
14.4.1 General
The control console is available in versions with three to five individual
controls or with a multifunction device.
DANGER!
Replace control if there is a fault with one of the control console's
controls. Do not open the control. If a control is opened, the
calibration is lost which may constitute a safety risk.
14.4.2 Replacement/installation of a control

An extra control (a fourth and fifth hydraulic function) can be fitted to the
cable harness already present.
1. Insert a feeler gauge (arrow) on the side of the control console, at
the joint in the panels.
2. Remove the cover (a).
3. Undo the four screws (c) (Torx 10) that hold the control.
4. Lift the control up.
5. Disconnect the control from the cable harness.
b
6. If the symbol/top (b) on a control is to be replaced:

- Using a pair of narrow pliers, press together the two locking pins
that are visible on the underside of the control arm nearest to the
potentiometer.
- Pull the top of the control upwards.
- Press the new top tightly into place on the control.
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14.4.3 Replacing the multi-function control

2. Loosen the screws (Torx 25) holding the control.
3. Lift up the multi-function control.
4. Disconnect the control from the cable harness.
DANGER!
Do not open the multi-function control. If the control is opened, the
calibration is lost which may constitute a safety risk.
Replacing the multi-function control's buttons.

The multi-function control is a sealed unit. Buttons may only be
replaced from the outside.

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14.4.4 Removing the control console from the

truck
1. Remove the armrest (a) and the box (b) under the armrest.
2. Undo the two contacts (c) under the armrest.

3. Remove the cable clamp (d) (10 mm hex).
c
d
4. Press in the catch (e) on the control console's side and push the
console into its rear position.
5. Rotate the catch (f) out, so that it points straight out of the control
console.
6. Release the control console by lifting it straight up. Take care that
the catch does not break off.
7. Remove the control console with its attendant wiring harness; be
careful with the connector units.

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14.4.5 Replacing the access card's circuit

board
WARNING!
Static electricity!
Risk of static discharge that can damage the electronics.
Before starting work on the electronics, make sure you take the
necessary steps to prevent static electricity - ESD protection.
1. Remove the control console according to“14.4.4 Removing the
control console from the truck”
2. Insert a screwdriver in the small hole to release the catch that locks
the access card unit (a).
3. Undo the cable connection. Angle the access card unit slightly so
as to draw it through the hole.
4. Connect the new card and refit.
5. Replace the console according to See section "14.4.8 Fitting the
control console in the truck".

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14.4.6 Dismantling the control console

WARNING!
Static electricity!
1. Remove the control console according to“14.4.4 Removing the
control console from the truck”
2. Insert a feeler gauge (arrow) on the side of the control console, at
the joint in the panels.
4. Remove the three screws (c) (Torx 20) on the bottom of the control
console in order to release the lower cover (b).

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5. Remove the four screws (d) (Torx 20) that hold the border (e)
around the display (f).
6. Disconnect the cable harness from the display. Use the clamp on
the contacts to undo the contact from the circuit board.
7. Remove the border and electronic card.
8. Remove the 10 screws (j) (Torx 20) from the bottom that hold the
inner plate (g) against the bottom section (h).
9. Release the panel adjustment catch (k) from its retainer in the sled
and lift the inner plate out (g).
k
j

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Installing an extra push button

1. Dismantle the control console.“14.4.6 Dismantling the control
console”
2. Install the new cable harness - see the wiring diagram.
3. Connect the cable harness to the display.
4. Refit the inner plate and the adjustment catch in the lower panel.
5. Remove the cover in the upper panel where the new push button is
to be fitted.
6. Press the new push button with its symbol firmly into the upper
panel.
7. Connect the wiring harness to the push button as specified in the
wiring diagram.
8. Refit the control console.
If the control console is equipped with an option wiring harness,
perform parts 5 - 8.
Replacing the travel direction selector with signal

button
1. Carry out steps 1–3 according to section “14.4.6 Dismantling the
control console” .
2. Remove the three screws (b) that hold the selector (a) in the panel.
3. Undo the cable connection and remove the selector from the panel.

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Replacing the display

WARNING!
Static electricity!
1. Carry out steps 1–6 according to “14.4.6 Dismantling the control
console”
2. Carefully prise the display out of its border and install the new
display.
3. Make sure the locking catch is fully down, and insert the contact in
the display. Press together, and use the catch to pull the contact
together; then lock the catch in place on the contact.
DANGER!
The display must not be repaired. Only replacement may be carried
out.
14.4.7 Assembling the control console

Reassemble in reverse order and replace the console. See section
"14.4.8 Fitting the control console in the truck".

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14.4.8 Fitting the control console in the truck

1. Put the wiring harness of the control console back in place. Insert
the connector units behind the panel and push them in towards the
opening near the armrest.
2. Place the control console in the track for the sled.
3. Push the console in until it reaches its rear position.
4. Rotate the catch (f) so that it points to the side.
5. Connect the two contacts (c) under the armrest.

6. Fit the cable clamp (d) (10 mm hex) with a torque of 3 Nm.
c
d
7. Replace the box (b) under the armrest, and then the armrest (a).
After mounting a new display, the truck will display error code 2.004.
1. Connect TruckCom .
2. Select “Copy truck configuration”
3. Select “Copy configuration to secondary unit: CID”.
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Magnetic sensor (5850)
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14.5 Magnetic sensor (5850)

General
The sensor [B47], for the automatic sideshift option to the centre
position, is mounted on a bracket located in front of the valve unit in the
fork carriage.
The sensor is connected electrically to contact [X40].
A
C
14.5.1 Replacing the magnetic sensor [B47]

2. Undo the two screws (A) that secure the sensor’s bracket (5 mm
Allen key).
3. Undo the connector unit for the sensor.
4. Undo the two screws (C) that secure the sensor and bracket (B) (3
mm Allen screws).
5. Replace the sensor. Tightening torque for screw (C) 1 ±0.2 Nm.
7. Secure the sensor bracket with screw (A) and washer. Adjust so
that there is an air gap between the sensor and the reference
magnet of 5 -1/+2 mm.
8. Check the sensor's function by activating the function or going to
the diagnostics screen: page 4, bit 20 (left) or 21 (right).

Magnetic sensor (5850)
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4 mm
D
5 +1/-2 mm
14.5.2 Reference magnet

The reference magnet (D) is mounted on the fork yoke and secured
with self-adhesive tape.
Before taping, the contact surfaces must be thoroughly cleaned with an
isopropanol/water solution (50/50). If necessary, the surfaces should
be de-greased before cleaning.
The magnet must be mounted lengthwise with a protrusion of 4 mm
behind the fork yoke and sideways centred above sensor [B47] when
the fork yoke is in the centre position. A recommended measurement
for the magnet location is 237.5 mm from the fork yoke’s side to the
magnet.
Also note that the magnet has a white mark. When fitting, this mark
must be to the left when viewed from the operator’s position.

Parameter settings
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14.6 Parameter settings

After the parameters have changed, the information will be copied from
the MCU to the CID at the next start-up of the truck. This is indicated
with an image of an hourglass.
If there is an error code that the MCU and the CID are missing the same
data, an active transfer must occur; see replacing CID.
14.6.1 Configuration menu

Calendar/hour counter menu
To set the current date and time, use the arrow keys to select the value
to be changed (hours, minutes, month and day), as well as the plus/
minus buttons to make the changes. The new settings are stored in the
MCU by pressing the green button (I). A service key is required to set
month and day.
Parameter menu (PAR)

To be able to change the parameters, a service key must be connected.
If the key is not connected, the parameters can only be read. It is not
possible to change the factory parameters without TruckCom.
Each parameter can be reached by entering the parameter number in
the box marked "Par". The parameter value can be entered using the
numerical keypad, or the plus/minus buttons.
The plus button increases the number by one (1) and the minus button
reduces it by one (1).
The value of the parameter is displayed in the box under "Par". The
value is changed by using the arrow key to select this box and then
entering the value with the keypad or the plus/minus buttons. The value
is saved by pressing the green button (I).
The parameter's default value can be selected by selecting the factory
icon and pressing the green button (I).

Parameter settings
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Setting operator parameters

Operator parameters that apply to the operator logged in on the truck can be
set from the operator parameter menu. The menu shows an operator
symbol at the top left-hand side of the screen. The number of the selected
operator's profile is displayed to the right. In the middle left-hand side of the
screen, icons are shown that indicate which of the operator parameters have
been chosen. The number of the selected parameter is displayed to the right
of this. At the lowest bottom left, the factory symbol is shown.
The arrow keys are used for moving between:
• the parameter symbol, where the +/- keys are used for choosing the
parameter that is to be entered
• the factory symbol, where the parameter value is reset to the default
setting when the green button is pressed
and
• the parameter values
The screen changes appearance depending on which operator parameter
has been chosen.
For parameter 1, the steering progressiveness, a screen is shown with two
adjustable fields representing high speed – “Hare” – and low speed –
“Snail”.
For parameters 2 to 5, a row of bars are displayed. The number of bars

depends on how many steps the selected parameter can be adjusted by.
The filled bars show the current parameter value.
When parameter values are chosen, the value that has been programmed is
indicated with an arrow above the bar for that value. The value is changed
using the +/- keys and is stored when the green button is pressed.
Operator parameter 6, the lift height at which the Ergo cab will begin to tilt, is
set from a menu with a special appearance.
The height is changed using the + and - keys or using the numerical keypad.

PIN menu
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14.7 PIN menu

All the PIN codes can be reset to their factory settings by selecting the
factory symbol (a) and then pressing the green (l) button. During the
time that the information is being stored in the MCU, an hourglass is
displayed on the screen.
The PIN block menu (b) and PIN programming menu (c) are accessed
from here.
The PIN codes are organised in blocks and profiles, with ten PIN codes
for each of the ten operator profiles.
Table 1: Standard PIN code set

Profile: 1 2 3 4 5 6 7 8 9 10
block 0 0001 0002 0003 0000 0000 0000 0000 0000 0000 0000
block 1 7901 1437 3731 1049 9439 7265 1322 2869 1574 5421
block 2 4854 2907 9175 5799 1490 3031 7392 5622 5023 1787
block 3 3174 1026 3815 6703 1179 5152 7514 5668 3215 4659
block 4 7110 5477 3846 9491 5918 8222 6923 8139 7025 9197
block 5 6276 9879 9658 1690 4042 5201 9807 4332 9715 2549
block 6 4142 8620 3754 8432 8788 7430 1948 2595 8527 7474
block 7 1482 7135 2395 7365 7092 4611 2831 4185 6067 1930
block 8 4731 1022 5377 3257 7334 9009 7881 8843 7436 2876
block 9 5878 2828 1910 6907 2136 5730 2957 7691 3162 3242

PIN menu
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14.7.1 Menu for activating a PIN block

Each PIN block can be activated (E, enable) or deactivated (D, disable)
separately.
The PIN blocks are listed in two columns with a number from 0 to 9.
Enabled/disabled status is indicated by an "E" or a "D" to the right of
each block number.
To change status, use the arrow keys to select a block. Use the plus
button to activate the block and the minus button to deactivate it. The
value is saved by pressing the green button (I) and the next block in the
list is selected.
When a PIN block is deactivated, all PIN codes for this block are set to
0000. When a PIN code is activated, all PIN codes are set to the default
values specified in Table 1.
14.7.2 Menu for programming a PIN (P)

It is possible to program your own PIN codes in this menu.
Use the block and profile number to select the PIN code to be changed;
the value for the block and profile is changed using the plus/minus
buttons or numerical buttons.
If 0000 is entered as a PIN code, the profile cannot be accessed without
using the service key.
A new PIN code is entered using the numerical buttons in the PIN box.
The value is saved in the MCU by pressing the green button (I).

Calibrations
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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 the neutral (unactuated)
position. 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.

Calibrations
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14.8.2 Height measurement/reach movement

length calibration
Figure Meaning
Movement must be upwards
Movement must be downwards
Calibration ready
Movement must be inwards
Movement must be outwards
Calibration ready

Calibrations
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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 in 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 2012-10-03 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. Lift 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
programmed value in number 6 will then change when new
adjustment occurs.
Calibrations
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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
1. Go to screen 8. If you are in screen 7, this is done by putting the
marker in the top box and pressing the plus button. Confirm using
the green button (I).
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
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14.8.3 Valve calibration

The valve mode is used to calibrate the valves. The following valves
can be calibrated:
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.

Calibrations
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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.

Calibrations
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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.

Calibrations
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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.

Calibrations
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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.

Calibrations
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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.

Calibrations
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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.
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
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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.

Calibrations
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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.

Calibrations
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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. Press the plus button at intervals of approximately 0.5–1 second
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. Press the plus button at intervals of approximately 0.5–1 second
until the cab starts to sink.
15. Switch off the truck by pressing the red button (O) to save the
calibration.

Calibrations
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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 indicator

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.

Calibrations
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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.

Replacing the wiring harness
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14.9 Replacing the wiring harness
A
B
C
0
Pos. Description
A Connector lock
B Connector, female part
C Bracket
D Connector, male part
Proceed as follows when replacing the wiring harness:

1. When prying the X connectors apart, press in the connector lock
(A) to the female part (B) and pull upwards.
2. Disconnect the female part (B) of the connector from the male part
(D).
3. Then remove the male part (D) by pulling it downwards.
The bracket (C) remains on the connector panel.

main computer unit MCU (A5)
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14.10 main computer unit MCU (A5)

The MCU is the truck's main computer and regulates driving, steering
and fork lifting/lowering. The MCU must communicate with the driving
regulator, lifting regulator, steering servo and displays via CAN
(Controller Area Network). In the MCU, the settings for the truck’s
programmable parameters are stored for steering, travel speed,
retardation and lift height limits.
The MCU monitors and controls the truck's steering and driving
functions, braking functions, hydraulic functions for lifting/lowering of
the forks, CAN communications as well as various functions such as
battery indicator and height measurements for the main lift.
Any errors in these functions are registered and corresponding error
codes are shown on the CID.
The MCU manages the recording and display of error codes, current
codes and reference codes that are generated by the electronic
modules in the truck. Information about these are sent via CAN.
The MCU can be reprogrammed via CAN. See the separate manual for
TruckCom.
There are two 42-pin JPT contacts on the card. These are colour coded
grey and black. See “Cable connections and pole bolts” on page 20 –
48. for a table with MCU connections.
14.10.1 Installing a new card in the truck

Note:
This action requires access to TruckCom!
1. Open the motor compartment as described in “Opening the motor
compartment” on page 9 – 1.
2. Remove the guard above the MCU.
3. Loosen the cable connections on the rear side.
4. loosen the two contacts on the MCU
5. Remove the fixing plate and remove the MCU.
Install in reverse order.
Use TruckCom to load the software and reset parameters from backup
that are stored in the CID.
1. Load new software in the MCU.
2. When downloading is complete, restart the truck. An error code is
displayed indicating that the MCU and CID do not have the same
parameter settings.
3. Press "Connect" again in TruckCom and choose the relevant
software if TruckCom does not do this automatically.
4. Select “Copy truck configuration” in TruckCom.
5. Select “Copy configuration to primary unit: MCU

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If the new program is loaded in the MCU and the error code 2002 or
2101 is obtained, all factory parameters must be programmed for the
current truck type and new calibrations for all the functions carried out.
14.10.2 Voltage supply

The nominal supply voltage is 48 V.
14.10.3 Battery negative

The battery negative is connected directly to the negative pole on the
battery, and as such is isolated from
the truck chassis.
14.10.4 Internal status monitoring

A green LED indicates operational status. The LED is situated between
the two JPT connectors and is visible from the outside. The LED
indicates hardware and software status, Power OK and error status.
14.10.5 Resetting the battery indicator

The battery indicator will be reset when the battery voltage exceeds 50
V when logging in on a standard truck, but only when the battery
connector was disconnected

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Hydraulic hygiene
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15 – Hydraulic system 6000
15.1 Hydraulic hygiene

Note:
Risk of malfunction.
If impurities get into the hydraulic system, there is a risk of
malfunctions in part or all of the hydraulic system. There is also a risk
of severe damage to components.
For all work on the hydraulic system, the following instructions must
be followed.
15.1.1 Washing
Hydraulic components, including hydraulic hoses and pipes, must be
cleaned with a filtered washing fluid using a method suitable for the
components concerned.
The washing fluid must have purity code 19/16/13 in accordance with
ISO4406:1999 or 16/13 in accordance with ISO4406:1987.
Blowing clean with dry filtered air may be done when this is the only
practical method to carry out cleaning.
15.1.2 Packaging
After cleaning, all openings must be sealed with protective plugs.
Connecting surfaces must be protected against handling damage and
dirt penetration.
Completely dry components can be packed in plastic bags or boxes
with lids.
The packaging (protective plugs, masking, plastic bag, etc.) must not
be removed until immediately before the component is to be fitted in a
workplace suitable for handling hydraulic components.
Tape must never be used without cleaning afterwards.
Protective plugs must be stored in plastic bags or boxes with lids until
they are used.
After use, discard the plugs and plastic bags.
15.1.3 Handling
Hydraulic components must be handled and transported with the
greatest care.
Transportation packaging must be used throughout the entire handling
chain.
This packaging must be clean and free from dust, etc.

Hydraulic hygiene
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15.1.4 Storage
Hydraulic components must be handled and stored so that:
• no rusting can occur
• dust and dirt particles are shielded out
• no mechanical deformation can occur
15.1.5 Work procedures

When working on the hydraulic system, great cleanliness must be
observed so that no impurities can enter the system.
No work that generates particles may be carried out in the same
workplace or close to where work is being carried out on the hydraulic
system.
The service technician must ensure that the components to be used are
carefully deburred and cleaned.
Couplings for pipe ends or other openings must never be removed until
the part is to be fitted to the receiving component.
Note:
All hydraulic components that have not been cleaned, e.g. pipe
couplings and nipples, must be blown clean before fitting.

Hydraulic unit (6100)
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15.2 Hydraulic unit (6100)
M3
Pos. Function:
T6 Tank
M3 Pump motor
P Pump

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15.2.1 Hydraulic tank, emptying

Method a (recommended):
1. Remove the pressure hose for extra hydraulic functions. This is
located on the side of the mast.
2. Use a suitable container to collect the oil.
3. Run the extra function. Press carefully on the control in order to
produce a low outflow of the oil.
The oil must not be reused and must be disposed of according to
current regulations.
Method b:
Pump out the oil from the hydraulic tank using a suitable pump.
The oil must not be reused and must be disposed of according to
current regulations.

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15.2.2 Hydraulic system, bleeding

1. Put the truck program in service mode and activate the service
mode for bleeding. The bleeding mode initiates pump motor start-
up and simultaneous opening of both the lifting and the lowering
valves. The pressure in the valve unit will reach about 1 MPa (10
bar).
2. Open the bleed nipple on the main lift cylinder approx. 2 turns. If the
bleed nipple cannot be reached from the operator compartment,
use a ladder or similar item leant up against the mast.
3. Once all the air has been removed from the cylinder, oil begins to
drip out.
After four or five drops, the bleed nipple must be closed.
4. Repeat bleeding on the other main lift cylinder.
5. Exit the truck program's service mode for bleeding.
6. Activate the service mode for separate operation of free lift and
main lift.
7. Run the free lift (NOTE! NOT main lift) between maximum height
and the fully lowered position 3 – 4 times to vent the air from the
free lift cylinder into the tank. End with the mast in its fully lowered
position.
8. Exit the truck program's service mode.
9. Check the oil level in the tank and top up as necessary to the right
level.

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15.2.3 Filter
Overview
a
f
b
Pos Description
a Air filter cover
b Cap
c Filter bridge
d Filter
e Filter holder
f Air filter

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Filter replacement (air and oil)
Step 1. Step 2. Step 3.
Steps 4 and 5. Step 6. Step 7.
Precondition
Motor compartment open.
Required tools
• Screwdriver or similar, Ø approx. 6 mm
Method
Note:
When replacing the oil filter, the metal filter holder must be reused. The
new filter must not be installed without a filter holder.
1: Use the blade of a screwdriver or similar tool to loosen the tank
cap. Then screw it off by hand.
2: Lift off the cap and the filter.
3: Lift up the cover over the air filter and remove the filter element.
4: Insert a new filter element in the holder.
5: Refit the cover over the air filter.

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6: Detach the filter holder from the filter bridge.

7: Remove oil filter from the filter holder.
8: Insert a new oil filter in the filter holder.
9: Secure the filter holder in the filter bridge.
10: Fit the filter in place and screw on the cap by hand.

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15.2.4 Remove the pump motor from the

truck
1. Lower the forks to their lowest position to reduce pressure in the
hoses and in the pump.
2. Disconnect the battery cut out connector.
3. Empty the hydraulic tank of oil in accordance with section “14.1.1
Hydraulic tank, emptying” see page 14–2.
4. Remove the power cables from the pump motor.
5. Undo the temperature and speed gauge contacts on the motor.
6. Remove the pressure hose (b) from the pump (quick change
connector) and undo the suction hose (c) (hose clips) from the
pump.
7. Attach a lifting eye to the motor shaft.
8. Remove the screws (a) (6 mm Allen screws) that hold the pump
motor mounting to the chassis.
Step 7: M12×1.75
9. Lift out the hydraulic motor with the hydraulic pump and place it on
a clean surface.

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15.2.5 Replacing the hydraulic pump

Removal of pump motor from the truck. See section "15.2.4 Remove
the pump motor from the truck".
1. Remove the suction connection (b) from the pump.
2. Remove the screws (a).
3. Separate the hydraulic pump (c) from the motor (d).
×n a b d
s mm
Step 2: s = 6, n = 2
4. Place the suction connection on the new pump unit.

5. Place a new O-ring on the pump between the pump and pump
motor.
6. Place the pump unit on the pump motor.
7. Tighten the screws.
×n
s mm
Step 7: s = 6, n = 2
23 ± 6 Nm

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15.2.6 Fitting the pump motor in the truck

1. Attach a lifting eye to the end of the motor shaft and connect it to an
overhead travelling crane if required.
2. Lift the hydraulic pump into the truck and at the same time run the
hydraulic hose (c) from the tank to the pump.
3. Tighten the hose clamp.
4. Tighten the screws (a) (6 mm Allen screws) that hold the pump
motor mounting.
5. Unscrew the lifting eye.
6. Replace the hydraulic hose (b) in the quick change connector.
7. Connect the temperature and speed gauge contacts and the power
cables.
8. Check the oil level and if necessary top up the hydraulic oil in the
tank.
9. Before running the hydraulic function:
Put the truck program in service mode and activate the service
mode for bleeding.

Main valve (6210)
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15.3 Main valve (6210)
15.3.1 Emergency lowering of forks

On the top of the valve block is an emergency lowering valve for the
mast. Both the main lift cylinders and the free lift cylinder are connected
to the emergency lowering valve.
1. Extend the reach carriage fully.
2. Switch off the truck and disconnect the battery connector.
3. Undo the two screws (8 mm Allen screws) that secure the
protective plate over the main valve in the reach carriage, and
remove the plate.
4. Open the emergency lowering valve (arrow) (3 mm Allen screw).

The screw only needs opening 1½ turns to lower the forks.
Note:
The slot-head screw next to the Allen screw must NEVER be removed.
5. Once lowering is complete, tighten the screw to 2.5 Nm only.

Main valve (6210)
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Main valve (6210)
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15.3.2 Replacing the main valve block

The main valve block consists of:
• Proportional carriage valves which are individually adapted and
cannot be replaced
• Proportional valves of cartridge type. These are replaceable
Valve Function: Type

Q2 Main lift - lift Replaceable cartridge
Q3 Free lift – lift Replaceable cartridge
Q4 Main lift – lowering Replaceable cartridge
Q5 Free lift – lowering Replaceable cartridge
Q6 Reach movement - in Non-replaceable carriage
Q7 Reach movement - out Non-replaceable carriage
Q11 Ergo: Cab tilt, up Non-replaceable carriage
Q21 Ergo: Cab tilt, down Non-replaceable carriage
In the event of defects in a non-replaceable valves, the entire main

valve block must be replaced.
Note:
Upon delivery of a new main valve block, it is adjusted for a 2.0-tonne
mast.
For trucks with a 2.0-tonne mast, only the opening point for valve Q4/
Q5 will normally need to be calibrated.
For trucks with other masts, the opening point must be calibrated and
the maximum opening point must be adjusted.

2. Make sure the forks are in their bottom position and that there is no
load affecting the mast.
3. Put the truck in service mode and go to the pressure equalisation
mode in the service menu. All the valves are opened slightly and
any residual pressure in the system is equalised.
5. Undo the two screws (8 mm Allen screws) that secure the
protective plate over the main valve in the reach carriage, and
remove the plate.
6. Remove all the hoses from the main valve. Mark them to facilitate
reassembly.
7. Place protective plugs on all hoses and the main valve.

Main valve (6210)
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8. Disconnect all cables from the main valve, (check that their
markings are legible).
9. Undo the two screws (6 mm Allen screws) that hold the valve in
place in the reach carriage, and remove the main valve.
11. Before running the hydraulic function:
Put the truck program in service mode and activate the service
mode for bleeding.

Main valve (6210)
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15.3.3 Replacing the lifting/lowering valves

The same procedure is used for all valves, except that the valve unit
must be removed to in order to replace the lowering valves [Q4] and
[Q5]. For ease of access, the coil next to the valve to be replaced
should be removed.
The valve unit and components next to it must always be cleaned

thoroughly with brake cleaner or similar before replacing the valves. In
order to avoid contaminating the valve unit, tools, gloves and hands
must be clean. See the truck repair manual for more information about
hydraulic hygiene.
Before replacing the valve it should be checked for faults; if there is a

metal shaving or similar in it you may try to remove it and then cleaning
the valve in order to avoid having to replace it.
Overview
g
f
d
c
b
a
Pos. Description Note.

a Plastic nut
b O-ring
c Coil
d Coil connector
e Proportional valve
f Washer Only on lowering valves
g Spring Only on lowering valves

Main valve (6210)
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Method
Note:
Steps 1 and 2 only apply when replacing a lift valve, [Q2] or [Q3].
Before replacing one of the lowering valves [Q4] or [Q5], you must
remove the valve unit from the truck, see steps 1 – 9 in the
instructions “Replacing the main valve block”
2. Disconnect the coil electrical connection.
3. Clean the valve unit. Be extra careful around valves and hoses that
are to be disconnected.
4. Unscrew the plastic nut by hand.
Note:
There is an O-ring inside the nut which must not be lost.
5. Remove the O-ring.
6. Pull the coil straight out.
Steps 4 and 5 Step 6

,
7. Use a 30 mm, or alternatively a 32 mm wrench (valve [Q4]), to

remove the valve. Then pull the valve straight out. Make sure no
dirt or paint chips enter the valve unit.
Note:
The hollow washers and springs inside the valves [Q4] and [Q5] must
not be lost.

Main valve (6210)
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Step 7.
8. Check the valve and the cavity, and clean these if there is any dirt
found.
- If you find dirt and you have cleaned the valve, continue with
steps
9 – 10.
- If there is no dirt found when checking, replace the valve
according to steps 11 – 14.
Note:
Be careful not to introduce any more dirt.
9. Install the valve according to steps 11 – 13.
10. Make another test run of the truck. If the function still isn't working,
replace the valve according to steps 11 - 14.
11. Mount the new valve, tightening torque 40 Nm for all valves except
for the lowering valve for the main lift [Q4] that must be tightened to
60 Nm.
60 Nm 40 Nm
32 mm 30 mm

Main valve (6210)
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Note:
When mounting the lowering valves, you must take care to replace the
spring and the washer correctly. The seat of the washer must lie in the
middle of the spring that must be placed centrally in the cavity.
12. Reassemble everything in reverse order.

13. Check that the connections are tight.
After replacing the valves [Q2] or [Q3], the new valves must be
calibrated, see section “14.8.3 Valve calibration” on page 14 – 29.
After replacing the valves [Q4] or [Q5], the new valves must be
calibrated and adjusted; see , see section “14.8.3 Valve calibration” on
page 14 – 29. and .“15.3.4 Adjusting the maximum opening pressure”
on page 20.

Main valve (6210)
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15.3.4 Adjusting the maximum opening

pressure
Note:
The maximum standard lowering speed is 0.6 m/s.
If proportional valve Q4/Q5 has been replaced, then calibration and
adjustment must be performed. When adjusting, as when calibrating,
the forks must have a load of approx. 500 kg.
To ensure the standardised lowering speed is not exceeded, the truck’s
lowering speed must be adjusted to approx. 0.53 m/s at an oil
temperature of 20 °C.
1. For calibration of valve, see section “14.8.3 Valve calibration” on
page 14 – 29.
2. Place a cord with weights at both ends over a fork. The distance
between the ends of the cord must be 1.06 m and it should be
sufficiently long for the longest end not to touch the floor when the
mast is raised 2 m within the free lift range and the main lift range
respectively. Attach the cord to the fork with a piece of tape.
1060 mm
3. Raise the forks so that longest end is >0.5 m above the floor within
the main lift (Q4) working range and the free lift (Q5) working range
respectively.
To ensure that each valve is fully open during the measuring
interval, the lowering movement must be started with an
acceleration distance of approx. 0.5 m before measuring is started
and the measuring must be concluded before the forks are 0.5 m
above the floor.
Main valve (6210)
7510399-020 2012-10-03 6070557 815, 816
4. Use a stop watch to measure the time between when the lower
weight touches the floor until when the upper weight also touches
the floor.
5. Lower the forks at the max. lowering speed.
6. The time measured in accordance with the above must be 2
seconds.
7. If the time is not 2 sec., adjustment is necessary:
10 mm Slacken the valve's locking nut with a 10 mm spanner.
Use a 3 mm Allen key to change the valve’s setting.
– Rotate clockwise to increase the time/reduce the lowering speed.
3 mm
– Rotate anticlockwise to reduce the time/increase the lowering
speed.
Tighten the locking nut and repeat the procedure until the correct
lowering speed is obtained.

Hydraulic connections (6230)
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15.4 Hydraulic connections (6230)

Pos. Function:
M Connecting the pressure sensor
M2 Connecting the pressure sensor
MP Pump pressure measuring
P Pump
T6 Tank
15.4.1 Tightening torques for hydraulic

connections
Tapered coupling with O-ring
Tighten the nut by hand against the stop and then tighten to the torque
or the degrees presented in the table below. These are generally used
on the majority of hydraulic hoses on the trucks.
Dimension ø Tightening torque Tightening angle [°]

[mm] [Nm]
6 23 30-45
10 30 30-45
12 50 30-45
15 60 30-45
18 70 30-45
20 80 30-45

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Tredo sealing
The nut/connection should be tightened by hand against the stop and
then tightened to the torque indicated in the table below.
Dimension Tightening torque [Nm]

R 1/8 12-18
R 1/4 25-45
R 3/8 50-70
R 1/2 70-100
R 5/8 100-140
R 3/4 150-200
R1 195-250
R 1 1/4 250-310
R 1 1/2 310-400
M 18 50-70
M 22 100-140
M 26 150-200

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Pipe coupling
Tighten the coupling by hand and then turn it another half turn to obtain
the correct tightening torque.
Coupling screwed into aluminium
Designation with Dimension Torque [Nm]

cutting edge
G 1/8 R 1/8 ~7
G 1/4 R 1/4 ~12
G 3/8 R 3/8 ~20
G 1/2 R 1/2 ~30
G 3/4 R 3/4 ~80
G1 R1 ~100

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Coupling screwed into steel

Pressure class L
Designation with Dimensio Torque Designation with Dimension Torque

cutting edge n [Nm] ELASTIC [Nm]
sealing ring
GE 6-LM M 10x1 ~20 GE 6-LM-ed M 10x1 ~10
GE 6-LR R 1/8 ~20 GE 6-LR-ed R 1/8 ~10
GE 8-LM M 12x1.5 ~29 GE 8-LM-ed M 12x1.5 ~20
GE 8-LR R 1/4 ~39 GE 8-LR-ed R 1/4 ~20
GE 10-LM M 14x1.5 ~39 GE 10-LM-ed M 14x1.5 ~29
GE 10-LR R 1/4 ~39 GE 10-LR-ed R 1/4 ~20
GE 12-LM M 16x1.5 ~59 GE 12-LM-ed M 16x1.5 ~29
GE 12-LR R 3/8 ~59 GE 12-LR-ed R 3/8 ~39
GE 15-LM M 18x1.5 ~69 GE 15-LM-ed M 18x1.5 ~39
GE 15-LR R 1/2 ~108 GE 15-LR-ed R 1/2 ~59
GE 18-LM M 22x1.5 ~108 GE 18-LM-ed M 18x1.5 ~59
GE 18-LR R 1/2 ~108 GE 18-LR-ed R 1/2 ~59
GE 22-LM M 26x1.5 ~128 GE 22-LM-ed M 22x1.5 ~69
GE 22-LR R 3/4 ~157 GE 22-LR-ed R 3/4 ~88
GE 28-LM M 33x2 ~216 GE 28-LM-ed M 33x2 ~118
GE 28-LR R1 ~265 GE 28-LR-ed M 33x2 ~137
GE 35-LM M 42x2 ~353 GE 35-LM-ed M 42x2 ~196
GE 35-LR R 1 1/4 ~392 GE 35-LR-ed R 1 1/4 ~235
GE 42-LM M 48x2 ~491 GE 42-LM-ed M 48x2 ~294
GE 42-LR R 1 1/2 ~491 GE 42-LR-ed R 1 1/2 ~294

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15.4.2 Quick change connector

Overview
Note:
It is important that the instructions for connecting and disconnecting
the quick change connectors are followed. Otherwise, both the hose
and insert in the main valve block must be replaced.
b
a
Pos Description
a Disassembly ring
b Assembly stop
Assembly
Step 1. Step 2
Step 3
1: Fit the assembly stop to the hose coupling’s male fitting.

Check that the disassembly ring runs freely in the groove.
2: Push the male fitting into the female fitting until the assembly stop
makes contact with the female fitting.
3: The coupling is now made and locked.

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Disassembly
Required tool Step 1.
Step 2. Step 3
Step 4 Step 5
1: Use a screwdriver or similar to remove the assembly stop.

2: Push the male fitting all the way into the female fitting.
3: Pull the male fitting out of the female fitting.
4: Refit the assembly stop to the male fitting.
5: Place protective plugs on the valve and hose.

Hydraulic system, mast (6300)
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15.5 Hydraulic system, mast (6300)
15.5.1 Mast-mounted hose reel (6370)

General
These assembly instructions contain the information needed for
trouble-free installation and operation. The enclosed operating
instructions contain information relating to inspection and maintenance,
as well as the instructions.
15.5.2 Fitting the hose reel

To preload the spring, the hose drum should be rotated in the direction
of hose extraction, with the hose fully wound.
Preloading the hose drum:
• For extraction to the right, rotate the drum clockwise.
• For extraction to the left, rotate the drum anticlockwise.
DANGER!
Loaded spring.
The hose can cause injury.
Always exercise caution when working with the hose reel.
The number of turns depends on the length and diameter of the hose -
see the table. The stated values apply as guideline values.
Spring preloading (turns)
Hose diameter Hose length (m)

(mm) 2.7 3 3.3 5 6 7 8.5
6.3 - - 4 3 3 3 1.5-2
8 4 4 - 3 3 - -
The hose is only pulled out from the drum once the correct preloading
value has been reached.

Hydraulic system, mast (6300)
7510399-020 2012-10-03 6070557 815, 816
15.5.3 Checks after fitting

When the hose reel is used for the first time, lift the forks carefully to the
maximum lift height. Check that the hose and hose drum work correctly
and count the number of turns that the hose drum rotates.
The total for the number of turns made by hand when preloading plus
the number of turns for maximum extraction must not exceed 10.
Turns on preloading + turns in operation = 10 turns max.
Note:
At maximum lift height, the hose must not be fully unwound from the
hose drum. At least ¼ of a turn of hose must still remain on the hose
drum.
Make sure that the hose drum can still be turned by hand with the hose
fully extracted. The hose drum must not lock.
Check that the hose rewinds correctly when the forks are lowered. The
hose must always be under tension; otherwise there is a risk of the
hosesliding over the side plates. If this is the case, adjust the preloading
tension.
Note:
The spring-loaded eye must face the direction in which the hose
unwinds.
Spare parts must conform to the technical specifications laid down by

the manufacturer. This requirement is always met if original spare parts
are used.

Main lift cylinder 6610
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15.6 Main lift cylinder 6610

General
The instructions below relate to the main lift cylinders in the mast. There
are two main lift cylinders in the mast. The cylinders are of plunger type,
i.e. they are piston-less cylinders.
In the cylinder's hydraulic hose quick change connector there is a hose
rupture valve that prevents the forks from falling in the event of rupture
to a hose.
We recommend that all masts, irrespective of lift height, be lifted off
before the cylinders are removed.

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15.6.1 Overview
Cylinder nomenclature
c
d
Pos Description
a Piston rod
b Cylinder head
c Air hose connection
d Circlip
e Cylinder pipe
f Piston
g Cylinder bottom
h Cylinder bottom

815, 816 6070557 2012-10-03 7510399-020
Nomenclature for cylinder head
d
e
Pos. Description
a Wiper
b Piston rod seal
c Guide belt
d O-ring
3 Support ring
Nomenclature for piston
Pos Description
a Plunge

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15.6.2 Removing the air cylinder from the

mast
Note:
Clean the surfaces around the cylinder connections before removing
the cylinder from the truck. When the oil couplings have been
removed, the cylinder couplings must be plugged to protect the
cylinder from dirt.
Note:
Use a clean rag and make sure that no dust from the rag or other
particles that could damage the cylinder remain on the surface.
1. Raise the mast and support the intermediate guide using blocks.
2. Loosen the lifting chain at the cylinder to be removed, and place it
on the floor over the reach carriage.
3. Remove the lift chain wheel.
4. Loosen the cylinder rod from the top member (b).
5. Lower the lift cylinder to the bottom.
6. Remove the hydraulic hose from the lift cylinder and valve block
and plug the valve block.
7. Check that the lift chain that still remains is not damaged.
8. Check that the lift chain does not get damaged nor damage
anything while you raise the mast to the top.
9. Undo the lift cylinder at its bottom stud (d).
10. Undo the cylinder support at the top (e or f).
11. Remove the cylinder from the mast.
g
b
a
f
i
c
d
h

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15.6.3 Replacing the hose rupture valve

The hose rupture valve is integrated in the quick change connector for
the hydraulic hose.
Note:
When fitting these components, it is very important that no dirt etc.
enters the hydraulic system.
1. Remove the hydraulic hose from the quick change connector and
plug it.
2. Unscrew the quick change connector from the cylinder.
3. Put a new quick change connector on.

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815, 816 6070557 2012-10-03 7510399-020
15.6.4 Dismantling the cylinder
Tools required Step 1
Step 2 Step 3, KM 8/ø = 58 mm.
Step 4
Step 5

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Tools required
• Lint-free cleaning material
• Ratchet handle
• KM-socket KM8 or hook spanner
Method
1. Clean the cylinder from dirt, etc.
Note:
2. Secure the cylinder pipe firmly and make sure that the piston and
rod are not jammed.
3. Loosen the cylinder head using a hook spanner or a KM socket.
4. Remove the cylinder head.
5. Carefully pull the piston rod out of the sheath pipe.

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15.6.5 Dismantling the piston.
Method
1. The plunge piston has slits and can be removed by hand.
15.6.6 Dismantling the cylinder head
Step 1 Step 2.
Step 3
Step 4

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Method
The cylinder heads of the main lift cylinders can have different
appearances. The procedure for dismantling is similar for all models.
Note:
Be careful not to scratch the cylinder head.
1. Start by removing the wiper.
2. Remove the piston rod seal.
3. Remove the guide belt. The band has slits and can be removed by
hand.
4. Turn the cylinder head and remove the O-ring and support ring.

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15.6.7 Fitting the cylinder head seals.
Step 2. Step 3
Step 4 Step 5
Step 6
Method
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1. Make sure the correct seals are at hand and free from defects.
2. Clean the surfaces that are to have a new seal using lint-free
material. Check if there is any damage on the surfaces. Minor
damage can be removed by polishing with fine sandpaper.
Note:
Never reuse old seals.
Note:
Note:
Be careful with the seals that are sensitive. They must only be
deformed with soft bends.
3. Fit the O-ring and the supporting ring. Check that the supporting
ring ends up in the correct place.
4. Fit the guide belt.
5. Fit the piston rod seal. Make sure it is fitted the correct way round.
6. Fit the wiper. Make sure it locates correctly in its groove.

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15.6.8 Fitting the piston seals
Step 2 Step 3

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Method
material. Check if there is any damage on the surfaces.
Note:
Note:
3. The plunger has slits and is easy to fit by hand.

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15.6.9 Assembling the cylinder
Step 2
Step 3 Step 4
Step 5, Loctite® 243 Step 6, KM 8/ø = 58 mm, T = 250 Nm

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Tools required
• Assembly grease, Kluber GL 261 or similar
• Loctite® 243
• KM socket KM8
• Torque wrench, 250 Nm
Method
1. Lubricate the piston with hydraulic oil.
2. Fit the piston rod in the cylinder pipe.
3. Apply assembly grease to the wiper and guide belt in the cylinder
head.
4. Fit the cylinder head onto the piston rod.
5. Apply Loctite 243 on the threads.
6. Tighten the cylinder head using the KM socket. Tightening torque
250 Nm.
7. Fit the cylinder to the mast according to “15.6.10 Assembling
cylinder in the mast”
8. Check the cylinder for leakage by first running the main lift
unloaded and then loaded. There must be no leakage or uneven
running.

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15.6.10 Assembling cylinder in the mast

Note:
9. Lift the cylinder into the mast. Check that the tension pin (g) is fitted
to the cylinder rod and that any shims (h) are refitted when
assembling the repaired cylinder.
10. Mount the cylinder on the bottom stud with screw (d) and washer.
Tighten according to the torque in the table.
11. Mount the cylinder support (e or f) with screw (a or c) and washer.
Tighten according to the torque in the table.
For RRE 200, 250: If a new cylinder or a new cylinder support (e)
has been fitted, check if shims (i) need to be fitted. Use enough
shims to centre the cylinder in the support.
Also adjust the cylinder sideways using the oval holes in the
cylinder support. If the truck has a fitting at the middle of the
cylinder, this too has to have shims. Mount with the screws (a) and
torque tighten according to the table.
Note:
If the shims are not applied properly to center the cylinder, the
cylinder may bend or the bracket may come loose.
12. Using blocks, chock up the inner runner approximately 50 cm
above the floor.
13. Lower the mast.
14. Remove the plugs from the hydraulic hose and valve block and
connect the hose.
15. Raise the forks until the lift cylinder makes contact with the top
beam.
16. If a new cylinder has been fitted, check whether shims (h) need to
be fitted. If shims are necessary, back off the bottom stud and fit the
required number of shims (h).
17. Screw the cylinder into position in the top beam with screw (b) and
washer. Tighten according to the torque in the table.
18. Lower the forks to the bottom.
19. Fit the chain wheel and lift chain.
20. Adjust the chain so that the mast does not pull to one side at the
top.

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g
b
a
f
i
c
d
h
Pos. Description Note

a Screw Tightening torque: 45 +11/-5Nm
b Screw Tightening torque:
110Nm (for 2.5-ton masts)
65Nm (for 1.6 and 2.0-ton masts)
c Screw Tightening torque: See section "23.2 Oil
and grease specification".
d Screw Tightening torque:
53Nm (for 2.5-ton masts)
47Nm (for 1.6 and 2.0-ton masts)

Free lift cylinder (6620)
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15.7 Free lift cylinder (6620)

General
The free lift cylinder is the cylinder located in the centre of the cylinders
in the mast. The free lift cylinder is a single-action cylinder.
There is a hose rupture valve fitted in the free lift cylinder that prevents
the load from falling in the event of rupture to a hose.

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15.7.1 Overview
c
d
Pos Description
a Piston rod
b Cylinder head
c Air hose connection
d Circlip
e Cylinder pipe
f Piston
g Cylinder bottom

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Pos. Description
a Wiper
b Guide belt
Pos Description
a Piston seal
b Guide belt
c Circlip
d Piston

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15.7.2 Removing the free lift cylinder from the

truck
Note:
cylinder from dirt.
Note:
1. Remove the feeder pipe on the free lift cylinder.
2. Plug the free lift cylinder.
3. Loosen the mounting bolts on the top of the free lift cylinder.
4. Lift the intermediate guide using an overhead crane to slacken the
twin hose and the cable.
5. Remove the twin hose and the cable from the hose rollers on the
free lift cylinder.
6. Chock up under the fork yoke.
7. Lower the traverse so that the fork yoke rests on the block and
there is slack in the free lift chain.
8. Tie the chains together so that they do not slide out of the upper
chain rollers.
9. Remove the inner split pin on the free lift chain pin.
10. Remove the free lift chain pin.
11. Lift the free lift chain from the free lift cylinder.
12. Remove the chain adjuster from the free lift cylinder.
13. Secure a lifting strap around the free lift chain bracket at the end of
the free lift piston and a lifting strap around the free lift cylinder (see
illustration).
14. Secure the lifting strap in a traverse.
15. Remove the mounting bolts on the top of the free lift cylinder.
16. Lower the free lift cylinder.
15.7.3 Replacing the hose rupture valve, free

lift cylinder
The hose rupture valve (lowering brake valve) is fitted in the hydraulic
cylinder's pipe connection and can be replaced using standard tools.
Note:

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Step 2 Step 3, KM 8/ø = 58 mm.
Step 4
Step 5

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Tools required
• hook spanner
Method
1. Clean the cylinder from dirt, etc.
Note:
rod are not jammed.
3. Remove the cylinder head using a hook spanner.
4. Remove the cylinder head.
5. Carefully pull the piston rod out of the sheath pipe.
15.7.5 Dismantling the piston
Method
1. The guide belt has slits and can be removed by hand.

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Step 1. Step 2
Method
Note:
Be careful not to scratch the cylinder head.
hand.

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Step 2. Step 3
Step 4
Method
Note:
Note:
Note:
4. Fit the wiper. Make sure it locates correctly in its groove.

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15.7.8 Fitting the piston seals
Step 2 Step 3
Step 4

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Method
material. Check if there is any damage on the surfaces.
Note:
Note:
3. Fit the piston seal, make sure it is fitted the correct way round.

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Tools required
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6 Step 7, T = 250 Nm

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Tools required
• Assembly grease, Kluber GL 261 or similar
• Loctite® 243
• Hook spanner 250 Nm
Method
2. Fit the piston rod in the cylinder pipe. Push the piston only so far as
to conceal the circlip in the cylinder pipe.
3. Spray Decordyn 350 into the cylinder pipe, then press in the piston
rod all the way to the bottom.
4. Apply assembly grease to the wiper and guide belt in the cylinder
head.
5. Fit the cylinder head onto the piston rod.
6. Apply Loctite 243 on the threads.
7. Tighten the cylinder head using the hook spanner. Tightening
torque 250 Nm.
8. Mount the cylinder in the mast according to “15.7.10 Assembling
the free lift cylinder in the mast”
9. Check the cylinder for leakage by first running the free lift unloaded
and then with a load. There must be no leakage or uneven running.

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15.7.10 Assembling the free lift cylinder in the

mast
Note:
1. Secure a lifting strap around the free lift chain bracket at the end of
the free lift piston and a lifting strap around the free lift cylinder (see
illustration).
2. Lift the free lift cylinder into its correct position.
3. Fit the free lift cylinder using its mounting bolts.
4. Remove the overhead crane.
5. Fit the chain adjuster.
6. Fit the free lift chain with its pin.
7. Install the cotter pin.
8. Remove the straps from around the free lift chain.
9. Lift the inner guide using a traverse.
10. Place the twin hose and the cable on the hose reels of the free-lift
cylinder.
11. Remove the overhead crane.
12. Remove the plugs on the free lift cylinder.
13. Fit the feeder pipe to the free lift cylinder.

Reach cylinder (6650)
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15.8 Reach cylinder (6650)
15.8.1 General
The reach cylinder is located in the reach carriage.
The reach cylinder is a double-acting cylinder.
The direction of the cylinder is governed by the main valve.
15.8.2 Removing the reach cylinder from the

truck
Note:
cylinder from dirt.
Note:
1. Fully extend the mast.
2. Remove the battery cut out connector from the truck.
3. Remove the reach carriage graduated rule. This is attached at
each end by snap fasteners and can be lifted out by gently tugging
on it.
4. Remove the hoses from the reach cylinder and plug them.
5. Remove the locking rings from the cylinder pins.
6. Remove the reach cylinder.

Reach cylinder (6650)
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15.8.3 Fitting the reach cylinder in the truck

Note:
1. Fit the reach cylinder to the pins.
2. Put the locking rings in position on the pins.
3. Fit the hoses to the cylinder.
4. Fit the reach carriage graduated rule. This has a snap fastener at
each end and is attached by gently pressing on it.

Fork tilt cylinder (6660)
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15.9 Fork tilt cylinder (6660)
15.9.1 General
The fork tilt cylinder is located on the mast behind the lower edge of
the fork yoke.
The cylinder is double-acting, which means it is the oil pressure that
moves the piston back and forth in the cylinder. When the piston is
pressed out, the lower edge of the fork yoke is moved outwards, and, in
doing so, the forks are tilted upwards.

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15.9.2 Remove the tilt cylinder from the truck

Mast with valve on the fork carriage:
×n
s mm
Step 4: s = 17, n = 4
b
c
e
d
×n
i
s mm
f h
Step 6: s = 5, n = 2 g
j
m
×n n
k l
s mm
Step 8: s = 6, n = 2

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Method
Note:
cylinder from dirt.
Note:
1. Raise the fork carriage to a comfortable working height.
2. Remove the forks.
3. Remove the spring clip for dismantling the side-shift (b) or rod (a).
4. Loosen the screws (k) and remove the stop lug (l).
5. Secure the fork yoke (c) with a rope and lift it out of the way using
an overhead crane.
6. Unscrew the screws (d) in order to remove the sliding block (f) and
remove plate (e).
7. Loosen the nut/screw (o)
8. Unscrew the screws (j) from the fork carriage (m).
9. Remove the tilt cylinder.
10. Knock out the tension pin (h) and remove the plate (g).

815, 816 6070557 2012-10-03 7510399-020
Mast without valve on the fork carriage:
b
c
d
×n e
s mm
f
Step 4: s = 13, n = 2
×n
s mm
Step 7: s = 6, n = 2

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Method
Note:
cylinder from dirt.
Note:
1. Raise the fork carriage to a comfortable working height.
3. Secure a lifting strap around the fork yoke (a) and, using a traverse,
take up the weight of the yoke.
4. Unscrew the screws (d) and washers (c).
5. Knock out the shafts (e).
6. Lift the fork yoke off.
7. Unscrew the screws (f).
8. Remove and plug the hydraulic lines to the tilt cylinder.
9. Remove the tilt cylinder.

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15.9.3 Fit the tilt cylinder in the truck

Mast with valve on the fork carriage:
×n
s mm
Step 2: s = 6, n = 2
×n e
c
d
s mm
Step 3: s = 5, n = 2
i
Mv = 10.2 Nm
f h
g
×n j
m
s mm
Step 4: s = 6, n = 2 n
k l
×n
s mm
Step 6: s = 17, n = 4 o

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Method
Note:
1. Fit plate (g) and lock it using the tension pin (h).
2. Fit the tilt cylinder with screws bolts (j).
3. Fit the gliding block (f) with screws (d) and fit the plate (e).
4. Tighten the gliding block with screw/nut (o) until the stud (n) can
barely rotate.
5. Lift the fork yoke (c) back into position using an overhead crane.
6. Fit the stop lug (i) with screws (k).
7. Refit the side-shift (b) or stay (a).
8. Fit the forks.

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Mast without valve on the fork carriage:
b
c
d
×n e
s mm f
Step 1: s = 6, n = 2
×n
s mm
Step 4: s = 13, n = 2

7510399-020 2012-10-03 6070557 815, 816
Method
Note:
1. Fit the tilt cylinder using screws (f).
2. Lift the fork yoke in position.
3. Knock the shafts (e) into position.
4. Secure the shafts in position using the screws (d) and washers (c).
5. Fit the forks.

Cab tilt cylinder (6660)
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15.10 Cab tilt cylinder (6660)
15.10.1 General
The cab tilt cylinder is fitted in trucks with tilting driver cabs. The cab tilts
approx. 10° at a pre-set lift height. The cylinder is a double-action
cylinder with piston sealing.
15.10.2 Overview
c
d
e
f
g
Pos Description
a Piston rod head
b Nipple x 2
c Circlip
d Cylinder head
e Oil coupling x 2
f Piston rod
g Piston
h Locking nut
i Cylinder bottom

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a
b
c
Pos. Description
a Wiper
b Seal
c Piston rod seal
d Guide belt
a
b
Pos Description
a Pressure element
b Piston seal
c Guide belt

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Step 3 Step 4
Step 5

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Tools required
• Small screwdriver
Method
1. Empty the cylinder of oil and clean off any contaminants, etc .
Note:
rod are not jammed.
3. Press the cylinder head inwards.
4. There is a hole in the cylinder head to facilitate removal of the
locking ring. Use a small screwdriver and push out the locking ring.
Note:
Be careful not to damage the surfaces.
5. Carefully pull out the cylinder head, piston rod and piston.

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15.10.4 Dismantling the piston rod
Step 2 Step 3
×n
s mm
Step 4. Step 5: s = 24, n = 1
Step 6

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Tools required
• Ratchet handle
• Socket 24 mm
Method
1. Fasten the piston rod to the piston rod head. Make sure the rod is
also supported.
Note:
Always protect the piston rod from sharp edges.
2. Remove the guide belt.
3. Remove the piston seal.
4. Remove the pressure element
5. Unscrew the locking nut. 1 x M16
6. Remove the piston and cylinder head.
Note:
Make sure that the cylinder head surfaces are not damaged by the
piston rod thread.
7. Make sure that there is no other damage to the pipe and rod.

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Step 1.
Step 2 Step 3
Step 4

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Method
hand.
4. Remove the last seal.
Note:

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Step 2.
Step 3 Step 4
Step 5 Step 6
Method
7510399-020 2012-10-03 6070557 815, 816
Note:
Note:
Note:
3. Fit the seal.
6. Fit the wiper. Check that it locates correctly in the groove.

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15.10.7 Mounting the piston rod
Tools required Step 1 Step 2.
×n
s mm
Step 3: S = 24, N = 1, Mv = 120 Nm
Step 5. Step 6
Step 7 Step 8

7510399-020 2012-10-03 6070557 815, 816
Tools required
• Socket 24 mm
Method
1. Apply assembly grease inside the cylinder head and fit the cylinder
head onto the piston rod.
Note:
piston rod thread.
Note:
The wiper is very soft, so be careful that it does not bend when fitting.
2. Fit the piston onto the piston rod.
3. Fit the locking nut, 1 x M16, over the piston rod and torque tighten it
to 120 Nm. The wrench must not slide on the piston rod.
Note:
Note:
Note:
6. Fit the pressure element.
7. Fit the piston seal. Check that the pressure element and seal are
fitted correctly.
8. Fit the guide belt, it has slits and can be fitted by hand.

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Step 1. Step 2
Step 4
Step 3
Step 5

7510399-020 2012-10-03 6070557 815, 816
Method
4. Fit the spring ring. Make sure it locates correctly.
5. Pull the piston ring backwards until the cylinder head returns to its
correct position.
6. Before the cylinder is taken into operation, it must be vented of air.
This is done by fitting the cylinder in the truck and letting it work 10
slow, full strokes. There must be no leakage or uneven running.

Sideshift cylinder (6670)
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15.11 Sideshift cylinder (6670)
15.11.1 General
Sideshift is used to move the forks sideways. Instead of repositioning
the machine only the forks are moved to be in correct position to pick or
deposit the load. Movement is +/-75 mm. The cylinder, which is located
on the fork yoke, is double-acting, which means it is the oil pressure
that moves the piston back and forth in the cylinder.

7510399-020 2012-10-03 6070557 815, 816
15.11.2 Overview
b
c
d
e
f
Pos Description
a Piston rod head
b Circlip
c Cylinder head
d Oil coupling x 2
e Piston rod
f Piston
g Locking nut
h Cylinder bottom

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a
b
c
Pos. Description
a Wiper
b Seal
c Piston rod seal
d Guide belt
a
b
Pos Description
a Pressure element
b Piston seal
c Guide belt

7510399-020 2012-10-03 6070557 815, 816
15.11.3 Dismantling the cylinder from the

truck
Note:
During servicing, the truck must be switched off and the battery
disconnected.
During maintenance, the hydraulic system must be depressurised.
The couplings must be sealed so that no dirt can enter the hydraulic
system.
Method
1. Put the truck in service mode and go to the pressure equalisation
mode in the service menu. Push the lifting lever to the lowering
position to start the pressure equalisation sequence. All the valves
are opened slightly and any residual pressure in the system is
equalised.
3. Remove and plug the hydraulic lines onto the cylinder.
4. Use circlip pliers to remove the circlips from the cylinder spigots.
5. Remove the cylinder.

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Step 3 Step 4
Step 5

7510399-020 2012-10-03 6070557 815, 816
Tools required
• Small screwdriver
Method
1. Empty the cylinder of oil and clean off any contaminants, etc .
Note:
rod are not jammed.
4. There is a hole in the cylinder head to facilitate removal of the
locking ring. Use a small screwdriver and push out the locking ring.
Note:
5. Carefully pull out the cylinder head, piston rod and piston.

815, 816 6070557 2012-10-03 7510399-020
15.11.5 Dismantling the piston rod
Step 2 Step 3
×n
s mm
Step 4. Step 5: s = 19, n = 1
Step 6

7510399-020 2012-10-03 6070557 815, 816
Tools required
• Ratchet handle
• Socket 19 mm
Method
1. Secure the piston rod onto the piston rod head. Make sure the rod
also has support.
Note:
Always protect the piston rod from sharp edges.
2. Remove the guide belt.
3. Remove the piston seal.
4. Remove the pressure element
5. Unscrew the locking nut, 1 X M12.
6. Remove the piston and cylinder head.
Note:
piston rod thread.
7. Make sure that there is no other damage to the pipe and rod.

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Step 1.
Step 2 Step 3
Step 4

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Method
hand.
4. Remove the last seal.
Note:

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Step 2.
Step 3 Step 4
Step 5 Step 6
Method
7510399-020 2012-10-03 6070557 815, 816
Note:
Note:
Note:
3. Fit the seal.
6. Fit the wiper. Check that it locates correctly in the groove.

815, 816 6070557 2012-10-03 7510399-020
15.11.8 Mounting the piston rod
Tools required Step 1 Step 2
×n
s mm
Step 3: S = 19, N = 1, Mv = 60 Nm
Step 5. Step 6
Step 7 Step 8

7510399-020 2012-10-03 6070557 815, 816
Tools required
• Socket 19 mm
Method
1. Cover the threads of the piston rod with a mounting ring. Apply
assembly grease inside the cylinder head and fit the cylinder head
onto the piston rod.
Note:
The wiper is very soft, so be careful that it does not bend when fitting.
2. Fit the piston onto the piston rod.
3. Fit the locking nut, 1 x M12, over the piston rod and tighten it to
torque 60 Nm.
Note:
Note:
Note:
6. Fit the pressure element.
7. Fit the piston seal. Check that the pressure element and seal are
fitted correctly.
8. Fit the guide belt. The band has slits and can be fitted by hand.

815, 816 6070557 2012-10-03 7510399-020
Step 1. Step 2
Step 3 Step 4
Step 5

7510399-020 2012-10-03 6070557 815, 816
Method
4. Fit the spring ring. Make sure it locates correctly.
5. Pull the piston rod backwards until the cylinder head returns to its
correct position.
6. Before the cylinder is taken into operation, it must be vented of air.
This is done by fitting the cylinder in the truck and letting it work 10
slow, full strokes. There must be no leakage or uneven running.
15.11.10 Refitting the cylinder in the truck

Note:
1. Assemble the cylinder on the studs.
2. Fit the circlips to the studs.
3. Fit the hoses to the cylinder.

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Mast/Lift system 7000
Main mast 1.6-2.5 t (7100)
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16 – Mast/Lift system 7000
16.1 Main mast 1.6-2.5 t (7100)
16.1.1 Replacing the full mast

When ordering a replacement mast, TMHE Technical Support should
be contacted to identify the mast.

Main mast 1.6-2.5 t (7100)
815, 816 6070557 2012-10-03 7510399-020
16.1.2 Removing the mast from the truck

2. Set all hydraulic functions on the mast to the depressurised
position, fork carriage fully lowered, tilt and side shift in the centre
position.
DANGER!
Oil under high pressure.
Some parts of the hydraulic system may still retain residual pressure
despite the system being depressurised.
Make sure there are no bystanders in the immediate truck vicinity and
make sure you stand safely to the side of the coupling you are about
to disconnect..
3. Switch off the power and disconnect the battery by disconnecting
the battery connector.
4. Remove the forks and any load support.
5. Secure the mast using a traverse and lifting device (see the section
"Tools").
6. Tie it up so that the weight of the mast is taken up by the traverse.
7. Undo the two screws (8 mm Allen) that hold the cover over the
main valve in the reach carriage and remove the cover.
8. Remove the hoses for the tilt (A1, B1), main lift (H2, H3) and free lift
cylinder (H1) from the main valve. Mark them to facilitate
reassembly.
9. Fit protective plugs on the main valve and hoses.
10. Disconnect any height indication and side shift cables.
11. If the truck is fitted with extra hydraulic functions, loosen the
hydraulic hoses from the valve block on the reach carriage. Fit
protective plugs on hoses and valve block.

Main mast 1.6-2.5 t (7100)
7510399-020 2012-10-03 6070557 815, 816
12. Unscrew and remove the screws (a) (17 mm Allen screws) for the
lower attachment. The 2.5 ton mast has two screws (14 mm Allen),
other masts have one screw on each side.
Note:
To achieve correct mast inclination during reassembly, mark the
shims used on the left and right hand sides.
a a
13. Undo the screws (b) (14 mm Allen screws) approximately one turn.
14. Remove screws (c) (10 mm Allen) and the circlips (d). .
d
15. Mark (with a scribe or centre punch) the eccentric cam in relation to
the reach carriage, to facilitate refitting and adjustment.
16. Turn the eccentric cams (e) (60 mm hexagonal screw) so that the
large level surfaces (f) are facing downwards.
e
f

Main mast 1.6-2.5 t (7100)
815, 816 6070557 2012-10-03 7510399-020
17. Lift out the mast.
If for any reason it should prove impossible to turn the eccentric

cams (e), proceed as follows:
- Unscrew the adjusting screws (h).
- Insert a suitable spacer (g) in the adjusting screw hole. Diameter
approx. 35 mm in and approx. 20 mm in length. Now use the
adjusting screw as a puller.
Note: If there is no spacer, the adjusting screw will drop down into the
eccentric cam once the thread runs out, and it will be impossible to
get it to rethread.
e g h
18. Carefully lower the mast to the floor.

19. Place the mast on a pallet on the floor or, for a more comfortable
working height, on a pair of trestles.
DANGER!
Unexpected/uncontrolled movements.
When laying down the mast, the shifting of the centre of gravity could
cause the mast to suddenly slide on the floor.
Ensure there are no bystanders in the area where the mast could
move suddenly, i.e. the mast length + 2 metre safety margin. Always
place yourself on the side of the mast at a safe distance and as far
away as possible that the controls of overhead travelling allow.
20. Clean or wash off any oil spillage on the truck.

Main mast 1.6-2.5 t (7100)
7510399-020 2012-10-03 6070557 815, 816
16.1.3 Adjusting mast play

General
The mast rollers are fitted on angled pins that can be adjusted when
mast play becomes excessive.
Lateral play is adjusted with shims, and radial play is adjusted using
oversized rollers. Oversized rollers are available in increments of 0.4
mm.
Preparations
1. Remove the mast from the truck. See the section "Removing the
mast from the truck".
Note:
Oil leaking.
Risk of valve or cylinder failure if dirt enters the hydraulic
connections.
Plug all hydraulic connections.
2. Place the mast horizontally on a number of pallets or similar items.

Main mast 1.6-2.5 t (7100)
815, 816 6070557 2012-10-03 7510399-020
3. Disassembly:
- The twin hose (a) and connector unit from the fork carriage.
- The twin hose reel (b) from the free lift cylinder.
- The twin hose (c) from the mast, but leave it in the outer runner.
- The feeder hoses (d) for the main lift cylinders.
- The feeder hose bracket (e) and the hose (f) for the free lift
cylinder from the inner runner.
e
c
b f
e
d

Main mast 1.6-2.5 t (7100)
7510399-020 2012-10-03 6070557 815, 816
4. Disassembly:
- The free lift chain (g) from the fork carriage and the free lift
cylinder.
- The main lift cylinders (h).
- The main lift chains (j), but leave them in the outer runner.
- The main chain rollers (k) and the twin hose reel (m) at the bottom
of the mast.

Main mast 1.6-2.5 t (7100)
815, 816 6070557 2012-10-03 7510399-020
5. Remove:
- The fork carriage (n) from the mast.
- The inner guide (o) from the mast using the BT lifting yoke (see
the section "Tools").
- Pull out the inner runner to its full travel length and lift out the
runner.
n
o
6. Clean the mast’s component runners and rollers as well as the fork
carriage rollers.
Adjusting lateral play

By shimming the mast rollers, lateral mast play can be adjusted.
Note:
-Maximum play at the bottom (with mast retracted) is 1 mm.
-Maximum play at the top end of the mast is 0.4 mm (both with mast
retracted and mast extended).
1. Remove the runner from the mast.
2. Remove the rollers that need to be shimmed.
3. Fit:
- The shims on the roller pins.
- The rollers.
- The guide in the mast.
4. Verify by measuring the assembly. Use an indicator gauge and a
crowbar to measure play. Measure the retracted and extended
mast.
5. Secure the intermediate and outer runners next to each other.
6. Fit the inner runner to the mast.
7. Measure and shim as specified in the instructions above.
8. Fit the fork carriage to the mast.
9. Measure and shim as specified in the instructions above.

Main mast 1.6-2.5 t (7100)
7510399-020 2012-10-03 6070557 815, 816
Adjustment of radial play

The play between roller and contact surface on the relevant beam must
not exceed 0.4 mm. Check using a feeler gauge. If there is more play
than this, the rollers must be replaced with oversized rollers. Oversized
rollers (rated) are available in increments of 0.4 mm.
When fitting oversized rollers, play may be < 0, provided that the mast
can be pushed together/drawn apart by hand, even if this is difficult to
do. After a short period of use, the rollers will show an imprint of the
contact surface, meaning that play is > 0.
Adjusting the damper parts

The end position dampers are adjusted using washers so that the
damper stops the runners simultaneously on both sides, and the ends
of the beams are level at the end position - see the diagram.

Main mast 1.6-2.5 t (7100)
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Adjusting the damper plate

If the mast emits a rattling sound on operation, this may be due to the
damper plates at the bottom and top of the mast being worn.
1. Check the amount of play between the damper plate and mast.
2. Pull the mast apart approx. 200 mm.
3. Remove the old plates at the bottom and top of the mast - see the
diagram.
4. If the plate is not worn out, the play in relation to the mast can be
adjusted using plate shims behind the plate. The shims are
available in two sizes: 0.5 mm and 1 mm.
a
b
Refitting the mast

1. Fit:
- Free-lift chain.
- The chain guard, if present.
- The main lift cylinders.
- The main lift chain rollers.
- The main lift chains.
- Twin hose, cable and contacts in the fork carriage.
- The twin hose roller onto the free-lift cylinder.
- The distributor block including the supply hose onto the supply
pipes for the main lift cylinders.
- The supply hose bracket on the inner guide.
Note:
The twin hose is liable to separate.
Risk of the twin hose breaking.
Make sure the twin hose rollers are in line.
Fit the mast to the truck - see the section "Placing the mast on the
truck".

Main mast 1.6-2.5 t (7100)
7510399-020 2012-10-03 6070557 815, 816
16.1.4 Replacing the mast damper plates

If the mast emits a rattling sound on operation, this may be due to the
damper plates at the bottom and top of the mast being worn.
1. Check the amount of play between the damper plate and mast.
2. Raise the mast approximately 200 mm from the floor.
3. Secure the mast with wooden blocks.
4. Remove the old plates at the bottom and top of the mast - see the
diagram.
5. If the plate is not worn out, the play in relation to the mast can be
adjusted using plate shims behind the plate. The shims are
available in two sizes: 0.5 mm and 1 mm.
a
b

Main mast 1.6-2.5 t (7100)
815, 816 6070557 2012-10-03 7510399-020
16.1.5 Placing the mast on the truck

1. Attach a lifting device (See section "22.4 Miscellaneous tools".) to
the mast and raise the mast to an upright position, suspended in
the overhead travelling crane.
2. If the eccentric cams (e) have been removed from the mast or are
new:
- Lubricate the mast pin (j) with MoS2 grease.
- Place the eccentric cam (e) on the pin (j).
- Lubricate the threaded hole in the eccentric cam (e) and screw in
the adjusting screw (h).
- Screw in the locking screw (b) by hand to stop the eccentric cam
falling off during the docking operation.
k j e h b
3. Turn the eccentric cams (e) so that the largest level surfaces attain
a horizontal position facing downwards.
4. Lubricate the cups on the mast attachment (k) in the reach carriage
with MoS2 grease.

Main mast 1.6-2.5 t (7100)
7510399-020 2012-10-03 6070557 815, 816
5. Dock the mast and turn the eccentric cams (e) through 90 degrees
so that their largest level surfaces (f) attain the vertical and face
forward (toward the forks). Observe any previous marking made on
the eccentric cam.
e
f
6. Screw the locking rings (d) in place with the screws (c) and their
washers, so that the eccentric cams cannot turn.
7. If necessary, centre the mast by using the adjuster screws (h) and
crosswise screwing in the adjuster screw on one side and
slackening on the other side. Refit the locking screw (b).
e h b

Main mast 1.6-2.5 t (7100)
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8. Screw in the screws (a) and their washers into the bottom bracket.
9. Measure the incline to the rear and shim as needed. This should
nominally be 2 shims, or 90° ± 10’.
a a
10. Engage the screws (a), but do not torque tighten them.
11. Adjust the lateral incline by loosening the screws (c) on the
eccentric cam locking rings (d).
12. Turn the eccentric cams until the correct lateral incline is achieved,
90° ± 6’.
Note: The eccentric cams must not be turned making the large
surfaces face inwards in the cups on the mast attachment in the reach
carriage.
13. Check the incline to the rear (90° ± 10’) once more, and add shims
as needed.

Main mast 1.6-2.5 t (7100)
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14. Tighten the screws (c) for the locking ring (d) to 124 Nm..
15. Tighten the screws (a) of the bottom bracket to:

1.6–2.0 ton masts: 519 Nm (one screw)
2.5 ton mast: 266 Nm (two screws).
16. Unscrew the locking screw (b) and apply Loctite 29320 (Loctite 242
Blue) to the threads.
17. Screw in the locking screw (b) until it makes contact.
18. Finally, tighten the locking screw (b) ¾ of a turn.
19. Connect the hydraulic hoses to the lift cylinders (H1 and H2) and
the free lift cylinder (H3) on the main valve.
20. Connect the hydraulic hoses to the tilt cylinder (A1 and B2).
21. Connect any electric cables for extra functions on the mast.
22. Bleed the hydraulic system, see the section "Hydraulic system,
bleeding".

Main lift chain system (7120)
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16.2 Main lift chain system (7120)
16.2.1 General
Applies to all machines with a mast.
DANGER!
When replacing the chain, be sure to also replace the chain bolt.
16.2.2 Checking the chain

The chains are subjected to two types of wear – outline wear and
stretching. Wear to the bolts and disc holes is caused by stretching.
The chains are also affected by the environment in which they are
used.
Noise
If there has been insufficient lubrication, there will be metallic friction on
the chain and this will result in noise.
The chain must be replaced.
Surface rust
Surface rust is easy to recognise as the chain will be reddish brown.
Deep-seated rust has generally started and the strength of the chain is
impaired.
Rusty links
Fretting corrosion results in a reddish-brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding if
lubricated.

7510399-020 2012-10-03 6070557 815, 816
Stiff links
If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.
Bolt rotation
Bolt rotation can be a phenomenon of stiff links.
The fault is easy to see when comparing with a new chain.
.
Loose bolts
If a bolt is loose it will protrude from the side of the chain, and this is due
to a stiff link or bolt rotation.

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Outline wear
H2 H3
P = Pitch.
H2 = Nominal plate height.
H3 = Minimum plate height.
A new lifting chain has a specific nominal disc height (defined as H2 in
the figure). As the truck is used, the lifting chain wears radially on the
side that rolls over the chain wheel. The minimum disc height (defined
as H3 in the figure) denotes the minimum permitted value of the disc
height.
Maximum permitted outline wear is 5% of the height H2. If a lifting
chain reaches the maximum level of wear, the chain must be replaced.
The nominal and minimum disc heights for each lifting chain are stated
in the table in the section “Stretching”.

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Stretching
The amount of stretch on a lifting chain is measured on the part of the
chain that runs over the chain roller. Stretching must not exceed 2 % in
the section of chain where wear is greatest. The measurement is best
made over 300-1000 mm of chain.
The nominal and maximum permitted chain lengths for lifting chains are
stated in the table below.
Type of Nominal Minimum Pitch P Nominal chain Maximum permitted

chain plate height plate height (mm) length for 20/30/50 chain length for 20/30/50
H2 ( mm) H3 (mm) plates (mm) plates (mm)
3/4", 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4", 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4", 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1", 4x4 23.6 22.4 25.4 508/762/1270 518/777/1295
1", 6x6 23.6 22.4 25.4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are one reason why
the chain stretches. The chain must be replaced if elongation exceeds
2%.
Damage
The chain must be replaced if damaged in any way.

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Damaged plates
If a plate has broken on the chain, this may be due to overloading or
corrosion.
Damaged bolts
It can be difficult to discover if a bolt has broken. It can appear as bolt
rotation and/or that the outer plate is loose.
Dirty chain
If a chain is very dirty replacement is recommended first and foremost.
It can also be removed and cleaned. See section "7.5.1 Cleaning and
washing".
16.2.3 Lubricating the chain

Both mineral and synthetic oils can be used to re-lubricate Rexnord
chains.
Note:
Lubricant must not contain substances such as molybdenum
disulphide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
The chains are sprayed with lubricant. Please note that the entire chain
must be lubricated, even the fastening bolts. It is particularly important
that the part of the chain that runs over the chain wheel is well
lubricated.
The lubricant must fulfil the requirements for viscosity for each
respective temperature. See section "23.2 Oil and grease
specification".
Note:
Do not use a special rust protective agent to prevent
rust on the lifting chains.
These agents impair lubrication of the chains. Regular lubrication is
the best method to prevent rusting.

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16.2.4 Main lift chain system, adjusting the

fork-to-floor distance
The lift chains must be adjusted at regular periods due to elongation.
The chain is checked during servicing as set out in the maintenance
schedule.
Using the free lift chain and main lift chains, the mast runners should be
adjusted so that the bottom part of the mast is level.
Then the forks are adjusted so that the fork holes are 10-15 mm from
the floor.
10-15 mm
Note:
The forks should be tilted into their horizontal position.

Reach carriage (7190)
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16.3 Reach carriage (7190)
16.3.1 Adjusting radial play in the reach

carriage
1. Run out the reach carriage and the battery.
2. Lift the battery off, but put it in a position so that it can be connected
up, alternatively so that power can be supplied to the truck from a
different external source.
3. Place a load on the forks. The weight of the load must be large
enough for both the right and left rear rollers to sit flush against the
top beam flanges.
4. Place the eccentric rollers (a) against the bottom flange and tighten
the lock nut (c) (36 mm hexagonal) until the axles (b) can be rotated
(32 mm hexagonal), but with some resistance.
(Tighten nut (c) approx. 0.5–1 turn after the nut has made contact
with the washer.)
b c
5. Check that the eccentric rollers are up against the beam (arrow)
once the nut has been tightened.
6. Slowly run the reach movement fully in and out again; do this
carefully so that the load holds the rear runners against the top
beam flanges for the entire time.

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7. Once the reach carriage is back in its original position, use a feeler
gauge to check play between the eccentric rollers and the beam
flange (arrow).
It should be easy to insert the feeler gauge and it should not be
pressed in. A suitable interval on the feeler gauge is 0.1 mm.
b c
8. Select a feeler gauge that is 0.1 mm thicker (or a minimum of 0.3

mm) than the one that can be inserted between the roller and
flange.
9. Turn the eccentric shaft (b) to increase play with the flange, insert
the selected feeler gauge and turn the shaft back so that there is
slight pressure from the eccentric roller against the feeler gauge.
10. Tighten the lock nut (36 mm hex nut) to 220 Nm. Make sure to hold
the shaft so that it does not rotate as the nut is tightened.
11. Withdraw the feeler gauge. (If the feeler gauge has got stuck, give
the tool in the eccentric shaft a slight tap in the opposite direction so
that the feeler gauge comes loose).
12. Restore the truck for normal operation.

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16.3.2 Adjusting axial play in the reach

carriage
When adjusting the lateral clearance of the reach carriage, it is
important that:
• the wheels on both sides are adjusted equally
• the reach carriage is centred in the chassis
• the carriage runs straight and smoothly without jamming or coming
loose.
1. Fully run out the reach carriage.

2. Measure the clearance between the reach carriage and support
arms at each roller.
3. Remove the locking screw (a) (16 mm Allen screw) from the
adjuster of each roller.
4. Adjust the rollers (10 mm Allen screw) so that the reach carriage is
parallel with the support arms and centred between the support
arms.
5. Once the reach carriage has been adjusted correctly, place the
adjusting rollers against the support arm and turn the adjusting
screws back a ¼ turn.
6. Lock the adjusting screws.
7. Test run the reach carriage out and in, making sure the carriage
runs smoothly without jamming.
8. Check that the rollers come up against the reach stop at the same
time as the carriage is run fully out.
9. If necessary, adjust the stop on the side the roller strikes first by
sanding it down until both rollers strike the stop simultaneously.

Lifting devices (7400)
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16.4 Lifting devices (7400)
16.4.1 Forks
General
Inspections and inspection intervals comply with ISO standard 5057.
Inspection
The forks must be carefully inspected by trained personnel. The aim of
an inspection is to discover any damage, malfunctions, deformation or
similar that may impair safety. A fork with such defects must be taken
out of service and must not be used until it has been repaired in a
satisfactory manner and, where necessary, tested. “See section
"16.4.2 Forks, repairs and testing".
Inspection intervals
Forks in operation must be inspected at intervals of no more than
twelve months and whenever a defect or permanent deformation is
discovered. In the case of demanding applications, more regular
inspections may be necessary.
Surface cracks
The fork (a) must be subjected to a careful visual inspection for cracks
and, if necessary, a non-destructive crack indication check. Pay
particular attention to the tilt stop and the upper and lower hooks (c, d),
including their attachments to the back of the fork carriage (b). The fork
must be taken out of service if surface cracks are discovered.
c
b

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Difference in height between the fork tips

Check a set of forks to see if there is any difference in height once they
are installed in the fork holder. If the difference in tip height exceeds 3%
of the blade length or the limit value recommended by the truck
manufacturer, the set of forks in question must be taken out of service.
Such a set of forks must not be taken into service again until they are
rectified and tested. See section "16.4.2 Forks, repairs and testing".
Position lock
Check that the position lock (if included in the delivery) is in good
condition and fully functional. If any fault is found, the fork must be
taken out of service until it has been repaired in a satisfactory manner.
Readability of the markings

If the marking on a fork as per ISO 2330 is not clearly legible, the fork
must be taken out of service.
Fork blades and back of fork carriage

The fork blade (a) and back (b) must be carefully checked for wear. Pay
particular attention to the area around the tilt stop. If the thickness of the
blade or back has been reduced to 90% of the original thickness, or to
the minimum thickness specified by the fork or truck manufacturer, the
fork must be taken out of service.
c
b
Mounting fixtures on the fork

Check the upper hook's support surface and the attachment surfaces of
both hooks for wear, crushing or other local deformations. If the defects
are so obvious that play between the fork and fork holder becomes
excessive, the fork must be taken out of service. Perform similar checks
on other types of mounting fixtures.

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16.4.2 Forks, repairs and testing

Repairs
Only the fork manufacturer or a specialist of equivalent expertise may
determine if the fork may be repaired and used again. Repairs must
only be carried out in accordance with the recommendations of the fork
manufacturer. It is not recommended that surface cracks or wear be
repaired by welding. If repairs are required to restore the fork to
acceptable condition, the fork may then need to be heat-treated in a
suitable manner.
Testing the yield point

A repaired fork (except for repairs to or replacement of position locks
and/or markings) may only be used again if it has undergone a yield
point test as described in ISO 2330 and been approved. However, the
test load must conform with the table.
Specified fork capacity, m Test load Ft
m ≤ 5000 2.5 m
m > 5000 2.1 m
Fork
a
b
d
L
e
c
a. Fork
b. Clamp
c. Spring pin
d. Washer
e. Spring
f. Lock

Fork carriage
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16.5 Fork carriage
a 16.5.1 Checking the fork carriage’s wear strip

The wear strip (a) between the yoke and ball beam on the fork carriage
is subject to wear and must be checked annually.
b
1. Measure the gap (b) between the yoke and the ball beam. When
the wear strip is new, the gap is 2 mm. If the gap is 4 mm or more,
the wear strip must be replaced.
2. Check the gap (c) between the stop lug and the fork yoke as well.
At the maximum tilt angle, the play must not exceed 1 mm.
3. Inspect and adjust the gap by inserting a 1 mm feeler gauge

between the fork yoke and the stop lug. The feeler gauge can be
removed once the forks have been tilted down. Tighten the four
screws to 45 ±11 Nm.
4. The gap can be adjusted with the screws on the stop lug and then
locked (see the screws and locks marked with arrows)
a Max tilt angle
a: Maximum tilt angle

Fork carriage
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16.5.2 Lubricating the fork carriage

The following locations should be lubricated once a year:
• Between the ball beam and the wear strip of the side shift unit (a)
• Between the yoke and the friction plate (b)

Fork spread unit
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16.6 Fork spread unit

Note:
If a fork spread unit has been fitted to the truck, the parameter
settings must be modified. See section "5.5 Service parameters,
hydraulics".
16.6.1 Servicing the fork spread unit

On usual truck servicing, the following points should be checked/
carried out:
• Lubrication of friction plates against fork and ball beam.
• Push grease into the grease nipples when servicing the truck. The
brass bushings in the fork sleeve and in the support rollers provide
some degree of lubrication, as they are provided with graphite
inlays.
• During lubrication, use a graphite grease, e.g. Q8 Rembrandt EP2.
• Check bearings and axles, and replace wear parts if there is
substantial play in the fork sleeve.
• If the upper chromed axle has been damaged, this must be replaced
immediately. Wear on the lower support rollers is the result of the
forks being used frequently for lateral conveyance. In very dirty
environments, these should be checked more often than in normal
environments.
• Check the forks. The thickness of the blade or shaft should be at
least 90% of the original thickness in accordance with ISO 5057.
• Check the screws and nuts. If necessary, tighten as normal.

Fork spread unit
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Replacing bearings
1. Remove the outer lock ring (d) and wiper seal (c).
2. Remove the inner lock ring (b) and wiper seal.
3. Remove the bearing (a).
4. Fit the new bearing and refit the outer and inner lock rings and
wiper seal.
5. Apply locking fluid to the screws (e) on fitting.
Roller replacement
1. Remove the tension pin (g) from the fork lug.
2. Push the axle (f) out.
3. Remove the roller (h).
4. Place a new roller in position.
5. Push the axle in.
6. Fit the tension pin.
a b c d
g h

Fork extensions with adjustable fork length
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16.7 Fork extensions with adjustable

fork length
Note:
If the truck is fitted with optional heavier forks, the parameter settings
must be modified. See section "5.5 Service parameters, hydraulics".
A standard fork can be extended with adjustable fork extensions. In this
way you can carry bulkier items. When the fork extension is fitted, a
check is made that it is suitable for fitting to a standard truck fork (see
the details on the identification plate).
Only use in pairs when the specified fork dimensions match, and the
length of the truck fork is greater than or equal to the minimum
permitted truck fork length.
Note:
Please note that load capacity is reduced once the fork extensions
are attached.
Note:
The fork extension must not be used if the mounting is unsafe or if it
is damaged, dirty or icy. The chamfered underside must face
downwards. Daily visual inspection is recommended.
• The fork extension must be regularly maintained, and inspected
once a year.
• If at any point the plate thickness of the fork extension is less than 3
mm, the fork extension must be replaced immediately.
• If the fork extension shows signs of distortion, cracks or other
damage, it must immediately be taken out of service.
• A crack indication check must be performed using the dye
penetration method.
• Check the function and safety of the locking pin.
To fit the forks, use the following locking pin:
Check that the fork extension is firmly attached; pull on the fork
extension to check it is secure.

Fork extensions with adjustable fork length
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c b
d e
a. Fork extension
b. Fork, main segment
c. Fork, extension
d. Fork, extension
e. Pin
f. Lock

Manual telescopic forks
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16.8 Manual telescopic forks
16.8.1 Installation
DANGER!
Risk of injury. Fingers, other body parts or objects may not be
inserted in the holes on the fork blade or extension piece. These
holes are only intended for the locking bolts.
Note:
1. Push the bolt (a) upwards until it reaches the stop.
2. Turn the bolt anticlockwise until it is held by the stop.
3. Remove the bolt.
4. Push/pull the extension piece (b) to the required position. Use the
handle under the tip on the extension piece.
5. The hole in the extension piece must be in line with a hole in the
original fork, so that the extension piece can be attached to the
original fork.
6. Avoid using too much force to position the extension piece, as this
can damage the stop screw (c).
7. Place the bolt in the hole. Check that the grooves in the bolt
correspond to the original fork.
8. Turn the bolt clockwise until it is held by the stop.

Manual telescopic forks
7510399-020 2012-10-03 6070557 815, 816
Note:
The locking bolts must not stick up above the surface of the fork. The
bolt must be correctly inserted. The fork must not be used until the
bolt has been correctly secured.
Avoid using too much force to pull the extension piece towards the
end stop, as this can damage the stop screw.
The stop screw (c) must be screwed into the extension piece and
secured with Loctite 242. It should only be removed when replacing
the extension piece. It must then be screwed back in and secured.
16.8.2 Maintenance
It is not necessary to grease the original fork or the extension piece.
Remove any dirt using a wire brush, for example.
The fork must be inspected annually.
The following checks are to be performed:
• The function of the fork arm’s locking device at the fork attachment
point
• The function of the extension piece’s locking device
• The function of the stop screw (it must not be possible to remove the
extension piece)
• Check the original forks for deformation (90 degree angle)
• Check for wear on the original fork (10% rule)
When the thickness of the steel on the extension piece has been
reduced to 3 mm or less at any point of the extension piece, this must
be replaced. Wear to the extension piece occurs most often near the
heel or under the fork tip. If wear to the original forks is 10% or more of
the nominal thickness, the original fork must also be replaced. (ISO
5057)
• Check for cracks in the fork heel and extension piece
• Check extension piece for wear (t= >3 mm)
• Check the extension piece for deformation and cracks
• Check the locking bolt and its function
Note:
Always replace the forks in pairs.

Hydraulic telescopic forks
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16.9 Hydraulic telescopic forks

Note:
The KOOI forks can be extended hydraulically.
There are two types: telescopic forks with separate flow dividers and
telescopic forks with an integrated system for flow distribution.

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16.9.1 Telescopic forks with separate flow

dividers
a
c
b
d
e
g
f
h
d
j
k
m
n o
p
q
s
r
a. Piston section 2 k. Rod seal

b. Piston seal m. Support ring
c. Piston section 1 n. Cylinder head assy.
d. Piston rod, diam. 15 o. Washer
e. Fixing screw p. Washer
f. Plastic plug q. Special bolt M10
g. Serial number on inner r. Piston with seals
fork s. Cylinder head with
h. Sealing strip, inner fork seals
j. Support ring

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Fitting instructions
The telescopic forks’ identification plates are marked with an L (left
side) and an R (right side). The forks are fitted on the fork yoke to the
left and right as per the markings viewed from the operator
compartment. Push the forks onto the fork yoke and check that the
locking pin is correctly positioned in the hole on the yoke.
Fit the flow divider on the back of the fork yoke. The flow divider must
be fitted in a horizontal position to ensure correct function of the
hydraulic circuit. Connect the accompanying hydraulic hose(s) to the
telescopic forks and the hoses from the forklift truck. Check that all
connections are correctly tightened and secure.
bar).
Initial operation of telescopic forks with separate

flow dividers
Before the forks can be used, the system must be bled.
1. Run the forks in and out ten times.
2. Move the mast from its front to rear position several times.
3. Run the forks in and out ten times.
4. Check that the hoses can move freely.
5. Check the system for oil leaks.

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16.9.2 Telescopic forks with integrated flow

dividers
b
a
e f
a. Telescopic forks, pair of forks

b. Piston
c. Cylinder head
d. Friction plate
e. Outer fork
f. Piston rod

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Fitting instructions
The telescopic forks’ identification plates are marked with an L (left
side) and an R (right side). The forks are fitted on the fork yoke to the
left and right as per the markings viewed from the operator
compartment. Push the forks onto the fork yoke and check that the
locking pin is correctly positioned in the hole on the yoke.
Connect the accompanying hydraulic hose(s) to the telescopic forks
and the hoses from the forklift truck. Check that all connections are
correctly tightened and secure.
bar).
Initial operation of telescopic forks with integrated

flow dividers
Before the forks can be used, the system must be bled.
1. Move the mast between its front and rear position a number of
times.
2. Push the telescopic forks back using the control. Hold the controls
in the rear position for approx. one minute so that the forks remain
pushed back and are flushed.
3. Move the forks in and out a number of times.
4. Check that the hoses are not blocked and that the system is not
leaking oil.

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16.9.3 Maintenance of telescopic forks

Note:
Whenever the telescopic forks are serviced, the truck must be turned
off and the battery disconnected.
If the telescopic forks are removed, the forks’ couplings must be
sealed to prevent dirt from entering the hydraulic system.
Note:
The forks are replaced as a pair. If one fork is damaged to the extent
that it must be replaced, both forks must be replaced.
1. Lubricate the top of the inner fork as required. Lubricate with

calcium grease (e.g. Q8 Ruysdael WR2). (a)
2. Check the wear on the forks’ underside and wear plate, particularly
on the back. Check the inner fork as per ISO 5057, with the
c exception of “fork blades and shafts”, as the inner fork is not subject
to wear (b).
3. Check for hydraulic leaks/damage. Examine the cylinder head to
b ensure there are no leaks. (This is easy to see once you remove
the outer fork (d)).
4. If the telescopic fork tilt stops are leaking, they must be removed
immediately. If the couplings are leaking, these must be tightened
a or replaced. (c)
d 5. If the wear plate on the underneath of the forks is completely worn,
or if the outer fork sleeve is starting to rub against the wear plate,
e the wear plate must be replaced with a new one to prevent damage
to the outer fork sleeves and the inner fork.
6. Once the outer fork has been removed you can easily check the
cylinder head. (e)

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16.9.4 Dismantling telescopic forks

Note:
Whenever the telescopic forks are serviced, the truck must be turned
off and the battery disconnected.
If the telescopic forks are removed, the forks’ couplings must be
sealed to prevent dirt from entering the hydraulic system.
1. Operate the forks to waist height and tilt the mast to its forward
position.
2. Switch off the truck and then withdraw the battery cut out
connector.
3. Remove the outer fork by removing the attachment bushings for
the spirals. Be careful not to damage the piston rods.
4. Unscrew the couplings at the top of the back of the fork, so that the
piston rods do not create a vacuum when removed.
5. Remove all Loctite from the coupling threads.
6. Undo the fixing screw between the two cylinder heads.
7. Place a collection vessel under the forks. Undo the cylinder head
using the cylinder head spanner. The right cylinder head (as
viewed by the operator) must always be unscrewed first, as there is
a plastic plug underneath the fixing screw.
8. Carefully remove the piston rods. Note that there are two loose
support rings on each side of the piston ring seal. Remember to
replace these when installing the piston rod on the fork.
9. The piston can now be unscrewed. To prevent the piston rod being
damaged while the piston is being unscrewed, it must be secured
in position to prevent the piston rotating. Due to the presence of
Loctite sealant, the pistons on forks with integrated flow dividers
must be heated with a burner before they can be unscrewed.
10. The cylinder head can now be removed from the piston rod.
11. Replace the parts.
12. Remove all Loctite from the piston rod thread.
13. Clean the piston rod and thread with Loctite 7063.
14. The cylinder head can now be reinstalled on the piston rod.

7510399-020 2012-10-03 6070557 815, 816
16.9.5 Assembling telescopic forks

1. Once the pistons are fully attached to the piston rod, they must be
secured with Loctite. For forks with separate flow dividers, use
Loctite 542. For forks with integrated flow dividers, use Loctite 270.
2. Hold the piston rod (together with the piston and cylinder head) in
line with the cylinders and carefully tap them in.
3. Apply copper paste to the cylinder head thread.
4. Replace the cylinder head using the cylinder head spanner.
5. Once all piston rods are in, tighten the fixing screw again.
6. Now tighten the couplings (secure with Loctite 542).
7. Run the forks out to approximately 150 mm.
8. The outer forks can now be installed. Make sure that the piston rod
holders end up immediately under the holes in the outer fork.
9. Place a screwdriver or a screw in one of the holes and hammer in
the attachment bushings for the spirals with a heavy hammer.
Remove the screwdriver or screw and drive in the other attachment
bushings for the spirals.
10. For forks with integrated flow dividers, the truck must be started
and the forks held retracted for approx. one minute using the lever,
so that air is vented from the system, which then fills with oil. For
forks with separate flow dividers, the forks must be extended and
retracted several times.

815, 816 6070557 2012-10-03 7510399-020
This page has been deliberately left blank

Peripherals - 8000
Introduction
7510399-020 2012-10-03 6070557 815, 816
17 – Peripherals - 8000
17.1 Introduction
This section is reserved for future use.

Peripherals - 8000
Introduction
815, 816 6070557 2012-10-03 7510399-020

Extra equipment - 9000
Introduction
7510399-020 2012-10-03 6070557 815, 816
18 – Extra equipment - 9000
18.1 Introduction
This section is reserved for future use.

Extra equipment - 9000
Introduction
815, 816 6070557 2012-10-03 7510399-020

Appendix “Destruction instructions”
General
7510399-020 2012-10-03 6070557 815, 816
19 – Appendix “Destruction
instructions”
19.1 General
These destruction instructions have been introduced to support our
company's objective of protecting the environment. By recycling mate-
rials, resources can be utilised more efficiently, while emission of unde-
sirable substances is reduced.
The instructions below indicate the proper sorting category for the
materials used in the various truck components. To achieve optimum
sorting, all components should be disassembled to a level correspond-
ing to the sorting categories.
19.2 Marking of plastics
19.2.1 General marking of products and

packaging material
Markings on plastics consist of three arrows, a number and usually also
a designation for the plastic material used. The picture shows an exam-
ple with the marking for polypropylene.
• 01: PET – Polyethylene terephthalate
• 02: PE-HD – Polyethylene with High Density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with Low Density
• 05: PP - Polypropylene
• 06: PS – Polystyrene
• 07: O – Others

Marking of plastics
815, 816 6070557 2012-10-03 7510399-020
19.2.2 Marking according to our standard

Standards: 58-02-001, 58-02-003 and 58-02-004.
Only a few examples of markings are presented here. Fore more infor-
mation, please refer to the standards mentioned above.
The product material and trade name are indicated between arrows.
Example: >PP<.
Abbreviations
- ABS: acrylonitrile/butadiene/styrene
- HDPE: High Density Polyethylene
- LDPE: Low Density Polyethylene
- PA: Polyamide
- PA6: Amide resin 6
- PA66: Amide resin 66
- PBT: Polybutylene terephtalate
- PC: Polycarbonate
- PET: Polyethylene terephtalate
- PMMA: Plexiglas
- POM: Polyoxymethylene, Polyformaldehyde
- PP: Polypropylene
- PUR: Polyurethane
Marking examples
Products made from a single substance
ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and carbon-
ate plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<

Pressure vessels
7510399-020 2012-10-03 6070557 815, 816
19.3 Pressure vessels

Pressure vessels sent for recycling/destruction must have been
depressurised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas dampers and accumula-
tors used in hydraulic systems.
19.3.1 Gas dampers

DANGER
Gas dampers have extremely high internal pressure. To prevent inju-
ry, always heed the instructions of the manufacturer.
Use safety goggles when disassembling springs.
To allow the gas to escape, only open and disassemble gas dampers
as prescribed by the manufacturer. An example of how to perform this
is given for “Stabilus Lift-O-Mat/Inter-stop”:
2 1
ca 20 mm
1: Drill or cut a hole in the cylinders, approximately 20 mm from the bot-

tom.
2: Drill or cut a hole in the cavity at the piston rod end.

Sorting categories
815, 816 6070557 2012-10-03 7510399-020
19.4 Sorting categories

• Plastic and rubber material
• Iron/steel (including bolts, washers and nuts)
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Cables
• Hazardous waste
• Complex materials - large amounts of several categories but non-
combustible and not hazardous
• Combustible material (including small plastic and rubber parts)
• Please return batteries to the manufacturer.
COMPONENT Category Comment

Chassis • Iron/steel
Covers and doors, • Iron/steel
sheet metal
• Handles: >ABS<
Covers and doors, • Plastic Sort according to the
plastic material marking
Forks and bodies • Iron/steel
Operator platforms • Iron/steel, also possible gas damp- Be sure to depressurise
ers dampers
• Mats, cushions: combustible
Roofs and overhead • Iron/steel
guards
Gates and operator • Iron/steel
protective devices
• Plastic handles: >PA<
• Crush protectors: >PMMA<
Hydraulic units • Oil Ensure the system has
been depressurised.
• Hydraulic hoses: Oil polluted mate-
Carefully drain all oil.
rial
Any accumulators should
• Oil tank: >PP< be emptied of gas and if
• Motor, valves: Electronic parts possible opened.
• Pump: Iron/steel
• Accumulator: Iron/steel

Sorting categories
7510399-020 2012-10-03 6070557 815, 816
COMPONENT Category Comment

Travel drive motors • Motor: Electronic parts
• Cables
• Parking brake: Hazardous waste
Drive gears • Iron/steel Carefully drain all oil.
• Oil Hazardous waste
Wheels • Tread: Plastic according to mark- If the tread and hub can-
ing not be separated, then
sort the wheel as com-
• Hub: Iron/steel
plex material
Tiller arms • Electronic parts Be sure to depressurise
dampers
• Cables
• Iron/steel, also gas dampers
Electric systems • PCBs, transistor regulators, Exan- Hazardous waste
sion unit SEU, contactors: Elec-
tronic parts
• Cables
• Small batteries Hazardous waste
• Fluorescent tubes Hazardous waste
Because of the chemical
content in fluorescent
tubes, do not destroy
them.
Obsolete fluorescent tube
must be packaged and
transported according to
local regulations.
Masts • Mast members, rollers, cylinders, Oil-polluted components
hydraulic pipes: Iron/steel should be handled as
hazardous waste
• Hydraulic hoses: Oil-polluted ()
• Cables
• Sensors/switches: Electronic parts
• Plastic components: According to
marking or as combustible waste
Chargers and connec- • Electronic parts
tors
• Cables

Sorting categories
815, 816 6070557 2012-10-03 7510399-020

Wiring diagram
Components
7510399-020 2012-10-03 6070557 815, 816
20 – Wiring diagram
20.1 Components
Des. Function: Component type Other Fig Schemat Schemati
ure ic chart c chart
(255534) (260844
CC)
A1 Central Information Electronic card 34 3, 9, 10, 3, 9, 10,
Display (CID) with 14, 17, 14, 19,
display 18, 21, 20, 23,
23, 24 25
A2 Power steering Electronic card 3 6 6
(EPS)
A5 Main micro- Electronic card 36 1, 4, 7, 1, 4, 7,
controller (MCU) 8, 9, 11, 8, 9, 11,
12, 13, 12, 13,
14, 15, 14, 15,
16, 17, 16, 19,
23, 24, 25
25
A6 Sensor control Electronic card 34 14 14
A9 Power distribution Fuse box 19 2 2
A11* Stereo/CD Stereo/CD 14, 18 20
16
A72* Impact Manager Shock switch ID 26 25 -
A82* Data management Electronic card T.W.I.S. unit in the 25 22 24
unit truck
B1 Temperature sensor Temperature 2 4 4
in [M1] sensor
B2 Temperature sensor Temperature 3 5 5
in [M3] sensor
B4 Hydraulic lift Pressure sensor 6 11 11
pressure
B5* Fork tilt angle Angle sensor 1
B6* Pressure Pressure sensor 7
measurement, main
lift
B11 Speed Pulse sensor 2 4 4
measurement [M1]
B12 Speed Pulse sensor 3 5 5
measurement [M3]

Wiring diagram
Components
815, 816 6070557 2012-10-03 7510399-020

(255534) (260844
CC)
B13 Pulse transducer, Twin sensor 35 9 9
steering wheel bearing
B17 Reference for 180° Inductive sensor 2 9 9
steering angle
B18 Height sensor free Sensor 1, 8 12 12
lift
B19 Height sensor main Sensor 8 12 12
lift
B20 Raise/lower forks Hall sensor Nominal output 34 10 10
B21 Fork carriage in/out Hall sensor voltage: 34 10 10
0.5 V (min)
B22 Fork tilt up/down Hall sensor 2.5 V (neutral 34 10 10
B23* Side-shift right/left Hall sensor position) 34 10 10
4.5 V (max)
B24* Fork spread/aux Hall sensor 34 10 10
B25 Height reference, Inductive sensor 1 13 13
forks near top of
mast
B26 Position for reach Inductive sensor Distance: 7 16 16
carriage, sensor 1 0-6.5 mm
B27 Position for reach Inductive sensor 7 16 16
carriage, sensor 2
B28* Cabin tilt in lowest Inductive sensor 18 16 16
position
B29* Cabin tilt in highest Inductive sensor 18 16 16
position
B31 Safety pedal Inductive sensor 5 7, 8 -
B31 Door safety switch Inductive sensor (Cold-store cab) 31 - 14
Distance
0-6.5 mm
B32 Pedals Hall sensor Nominal output 5 7, 8 7, 8
(acceleration and voltage:
brake) 0.5 V (min)
4.5 V (max)
B33 Height reference, Inductive sensor 7 13 13
mast near bottom
position
B35 Horn Horn 34 14 14
B36 Travel direction Hall sensor 34 14 14
selector.
B38* Height preselector, Hall sensor 34 23 25
next level

Wiring diagram
Components
7510399-020 2012-10-03 6070557 815, 816

(255534) (260844
CC)
B39* Height limitation Hall sensor 34 23 25
override
B40* Forks to horizontal Hall sensor 34 17, 24 19
position
B41* Side-shift to centre Hall sensor 34 17, 24 19
position
B42* Change of function Hall sensor 34 10 10
for fifth mini-lever
B43* Cab tilt activation Hall sensor 34 23 25
B44* Activation of extra Hall sensor 34 23 25
function 1
B45* Activation of extra Hall sensor 34 23 25
function 2
B46 Height reference Inductive sensor Distance: 8 12, 13 12, 13
mast lowering 0-6.5 mm
B47* Side-shift sensor Magnetic sensor 1 17, 24 19
B49 Seat switch Inductive sensor Distance: 9 14 14
0-6.5 mm
B50* Fork camera Camera 17 19 21
B57 Height reference, Inductive sensor 8 12, 13 13
mast lowering
B58 Height reference, Inductive sensor 1, 8 12 12
forks below 1 m
B59* Steering angle Inductive sensor Distance: 2 - 6
sensor 0-1.6 mm
B90* Shock sensor Shock sensor 25 22 24
B118* Shock sensor Shock sensor M For connection to 26 - -
type Impact Manager
E3* Working light Lamp 15, 17, 24 19
24
24
24
24
E10* Seat heater Resistor 9 14 14
E40* Window heating, 150 W 27 - 18
left

Wiring diagram
Components
815, 816 6070557 2012-10-03 7510399-020

(255534) (260844
CC)
right
door
front
roof
F1 Fuse for [T1] Fuse 160 A/200 A 6 4 4
F3 Fuse for [T2] Fuse 250 A/325 A 6 5 5
F60 Fuse for relays Fuse 3A 19 2 2
F61 Main fuse for [A5] Fuse 7.5 A 19 2 2
F62 Main fuse for [A1] Fuse 3A 19 2 2
F63 Fuse for [P6] Fuse 3A 19 2 2
F64 Fuse for activation Fuse 3A 19 2 2
of [A2]
F65* General Function Fuse 5A 19 2 2
Unit fuse
F66* Fuse for [T5] and Fuse 7.5 A 19 2 2
[T6]
F69 Fuse for [X42] and Fuse 10 A 19 2 2
[S133]
F71 Fuse for [A5] Fuse 7.5 A 19 2 2
F72 Fuse for [A2] Fuse 30 A 19 2 2
F73 Fuse for control Fuse 7.5 A 19 2 2
voltage
F74 Fuse for [A1] and Fuse 3A 19 2 2
[A5]
F75* Fuse for working Fuse 10 A 19 2 2
light
F76* Fuse for [T3] Fuse 7.5 A 19 2 2
F77* Fuse for seat heater Fuse 10 A 19 2 2
F90* Fuse for cab Fuse 100 A (Cold-store 30 - 1
heating cab)
F91* Control circuitry Fuse 7.5 A (Cold-store 29 - 17
fuse for heater cab)
F92* Fuse for heater Fuse 25 A (Cold-store 29 - 17
element cab)

Wiring diagram
Components
7510399-020 2012-10-03 6070557 815, 816

(255534) (260844
CC)
element cab)
element cab)
element cab)
F96* Fuse for heated Fuse 20 A (Cold-store 29 - 17
windows cab)
G1 Truck battery Battery 48 V 18 1 1
G3 Cooling of [T1] and Fan motor 2 4 4
[T2]
G4 Cooling of [M3] Fan motor 2 4 4
G5* Fan for ventilation Fan motor (Cold-store cab) 29 - 17
K1 Electronic ignition Electronic card 34 21 23
key
K20 Key relay Power relay 460–330 Ohm at 19 2 2
48 V DC
M1 Drive motor 3-phase AC motor 6 4 4
M3 Pump motor 3-phase AC motor 6 5 5
M6 Steering servo Stepper motor 37 6 6
motor
P4 Horn Horn 2 14 14
P5* Warning lamp LEDs Flashing: ~2 Hz 14, 15 15
Nominal current: 15
70 mA
P6* Load Information Electronic card 20 15 15
Display (LID) with
display
P7* Travel alarm Horn 13 - 25
P10* Loudspeaker Loudspeaker 16 18 20
P11* Loudspeaker Loudspeaker 16 18 20
P12* Travel alarm Lamp 15 - 25
P13* Travel alarm Lamp 15 - 25
P14* TV monitor Monitor 17 19 21
P17* Warning lamp LEDs Flashing: ~2 Hz 26 25 -
Nominal current:
70 mA
Q1 Parking brake Electromagnetic 32 Ohm 2 15 15
brake
Wiring diagram
Components
815, 816 6070557 2012-10-03 7510399-020

(255534) (260844
CC)
Q2 Valve for main mast Electromagnetic 22 Ohm 38 11 11
lift valve
Q3 Valve for initial mast Electromagnetic 38 5 5
lift valve
Q4 Valve for main mast Electromagnetic 38 11 11
lowering valve
Q5 Valve for initial mast Electromagnetic 38 5 5
lowering valve
Q6 Valve for reach Electromagnetic 25 Ohm 38 11 11
carriage in valve
Q7 Valve for reach Electromagnetic 38 11 11
carriage out valve
Q8 Valve for extra Electromagnetic 25 Ohm 38 11 11
hydraulic function, valve
direction A
Q Valve for extra Electromagnetic 38 11 11
hydraulic function, valve
direction B
Q10 Main relay Contactor 150 Ohm 3, 1 1
18
Q11 Valve for cabin tilt Electromagnetic 25 Ohm 32 4 11
upwards valve
Q12 Valve for extra Electromagnetic 12 11 11
hydraulic function 2 valve
Q16* Support arm brake Electromagnetic 4 15 15
(left) brake
Q17* Support arm brake Electromagnetic 4 15 15
(right) brake
Q18 Valve for fork tilt/ Electromagnetic 1 11 11
side-shift valve
Q21 Valve for cabin tilt Electromagnetic 32 4 11
downwards valve
Q30* Relay for cab Power relay 29 - 17
heating
Q31* Relay for initial Power relay 29 - 17
heating

Wiring diagram
Components
7510399-020 2012-10-03 6070557 815, 816

(255534) (260844
CC)
Q54* Timer relay for Relay, multi- 27 - -
heated windows function
Q55* Timer relay for Relay 27 - 18
heated windows
Q56* Timer relay for Relay 27 - 18
heated windows
R1* Heater element Heater element 4x400 W 29 - -
R2* Heater element Heater element 4x400 W 29 - -
R4* Speed control Potentiometer 30 - 17
R5* Temperature control Potentiometer 30 - 17
R10* Damping resistance Resistor 680 Ohm - 25
R102 Damping resistance Resistor 120 Ohm 15 15
for CAN1
R202 Damping resistance Resistor 120 Ohm 6 6
for CAN2
S21 Emergency stop Switch Normally closed 11 1 1
switch
S99* Working light off/on Push button 24 17, 24 19
S126* Seat heater off/on Push button 9 14 14
S133 Release of parking Switch 19 2 2
brake
S181* Power switch, Switch 27 - 18
heater coils
T1 Control of drive Frequency DC to 3-phase AC 3, 6 4 4
motor [M1] converter
T2 Control of pump Frequency DC to 3-phase AC 3, 6 5 5
motor [M3] converter
T3* Voltage converter DC/DC converter From +48 V DC to 10 18 20
+12 V DC
T4* Antenna Antenna 16 18 20
T5* Voltage converter DC/DC converter From +48 V DC to 10 20 22
+12 V DC
T6* Voltage converter DC/DC converter From +48 VDC to 10 20 22
+24 V DC
T20* Antenna Antenna T.W.I.S. 25 22 24
T30* Cab heater PWM module Cold store cab 29 - 17
X1* Connection for Contact (battery 18 1 1
battery glove)

Wiring diagram
Components
815, 816 6070557 2012-10-03 7510399-020

(255534) (260844
CC)
X3 Connection for Contact (battery 18 1 1
battery glove)
X15 Connector 2, 2 2
19
X16 Connector 19 2 2
X17 Connector 2, 1, 16 1, 16
18
X18 Connector 2, 4 15 15
X19 Connector 3, 4 15 15
X20 Connector 2, 1, 3, 8, 1, 3, 8,
11 15, 16, 14, 15,
17, 18, 19, 20,
20, 23, 22, 25
24
X21 Connection for roof Connector 11, 15×17× -
wiring harness 14 24
X22 Connector 2, 7 5, 11, 5, 11, 12,
12, 13, 13, 16,
16, 17, 19
24
X23* Connection for roof Connector 11, 18×19× -
wiring harness, 14 23
option
X24 Connection for Connector 3, 23 25
travel alarm [P7] 13
X25* Connector 11, 11×19× 11×21×2
23 23 5
X26* Connection for Connector 11 16 -
General Function
Unit (GFU)
pulse sensor, 35
steering arm
X28* Connection for TV Connector 14, 19 21
monitor [P14] 17
X29* Connection for Connector 14 23 25
blinkers [P12], [P13]
X30* Connector 10, 18, 19 -
11
X32 Connection for Connector 14 17, 24 -
Working light [E3],
[E6]

Wiring diagram
Components
7510399-020 2012-10-03 6070557 815, 816

(255534) (260844
CC)
X34 Connection for LID Connector 14, 15 15
[P6] 24
X35 Connector 11 8 -
X36* Connection for DC Connector 11, 20 -
outlet 24
X37 Connector 7, 11, 12, 11, 12,
21 13, 17, 13, 19,
24,
X38 Connector 7 12, 13 12, 13
X39 Connection for Connector 2, 5 7 7
pedals [B31], [B32]
X40 Connector 1, 11, 12, 11, 12,
21 13, 17, 13, 19,
19, 24 21
X41 Connection for CAN contact 14 15 15
service key
X42 Socket 48 V DC Connector 11 20, 25 22
X43* Socket 12 V DC Connector 24 20 22
X44* Socket 24 V DC Connector 24 20 22
X45* Connection for DC/ Connector 10, 20 -
DC transformer 11
X46* Connection for Connector Cold store cab 29 - 17
heater
X47 Connection for seat Connector 2 14 14
X48 Connector 21, 19 21
23
extra hydraulic 23
functions
X50 Connection for forks Connector 17, 19 21
camera [B50] 22
impact sensor [B90] 25
X53 Connector 1 17, 24 19
X57* Connection for Connector 27 - 18
heated windows
X58* Connector 11 8 8
X61* Connector 9 14 14

Wiring diagram
Components
815, 816 6070557 2012-10-03 7510399-020

(255534) (260844
CC)
X63* Connection seat Connector 9 14 14
heater
X130 Connection MCU Connector 2, 1, 4, 7, 1, 4, 7,
36 8, 9, 11, 8, 9, 11,
12, 13, 12, 13,
14, 15, 14, 15,
16, 17, 16, 19
23, 24
X131 Connection MCU Connector 2, 1, 4, 7, 1, 4, 7,
36 8, 11, 8, 11, 12,
12, 13, 13, 14,
14, 15, 15, 19,
17, 23, 25
24, 25
X499 Connection for Connector 11, 3, 9 3, 9
control panel 33
X500 Connection for Connector 11, 3, 9 3, 9
control panel 33
* option

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
20.2 Component location

Figure 1 (Fork carriage)
X53 B47
X40
Q18
B5
B18
B25/
B58

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 2 (Chassis wiring harness)
X15
X39
P4
X52
X15 X39
X15
X20
X15
X39
G4
X15
X39
X47
X15
X39
X22
X15
X39
Red “+”
X15
X39
Q1 Yellow “IN”
Black “-”
X15
G3
X15
B1
X17
X15
X18
X15 X15
B11
B59
B17
X15
X130
X15
X131

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 3 (Chassis wiring harness)
B2
B12 A2
X24
X19
T1
T2
Q10

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 4 (Support leg brake)
Q17
Q16
X18
X19
Figure 5 (Pedals)
S27
S29
B32
X39

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 6 (Motor wiring harness)
F3
F1
M3
M1
T2 T1
Cable Pos. Pos.

7 T2 : W M3 : W
6 T2 : V M3 : V
5 T2 : U M3 : U
4 T1 : W M1 : W
3 T1 : V M1 : V
2 T1 : U M1 : U

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 7 (Reach carriage wiring harness)
X22
X37 X38 B33

B26
B27
X56
Q6
Q7
Q9
Q8
B6
Q4
Q2
Q5
Q3
B4
If pressure sensor B6 is not used, mount

contact marked B6 at marked position B6

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 8 (Level/position meter)
B57
B46
B19
B18
B58

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 9 (seat)
X62
S126
X63 X61
E10
X62
F77
B49
X63
X62
X61

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 10 (DC/DC)
X45
X30 T3
T5
T6

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 11 (Driver position wiring harness)
X36 S21 X35 X26
X27 X45
X21
X42
X30
X499
X58
X23
X500
X20
X25

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 12 (Extra hydraulic function(s))
Q14 Q12
X49
Q15 Q14 Q12
X49

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 13 (Travel alarm)
X24
P7
126 27

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 14 (Roof wiring harness)
X34
X28
X29
X41
X32
P5
A11
X21
X23

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 15 (Roof)
P13
E3
P5
E4
E5
P12
E6

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 16 (Sound system)
P10
P11
A11
T4

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 17 (Forks camera)
X28
P14
X50
X50
B50

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 18 (Battery harness)
X3
X1
X17
Q10
G1
X3
X1
B29
B28
X17
Q10

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 19 (Fuse box)
S133
A9
X15
X16
F69 F71
F67
F66
F65
F64 F72
F63
F73
F62
F74
F61 F75
F76
F60
F77
A9
X15:2 F73 X15:29

F74 X15:10
K20
X15:4 A1 A2 F75 - OPTION X15:8
F76 - OPTION X15:6
X16:2 1 2 26 F77 - OPTION X15:3
F60 X15:1
F61 X15:5
F62 X15:7
F63 X15:9
F64 X15:19
F65 - OPTION X15:28
F66 - OPTION X15:25
X15:15
F67 - NOT USED X15:24
X15:14
F69 X15:23
S133
2 1 X15:11
5 4 X15:20
X15:22
X16:1 F71 X15:21

F72 X15:26
X15:27
X15:17

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 20 (LID)
X34
P6

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 21 (Mast wiring harness)
X40
X37 X40
X37 X40 X37

X48
TV-Camera ( Fork ), Options

TV-Kamera ( Gaffel ), Tillbehör
TV-kamera ( Gabel ), Zubehör
TV-Caméra ( Fourche ), Options
X48

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 22 (Fork carriage wiring harness)
X40
X37
X48
X40 X40 X40
B25 / B58 B18 Q18 B25 / B58 B18 B5 B25 / B58 B18 Q18 X50
Standard Options TV - Camera

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 23 (Reach carriage wiring harness options)
X25
X49 X48

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 24 (Working light wiring harness)
E6
X32 S99
E4
E5
E3
S32
E6
E5
E4
S99
X32 X32 X32

E4
S99 S99 S99
E5 E3 E3
E6 E4 E4
E6 E5

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 24 (Extra outlet DC)
12V
X44 24V
F66
X36
Figure 25 (T.W.I.S.)
X52
A82
T20
B90

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 26 (Shock Switch / Impact Manager)
If lamp is used, attach P17

connector P17 to lamp
A72
X42
B118
Dismantle connector X131 from MCU

Dismantle existing blind plug on position 19
Mount cable 142 on pos 19
Make sure that cable are correct mounted
X131

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 27 (Heated windows CC)
Q55 Q56
E41
E43
E44
E42
E40
Q54
S181
S181
X57
F96

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 28 (Cabling driver position CC)

Load speaker
E6 E4
S99
Can
X41 X29 X28 X34 A11:A A11:B P5 E5 E3
R4 R5 X27 X42 X58

X41 Can
S99 Swich working light
E3 Working light
E4 Working light
E5 Working light
E6 Working light
X29 Direction light
P5 Warning light
X28 Monitor splice
A11:A Radio
A11:B Radio
X34 LID splice
R4 Control heater
R5 Contol heater
X27 Steering sensor
X42 AUX 48v
X58 AUX Driving direction
B32 Brake-Accelerator
X46 Heater
X25 Option
X20 Chassis wiring harness splice
X499 CID
X500 CID B32 X46
T3 DC/DC
T5 DC/DC
T7 DC/DC X25 X20
B31 Door switch
T3
X499
T5
X500
T7
B31

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 29 (Heater CC)
R1 R2
G5
X46
T30 T30:1 T30:2 Q31 Q30
F91
F92
F93
F94
F95
F96

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 30 (Cab heater wiring harness CC)
R5 R4
1
1
40
160
160
40
F90

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 31 (Safety switch for door CC)
B31
Figure 32 (Cab tilt wiring harness)
X56
Q21
Q22

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 33 (Control panel)
X499
A6
X500
X500 X499
K1

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 34 (Control panel)

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 35 (Steering arm)
B13
X27

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 36 (MCU)
X131 X130
A5

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816
Figure 37 (Control motor)
M6

Wiring diagram
Component location
815, 816 6070557 2012-10-03 7510399-020
Figure 38 (Main valve block)

Std
Q7
Q3 Q9 Q6
Q4 Q2
Q8 Q5
Ergo
Q3
Q9
Q2 Q6
Q21 Q7 Q4 Q11
Q5
Q8

Wiring diagram
Component location
7510399-020 2012-10-03 6070557 815, 816

Wiring diagram
Cable connections and pole bolts
815, 816 6070557 2012-10-03 7510399-020
20.3 Cable connections and pole bolts
20.3.1 ACT/ACH transistor regulators

Connections, travel control (ACT)
Connection Cable Designation Active In/Out
1 14 Motor temperature In
2 35 Cab tilt, down 0 V PWM Out
3 -
4 -
5 -
6 11 GND 0V Out
7 218 CAN2 - GND 0V In
8 219 CAN2 H 0–5 V In/Out
9 27 Off/On 48 V In
10 34 Cab tilt, up 0 V PWM Out
11 10 Sensor + 12 V, 50 mA Out
12 -
13 12 Pulse transducer, 12 V, 1 Kohm In
phase 1
phase 2
15 –
16 220 CAN2 L 0–5 V In/Out
B+ 8 Battery + 48 V In
B- 40 Battery - 0V In
U 2 Motor winding U 0-33 V Out
V 3 Motor winding V 0-33 V Out
W 4 Motor winding W 0-33 V Out

Wiring diagram
7510399-020 2012-10-03 6070557 815, 816
Connections, lift transistor regulator (ACH)

Connection Cable Designation Active In/Out
1 19 Motor temperature In
2 35 Valve, lower initial 0 V PWM Out
mast
3 -
4 -
5 -
6 16 GND 0V Out
7 218 CAN2 – 0V In
8 219 CAN2 H 0–5 V In/Out
9 27 Off/On 48 V In
10 36 Valve, lift initial mast 0 V PWM Out
11 15 Sensor + 12 V, 50 mA Out
12 16 Choice of ID 0V In
phase 1
phase 2
15 219 CAN2 H 0–5 V In/Out
16 220 CAN L 0–5 V In/Out
B+ 8 Battery + 48 V In
B- 40 Battery – 0V In
U 5 Motor winding U 0-33 V Out
V 6 Motor winding V 0-33 V Out
W 7 Motor winding W 0-33 V Out

Wiring diagram
815, 816 6070557 2012-10-03 7510399-020
20.3.2 Connections to CID

Connections, CID
Connection Wires Designation Active In/
Out
X503:1 39 +5 VDC for sensor +5 VDC, ±2 % Out
X503:2 101 Height preselector, next level <1.6 V/>3.5 V In
X503:3 103 Fork tilt to horizontal position <1.6 V/>3.5 V In
X503:4 105 Extra function for joystick #5 <1.6 V/>3.5 V In
X503:5 107 Extra function #1 <1.6 V/>3.5 V In
X503:6 –
X503:7 49 Analogue minus +0 VDC Out
X503:8 102 Height pre-set – pressurised <1.6 V/>3.5 V In
X503:9 104 Side-shift to centre position <1.6 V/>3.5 V In
X503:10 106 Cab tilting <1.6 V/>3.5 V In
X503:11 108 Extra function #2 <1.6 V/>3.5 V In
X503:12 –
X504:1 Direction indicator, right In
X504:2 48 Steering pulse sensor 2B Pulse train In
X504:3 40 B- 0V In
X504:4 44 Steering pulse sensor 1B Pulse train In
X504:5 45 Minus for steering sensors 1 & 2 0V Out
X504:6 120 CAN1 low 0.5-2.5 V In/Out
X504:7 28 Key relay – status 48 VDC In
X504:8 120 CAN1 low 0.5-2.5 V In/Out
X504:9 119 CAN1 high 4.5-2.5 V In/Out
X504:10 Direction indicator, left In
X504:11 47 Steering pulse sensor 2A Pulse train In
X504:12 46 +5 VDC for steering sensor 2 +5 VDC, ±2 % Out
X504:13 43 Steering pulse sensor 1A Pulse train In
X504:14 42 +5 VDC for steering sensor 1 +5 VDC, ±2 % Out
X504:15 119 CAN1 high 4.5-2.5 V In/Out
X504:16 21 Emergency stop (ESO) 48 VDC In
X504:17 32 Key relay out 48 VDC Out
X504:18 24 48VDC 48 VDC In
X505:1 39 +5 VDC for sensor +5 VDC, ±2 % Out
X505:2 50 Joystick for Lift/Lowering 0.3 – 4.7 V In
X505:3 53 Joystick for AUX1/Fork side-shift 0.3 – 4.7 V In

Wiring diagram
7510399-020 2012-10-03 6070557 815, 816
Connections, CID
Connection Wires Designation Active In/
Out
X505:4 94 Travel direction selector. 0.3 – 4.7 V In
X505:5 93 Horn <1.6 V/>3.5 V In
X505:6 –
X505:10 49 Analogue minus 0V Out
X505:11 51 Joystick for Reach Movement 0.3 – 4.7 V In
X505:12 54 Joystick for AUX2/Fork spread 0.3 – 4.7 V In
X505:14 <TBD>
X505:15 –
X505:17 52 Joystick for Fork tilting 0.3 – 4.7 V In
X506:1 132 +5 VDC for electronic start key +5 VDC, ±2 % Out
X506:2 133 Minus for electronic start key 0V Out
X506:3 134 Activation of electronic start key Out
X506:4 135 Clock for serial interface (SPI) Pulse train Out
X506:5 136 Data master in (SPI) Pulse train In
X506:6 137 Data master out (SPI) Pulse train Out

Wiring diagram
815, 816 6070557 2012-10-03 7510399-020
20.3.3 Connections on the MCU

There are two 42-pin closed JPT contacts on the same side of the board.
Connections, MCU
Connection Wires Designation Active In/Out
X130:1 55 Current source +5 V 5V Out
X130:3 69 Lift pressure 0.5-4.5 V In
X130:4 85 Brake pedal, reference 1 (min.–max.) 0.5-4.5 V In
X130:5 70 Voltage measurement, battery 48 V In
X130:6 90 Ground, analogue 0V
X130:8 220 CAN2 low 0.5-2.5 V In/Out
X130:10 81 Cab tilt in upright position 48 V In
X130:11 79 Reach carriage, sensor 2 48 V In
X130:12 75 Height sensor - forks, upper free lift, pulse A 48 V In
a
)
X130:13 131 Height sensor - forks, upper free lift, pulse B 48 V In
X130:16 74 Fork tilt angle 0.5-4.5 V In
X130:17 87 Accelerator 0.5-4.5 V In
X130:18 86 Brake pedal, reference 2 (min.–max.) 4.5-0.5 V In
X130:19 71 Battery measurement 2 0V In
X130:20 30 Ground, digital 0V Out
X130:22 219 CAN2 high 4.5-2.5 V In/Out
X130:23 117 Current measurement +15 V, service key 15 V Out
X130:24 80 Cab tilt in lowered position 48 V In
X130:25 57 Steered wheel 180° 48 V In
X130:26 76 Height sensor - forks, upper free lift, pulse B 48 V In
X130:27 139 Height reference - forks below free lift 48 V In
X130:29 56 Ground, analogue 0V
X130:30 125 Input signal, pressure sensor, mast
X130:31 84 Safety pedal 48 V In
X130:32 72 Battery measurement 1 0V In
X130:33 218 CAN2 ground 0V Out
X130:34 118 Ground, service key 0V
X130:37 29 Current source +15 V 15 V Out
X130:38 78 Reach carriage - sensor 1 48 V In
X130:39 73 Height reference - forks below free lift 48 V In
X130:40 130 Height sensor - forks, upper free lift, pulse A 48 V In
X130:41 83 Seat switch 48 V In

Wiring diagram
7510399-020 2012-10-03 6070557 815, 816
Connections, MCU
Connection Wires Designation Active In/Out
X131:1 22 Current source 48 V In
X131:2 141 Height reference – forks b) 48 V In
X131:4 Options: Speed limitation 3 In
X131:5 21 Status, emergency switch off In
X131:6 28 Status, key relay 48 V In
X131:7 31 Main relay 48 V Out
X131:8 121 Direction indicator lights, left 48 V Out
X131:9 33 Fan control 0-48 V Out
X131:10 67 Valve for AUX. 3 0-48 V Out
X131:11 63 Valve for fork tilt/fork reach carriage/AUX. 0-48 V Out
X131:12 97 Brake, right-hand support leg 0–48 V PWM Out
X131:13 60 Valve for reach carriage 0-24 V PWM Out
X131:14 40 Ground 0V
X131:15 23 Charging capacitor 48 V In/Out
X131:18 111 Fork reach sensor, left-hand side 48 V In
X131:19 124 Login, special 48 V In
X131:20 95 Parking brake 48 V Out
X131:21 65 Valve for fork spread/AUX. 2 0-48 V Out
X131:24 68 Valve for AUX. 4 0-48 V Out
X131:25 88 Horn 48 V Out
X131:26 59 Valve for main mast lift 0-24 V PWM Out
X131:27 119 CAN1 high 4.5-2.5 V In/Out
X131:32 112 Fork reach sensor, right-hand side 112 In
X131:34 34 Fan, chassis 0-48 V Out
X131:35 122 Direction indicator lights, right 48 V Out
X131:36 98 Warning lamp 48 V Out
X131:37 62 Valve for reach carriage 0-48 V Out
X131:38 66 Valve for fork tilt/fork reach/AUX. 1 0-48 V Out
X131:39 96 Brake, left-hand support leg 0–48 V PWM Out
X131:40 58 Valve for main mast lowering 0-24 V PWM Out
X131:41 61 Reach carriage valve 0-24 V PWM Out
X131:42 120 CAN1 low 0.5-2.5 V In/Out
a."Mast near to lowered position" when height measurement is not used.
b."Forks near top of mast" when height measurement is not used.

Wiring diagram
Fuse box A9
815, 816 6070557 2012-10-03 7510399-020
20.4 Fuse box A9

F73 F75 F77
S133 F72 F74 F76
F71 F67 F65 F63 F61

F69 F66 F64 F62 F60
Description Protects (Function)

F60 +48 VDC Emergency stop circuit
F61 +48 VDC, MCU supply
F62 +48 VDC, CID supply
F63 +48 VDC, LID supply
F64 +48 VDC, Steering servo supply (electronics)
F65 Options: +48 VDC, GFU supply
F66 Options: +48 VDC, DC/DC transformer and DHU
supply
F67 –
F69 +48 VDC, Extra equipment supply
F71 +48 VDC, Capacitor charging
F72 +48 VDC, Steering servo supply (high current)
F73 Supply 48 VDC
F74 Status, key relay
F75 Options: Work light
F76 Options: Stereo/Camera
F77 Options: Seat heating
S133 Function: Emergency mechanical brake release

Wiring diagram
Overview
7510399-020 2012-10-03 6070557 815, 816
20.5 Overview
See the following pages for electric overview!

Wiring diagram
Overview
815, 816 6070557 2012-10-03 7510399-020
21 21
1
27 27
MCU A5
29
(X130:37) OUT.+15VDC 1
75
B19 (X130:12) INP.HEIGHT SENSOR Main Lift A
30 76 95
R (X130:26) INP.HEIGHT SENSOR Main Lift B
29 B18 130 OUT.PARK
(X130:40) INP.HEIGHT SENSOR Free Lift A BRAKE 95
131
21
1
30 (X130:13) INP.HEIGHT SENSOR Free Lift B
R (X131:20) K20
1
21
27 73 P4 Q1
(X130:39) INP.MAIN LIFT HEIGHT REF. (A9)
88
32
B46 OUT.HORN (X131:25)
26
27 40
(X130:27) INP.MAIN LIFT HEIGHT REF.
139
OUT.(PWM) LEFT SUP. ARM (X131:39) 96
Q16
B57
26
BRAKE
OUT.(PWM) RIGHT SUP. ARM (X131:12) 97
F74 (A9)
30
27 141 Q17
(X131:2) INP.FREE LIFT HEIGHT REF.
3A
B58
80 (X130:24) INP.CABIN TILT, LOWER POS. 32
27
28
B28
27
28 28
30 INP.KEY POWER RELAY. STATUS (X131:6)
100
24
81
(X130:10) INP.CABIN TILT, UPPER POS.
98
B29 OUT.WARNING LAMP (X131:36)
> (X15:9) LID
> (X15:7) CID
30 P5
58
OUT.(PWM) MAIN MAST LOWER (X131:40)
Q4
B17
27
27 57 (X130:25) INP.STEERING 59
WHEEL180 DEG. OUT.(PWM) MAIN MAST LIFT (X131:26)
Q2
F63 (A9)
F62 (A9)
30 OUT.(PWM) REACH IN (X131:13) 60

7,5A
Q6
7,5A
(X130:20)OUT.GND.DIGITAL
55 61
OUT.(PWM) REACH OUT (X131:41)
B31 84 Q7
90 (X130:31) INP.LEFT FOOT SWITCH
62
B32 OUT.AUX Dir. A (X131:37)
85 (X130:4) INP.BRAKE REF. 1 Q8
(2)
63
(6) OUT.AUX Dir. B (X131:11)
1 (3) 86 (X130:18) INP.BRAKE REF. 2 Q9
X3
34
(1) OUT.FAN, CHASSIS (X131:34) M G4
X1 (4) 87 (X130:17) INP.ACCELERATOR SIGNAL
27
66
OUT.TILT/SIDESHIFT AUX (X131:38)
Q18
+ -
G1
90 33
(X130:6) GND. ANALOG OUT.FAN,CONTROLLERS (X131:9) M
G3
X1
1
70
(X130:5) INP.BATT. VOLT. STATUS
71
(X130:19) INP. BATT.MEASURE 2
SHUNT
72 (X130:32) INP. BATT.MEASURE 1
27 83
(X130:41) INP.SEAT SWITCH
40
40 B49
INP.REACH CARRIAGE SENSOR 1 (X130:38) 78 27
B26
55 (X130:1) OUT.+5VDC
79
INP.REACH CARRIAGE SENSOR 2 (X130:11)
55 P 69
(X130:3) INP.LIFT PRESSURE 30 B27
B4 30
(X130:20)GND.
1
F60 (A9)
56 CAN1
(X130:29) GND ANALOG 117
15v (X130:23)
3A
118
Gnd (X130:34)
21
(X131:5) E.S.O. STATUS 119
20
H (X131:27)
21
1
120
L (X131:42)
S21
21
F71 (A9) R101

23
(X131:15) MAIN CONT./CAP CH.
7,5A CAN2
Q10 Gnd (X130:33)
218
31 (X131:7) OUT.MAIN CONT.
21 31 219
H (X130:22)
22 220
(X131:1) INP.+48VDC POWER L (X130:8)
1 8 40 (X131:14) GND, POWER
To T1
F61 (A9) 22 CAN 1

1
7,5A CAN 2
F72 (A9) 250
based on F64 (A9) 30A 9
1 9
255534 rev.C
03339L.wmf 3A

Wiring diagram
Overview
7510399-020 2012-10-03 6070557 815, 816
= Height measuring
21
27
F69 (A9)
1 1 116 27
10A
95 95 40
S133
(A9)
27
F73 (A9)
26
7,5A
B1 14
21
CID (K1:1)THERMO ELECTICAL SENSOR IN M1
11 (K1:6) Gnd. ACT
(X504:16) EMERGENCY
SWITCH OFF STATUS A1 10
(K1:11) +12VDC T1
12 (K1:13) Speed A
27
32 32 B11 13
(X504:17) OUT. KEY POWER RELAY (K1:14) Speed B
(U) 2
From 8
F1 3
28 28 Q10 (B+) (V) M
(X504:7) KEY POWER 325A 4
RELAY STATUS 40 (W)
(B-) M1
27 L (K1:16) 220
(K1:9) +48VDC LOGIC SUPPLY
CAN2 H (K1:8) 219
218
27 41 Gnd(K1:7)
(K1:2) OUT.(PWM) CAB TILT DOWN
24
Q21
From F62 (A9) (X504:18) +48VDC POWER
27 64 (K1:10)OUT.(PWM) CAB TILT UP
40 Q11
(X504:3) GND
19
42
B2 16
(K1:1) THERMO ELECTICAL SENSOR IN M1
(K1:6) Gnd.
ACH
(X504:14) +5V, STEER SENSOR 1
43
(X504:13) STEER SENSOR 1 PULSE A 15
(K1:12) CONTROLLER ID T2
44 (K1:11) +12VDC
(X504:4) STEER SENSOR 1 PULSE B 17
45 (K1:13) Speed A
(X504:5) GND B12 18 5
B13 46 (K1:14) Speed B (U)
(X504:12) +5V, STEER SENSOR 2 8 6
47
(X504:11) STEER SENSOR 2 PULSE A
(B+) (V) M
From 7
48
(X504:2) STEER SENSOR 2 PULSE A
40 F3 325A (W)
Q10 (B-) M3
27
(K1:9) +48VDC LOGIC SUPPLY
220
L (K1:16)
39
120Ω
B20 27 35
CAN2
49 50 (K1:2) OUT.(PWM) LOWER

(X505:2) INP.LIFT/LOWER
Q5 INITIAL H (K1:15)
219
B21 MAST (K1:8)
51 27 36 (K1:10) OUT.(PWM) LIFT
(X505:11) INP.REACH IN/OUT 218
Q3 Gnd(K1:7)
B22 52
(X505:17) INP.TILT
B23 53
(X505:3) INP.AUX 1 / SIDESHIFT 250
(X901:8) +48VDC
(X901:16) +48VDC
EPS
(1)
B35 (2)
93
(X505:5) INP.HORN REQUEST
9
A2
A6 (X901:6) INP.ENABLE
(4) B36 M
(3) 94 (X505:4) INP.TRAVEL DIR. CHANGE REQUEST
39
40 CAN 2
(X901:7) GND POWER M6 219
49
H (X901:2)
(X901:15) GND POWER 220
L (X901:10)
120Ω
R202
100
LID P6
(X202: 2 +48VDC POWER)
B42 105
(X503:4) INP. 5TH LEVER, FUNCTION SHIFT 40
(X202:1 GND)
CAN 1 H L
(X202: 3 4)
49
49
39
(X505:10) GND. ANALOG

120
119
(X503:7) From F63 120Ω

39 (A9)
(X505:1) +5VDC SOFTWARE CONTROLLER
(X503:1) R102
4 CAN 1
(X504:9)
119
(X504:15) CAN1 H 3 SERVICE KEY
118
120
(X504:8) 2 X41
(X504:6) CAN1 L 117
1
CAN 1
218
219
220
CAN 2
250
9
based on 255534 rev.C
03339R.wmf

Wiring diagram
Overview
815, 816 6070557 2012-10-03 7510399-020
WITHOUT HEIGHT MEASURING

O.T.P.(OPTIPACE)
from F73(A9)
27 75 (X130:12) INP.HEIGHT REF MAST MCU A5 A2

203 (X901:3) OUT.12VDC REF.SENSOR
NEAR LOWER POSITION
B33 211
(X901:11) OUT.STEER WHEEL REF
30
B59
202
27 73 (X901:12) OUT.GND.SENSOR
(X130:39) INP.MAST LOWER POS B
27
B46
27
139 (X130:27) INP.MAST LOWER POS B.
B57
30
27 141
(X131:2) INP.ORKS NEAR MAST TOP
B25
30
30
(X130:20)OUT.GND.DIGITAL
from F73(A9)
OUT.FORK SPREAD / AUX (X131:21) 65

Q12
27
OUT.AUX VALVE 3 (X131:10) 67 Q14
OUT.AUX VALVE 4 (X131:24) 68 Q15
B32
TRAVEL REQUEST
27 S29 91
(X131:16)INP.TRACTOR DIRECTION TRAVEL REQ.
S27 92
(X131:30)INP.FORK DIRECTION TRAVEL REQ.
TILT / SIDE SHIFT
27 74
(X130:16)INP.FORK TILT ANGLE
B5
30
TRAVEL ALARM
P7
B47 27
126 from F73(A9)
OUT.TRAVEL ALARM(X131:23)
27 SOUTH SENSING
1
111 TRAFFICATORS
2 (X131:18)INP.SIDESHIFT SENSOR,
LEFT SIDE P12
OUT.TRAFFICATOR LEFT(X131:8) 121
NORTH SENSING
112
3 (X131:32)INP.SIDESHIFT SENSOR,
30 RIGHT SIDE P13
4 122
OUT.TRAFFICATOR RIGHT(X131:35)
R10
27
from F73(A9)
680Ω/2W
based on 255534 rev.C

03346L.wmf OPTION

Wiring diagram
Overview
7510399-020 2012-10-03 6070557 815, 816
AUX.+48VDC (BATTERY) GENERAL FUNCTION UNIT SEAT HEATING
X42 X26 E10:1 SEAT E10:2 BACK REST

116 from CAN1(L) 120
4 129 S126 138 429
from F69(A9) from F77(A9) 40
119
40 from CAN1(H) 3
40
2
99
from F65(A9) 1
WORKING LIGHT
1/25 PROD I
REAR LEFT REAR RIGHT
S99 E5 E6
190 191 193 40
from F75(A9)
CID
255534
E3 E4
A1 192
ELECTRONIC START KEY

DC/DC CONVERTERS
OUT. +5V DC (X506:1)

132
1 K1 109
T5
(6) INP.+48VDC
OUT. GND (X506:2) 133 2 40
(3) INP.GND
OUT. ENABLE (X506:3) 134 3 128
(4) OUT.+12VDC
OUT. SCK (SPI CLOCK) (X506:4) 135 4 X43 140
(5) OUT.GND.
INP. MISO(SPI DATA MASTER IN) (X506:5) 136 5
OUT. MOSI (SPI DATA MASTER OUT) (X506:6) 137 6
109
T6
from F66(A9) (6) INP.+48VDC
40 (3) INP.GND
224
AUX 2 / FORK SPREAD (4) OUT.+24VDC
X44 240 (5) OUT.GND.
39
B24 54 (X505:12) INP. AUX 2/ FORK SPREAD
49 DATA HANDLING UNIT/
SHOCK SENSOR.
A82 TV MONITOR
NEXT HEIGHT LEVEL
39
from F66(A9)
109
40
(1) INP.+48VDC
115
B50
(8) INP.GND. (103) GND.
B38 101 119 114
(X503:2) INP. HEIGHT PRE-SELECTION, (102) +12VDC
49
NEXT LEVEL
T20 (2) INP. CAN1 HIGH
120 156
HEIGHT LIM. OVERRIDE (3) INP. CAN 1 LOW (104) SCREEN
39 110
(101) VIDEO SIGNAL
49 B39 102
(X503:8) INP. HEIGHT LIMITATION,
OVERRIDE B90
CABIN TILT
from F73(A9)
27
40
(1) INP.+48VDC
110
P14
(A:1) VIDEO SIGNAL
39 (2) INP.GND.
B43 119 156
106 from CAN1(H) (3) INP. CAN1 HIGH (A:2) SCREEN
(X503:10) INP. CABIN TILT REQUEST
49 114
120 (B:1) +12VDC
from CAN1(L) (4) INP. CAN 1 LOW
SPARE FUNCTION INP. 115
(B:2) GND.
39
49 B44 107
(X503:11) INP. SPARE FUNCTION 1
39
STEREO/CD
B45
49
108
(X503:11) INP. SPARE FUNCTION 2 T3
TILT / SIDE SHIFT 113 (6) INP.+48VDC
from F76(A9)
39 40
(3) GND.
B40 103 (X503:3) INP. FORK TILT, 114
49 ZERO DEGREE POSITIONING (4) OUT.+12VDC
115
39 (5) OUT.GND
B41 340
104 (X503:9) INP. SIDESHIFT LOAD INFORMATION DISP.. (2) OUT.GND
49 CENTRAL POSITION REQUEST 312
119
(X202:3) CAN1 H
P6 (1) OUT.+12VDC
120
49
49
(X202:4) CAN1 L. (A:4)+12VKEY
A11
39
(X505:10) GND. ANALOG 100 312

(X503:7) (X202:2) INP. +48VDC (A:7) INP.+12VDC
39 40 340
(X505:1) +5VDC SOFTWARE CONTROLLER (X202:1) INP. GND. (A:8) INP.GND
(X503:1)
(B:5) OUT.LEFT (+)
LT+
from F63(A9) P10 (B:6) OUT.LEFT (-)
LT-
RT+ (B:3) OUT.RIGHT (+)

P11
T4 RT-
(B:4) OUT.RIGHT (-)
OPTION based on 255534 rev.C

03346R.wmf

BATTERY CONNECTOR
X3 SHUNT BAR
1 40
Sh. 2 Sh. 2
20 – 60
T code
815, 816
ELECTRONIC CARD, MAIN CONTROL UNIT
A5
40
X131:14 GND, POWER
X1 G1 X1
+ - 72
X130:32 INP. BATT. MEASURE 1
Wiring diagram
48V
X1 WHEN OPTION BATT. CHANGE POWER CABLES X17
71
6070557
70
X130:5 INP. BATT. VOLTAGE STATUS
Repair manual
MEASURING WIRES
21 21
Sh. 2 X131:5 INP. EMERGENCY SWITCH OFF
EMERGENCY SWITCH OFF STATUS

X20 S21 X20 Q10
20 1 2 21 A1 A2 31
Sh. 2 X131:7 OUT. MAIN CONTACTOR
Details up to and including serial no. 6206800
2 1
Date
8
Sh. 2
2012-10-03
23 23
Sh. 2 X131:15 INP. MAIN CONTACTOR / OUT.
CAP. CHARGE
22 22
Sh. 2 X131:1 INP. +48VDC POWER MCU
RRE140/160/180/200/250
28 28
Sh. 2 X131:6 INP. KEY POWER RELAY STATUS
119/RD 119/RD
Sh. 3 X131:27 CAN 1 HIGH
R101 120
120/WH
X131:42 CAN 1 LOW
20.6 Details up to and including serial no. 6206800
255534
255534
7510399-020
Publication no.
1/25 I
PROD H
1/25 PROD
© BT
© BT
FUSE CENTRAL MODULE
A9
32 X15:2 F73 X15:29 27

7510399-020
Sh. 3 Sh. 4 +48VDC SUPPLY

Publication no.
7,5A
F74 X15:10 28
K20 Sh. 1 3 KEY POWER RELAY STATUS
3A
21 X15:4 A1 A2 F75 - OPTION X15:8 190
Sh. 1 3 Sh. 17 WORKING LIGHT
10A
F76 - OPTION X15:6 113
Sh. 18 STEREO/CAMERA CONVERTER SUPPLY
7,5A
1 X16:2 1 2 26 F77 - OPTION X15:3 129
Sh. 1 Sh. 14 SEAT HEATER
10A
Date
F60 X15:1 20
Sh. 1 +48VDC ESO CIRCUIT
Repair manual
3A
F61 X15:5 22
Sh. 1 +48VDC MCU SUPPLY
7,5A
F62 X15:7 24
2012-10-03
Sh. 3 +48VDC CID SUPPLY

7,5A
F63 X15:9 100
Sh. 15 +48VDC LID SUPPLY
7,5A
F64 X15:19 9
Sh. 6 +48VDC STEER SERVO ELECTRONIC SUPPLY
3A
F65 - OPTION X15:28 99
Sh. 16 +48VDC GFU SUPPLY
5A
F66 - OPTION X15:25 109
Sh. 20 +48VDC AUX CONVERTERS SUPPLY, DHU SUPPLY
7,5A
X15:15
X15:14
F69 X15:23 116

Sh. 20 +48VDC BATTERY VOLTAGE, AUX EQUIPMENT SUPPLY
10A
6070557
EMERGENCY BRAKE RELEASE S133

2 1 X15:11
RRE140/160/180/200/250
5 4 X15:20 95
Sh. 15 OUT. PARKING BRAKE
X15:22 40
Sh. 1 3 B-
8 X16:1 F71 X15:21 23

Sh. 1 4 Sh. 1 +48VDC CAP. CHARGE
7,5A
F72 X15:26 250
Sh. 6 +48VDC STEER SERVO POWER SUPPLY
30A
X15:27
X15:17
T code
815, 816
255534
2/25 PROD I
255534
2/25 PROD H
Wiring diagram
20 – 61
20 – 62
T code
815, 816
ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY

A1
X20 X499
24 24 24/BN
Wiring diagram
Sh. 2 X504:18INP. +48VDC POWER
X20 X499
40 40 40/WH
h. 2 4 X504:3 INP. GND
6070557
X20 X499
Repair manual
21 21 21/GN
Sh. 2 X504:16INP. EMERGENCY SWITCH OFF STATUS
X20 X499
32 32 32/GY
Sh. 2 X504:17OUT. KEY POWER RELAY
X20 X499
28 28 28/YE
X20 X500
119/RD 119/RD 119/YE-BN
. 1 15 X504:15CAN 1 HIGH
Date
119/WH-GY
X504:9
2012-10-03
X20 X500
120/WH 120/WH 120/GY-BN
. 1 15 X504:6 CAN 1 LOW
120/RD-BU
X504:8
RRE140/160/180/200/250
255534
3/25 PROD I
255534
3/25 PROD H
7510399-020
Publication no.
© BT
© BT
MOTOR CONTROLLER, DRIVE
T1
7510399-020
Publication no.
F1
8 2
Sh. 2 5 B+ + U DRIVE MOTOR
325A M1
U
40 3 V
Sh. 3 5 B- V
W M
3~A
THERMO ELECTRICAL SENSOR IN M1
Date
14 4
Repair manual
K1:1 W
B1
2012-10-03
11 ELECTRONIC CARD, MAIN CONTROL UNIT

K1:6
A5
10 218/BU
K1:11 +12VDC SUPPLY K1:7 X130:33 CAN 2 GND
SPEED MEASURING IN M1
B11
1 2 12 219/RD
K1:13 K1:8 X130:22 CAN 2 HIGH
B
+
4 3 13 220/WH
K1:14 K1:16 X130:8 CAN 2 LOW
A
-
64 64
6070557
Sh. 11 K1:10 OUT. (PWM) CABIN TILT UP
41 41
Sh. 11 K1:2 OUT. (PWM) CABIN TILT DOWN
RRE140/160/180/200/250
218/BU
Sh. 5
27 27
Sh. 2 5 K1:9 +48VDC LOGIC SUPPLY
219/RD
Sh. 5

A5 220/WH
Sh. 5
G3
1 2 33
M X131:9 OUT. FAN, CONTROLLERS
G4 255534
T code
+ - 34
M X131:34OUT. FAN, CHASSIS
815, 816
4/25 PROD I
255534
4/25 PROD H
Wiring diagram
20 – 63
20 – 64
T code
815, 816
MOTOR CONTROLLER, LIFT

T2
F3
8 5
Sh. 4 B+ + U PUMP MOTOR
325A M3
Wiring diagram
U
40 6 V
Sh. 4 6 B- V
W M
3~A
6070557
19 7
K1:1 W
Repair manual
B2
16
K1:6
16 218/BU
K1:12 CONTROLLER ID K1:7 Sh. 4
15 219/RD
K1:11 +12VDC SUPPLY K1:8 Sh. 4 6

B12
Date
1 2 17
K1:13 K1:15
B
+ 120
2012-10-03
4 3 18 220/WH
K1:14 K1:16 Sh. 4 6
A
-
27 27
X22 Q5 X22
RRE140/160/180/200/250
1 2 35
K1:2 OUT. (PWM) INITIAL MAST LOWER
Q3 X22
1 2 36
K1:10 OUT. (PWM) INITIAL MAST LIFT
255534
5/25 PROD I
255534
5/25 PROD H
7510399-020
Publication no.
© BT
© BT
ELECTRONIC ASSY, STEER SERVO
7510399-020
A2
Publication no.
40 40
Sh. 5 14 X901:7 GND POWER
40
X901:15 GND POWER
250 250
Date
Sh. 2 X901:8 +48VDC POWER SUPPLY
Repair manual
M6
250
X901:16
2012-10-03
+48VDC POWER SUPPLY

M
9 9
Sh. 2 X901:6 INP. ENABLE
219/RD 219/RD
R202 120
220/WH 220/WH
Sh. 5 X901:10 CAN 2 LOW
6070557
203
X901:3 OUT. 12VDC FOR REFERENCE
SENSOR
211
X901:11 INP. STEERING WHEEL REFERENCE
RRE140/160/180/200/250
POSITION
212
X901:12 OUT. GND FOR REF. SENSOR
255534
T code
6/25 PROD I
815, 816
255534
6/25 PROD H
Wiring diagram
20 – 65
20 – 66
T code
815, 816
PEDALS BASIC MODEL

Wiring diagram

A5
6070557
X39 B31
55/RD 1
Sh. 8 X39
Repair manual
2 84
X130:31 INP. LEFT FOOT SWITCH
3
X39
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X39
85/WH
6 2 X130:4 INP. BRAKE REFERENCE 1
Date
X39
86/BK
3 X130:18 INP. BRAKE REFERENCE 2
2012-10-03
X39
87/GY
1 4 X130:17 INP. ACCELERATOR SIGNAL
X39 S29 X39

27 5 7 91
Sh. 5 8 X131:16 INP. TRACTOR DIRECTION
RRE140/160/180/200/250
TRAVEL REQ.
S27 X39
8 92
X131:30 INP. FORK DIRECTION TRAVEL REQ.
7510399-020
255534
Publication no.
7/25 PROD I
255534
7/25 PROD H
© BT
© BT
7510399-020
Publication no.
PEDALS ERGO MODEL

Date
Repair manual
A5
X20 X35 B31
2012-10-03
55/RD 1
Sh. 7 11 X35 X20
2 84
3
X35 X20
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X35 X20
85/WH
X35 X20
6070557
86/BK
X35 X20
87/GY
1 4 X130:17
RRE140/160/180/200/250
INP. ACCELERATOR SIGNAL
X20 X58 S29 X58 X20

27 5 7 91
TRAVEL REQ.
S27 X58 X20

8 92
T code
815, 816
255534
8/25 PROD I
255534
Wiring diagram
8/25 PROD H
20 – 67
20 – 68
T code
815, 816

A1
B13
X27 X499
42/BK 42 42/BU
X504:14 +5VDC, STEER SENSOR 1
Wiring diagram
X27 X499
1 3 43/RD 43 43/RD
X504:13 STEER SENSOR 1 PULSE A
A
+
X27 X499
6070557
45/OR 4 2 44/BN 44 44/BK

X504:4 STEER SENSOR 1 PULSE B
B
-
Repair manual
X27 X499
45 45/VT
X504:5 GND, STEER SENSORS
X27 X499
46/YE 46 46/GY-PK
X27 X500
5 7 47/BU 47 47/BN-GN

A
+
X27 X500
Date
45/VT 8 6 48/GN 48 48/WH-YE

B
-
2012-10-03
RRE140/160/180/200/250
A5
B17
27 1 2 57
Sh. 8 11 X130:25 INP. STEERING WHEEL 180 DEG.
3
30
Sh. 12
255534
7510399-020
Publication no.
9/25 PROD I
255534
© BT
9/25 PROD H
© BT
7510399-020
Publication no.

A1
39/RD 39/RD
Sh. 14 X505:1 OUT. +5VDC, SOFTWARE
CONTROLLED
Date
Repair manual
X503:1
2012-10-03
49/BU 49/BU
Sh. 14 X505:10 GND, ANALOG
X503:7
B20
1
3 50/BK
X505:2 INP. LIFT/LOWER
2
B21
1
3 51/BN
X505:11 INP. REACH IN/OUT
2
6070557
B22
1
3 52/OG
X505:17 INP. TILT / AUX 1
RRE140/160/180/200/250
2
B23
1
3 53/YE
X505:3 INP. AUX 2 / SIDESHIFT
2
B24
1
3 54/GN
X505:12 INP. AUX 3 / FORK SPREAD
2
B42
3
T code
1 105/GN
815, 816
X503:4 INP. AUX 4 / FIFTH LEVER B24,

2 FUNC. SHIFT
255534
255534
Wiring diagram
10/25 PROD
10/25 PROD
I H
20 – 69
A5
20 – 70
T code
X22 Q4 X22
27 1 2 58
815, 816
Sh. 9 12 X131:40 OUT. (PWM) MAIN MAST LOWER
X22 Q2 X22
1 2 59
X131:26 OUT. (PWM) MAIN MAST LIFT
X22 Q6 X22
1 2 60
X131:13 OUT. (PWM) REACH IN
Wiring diagram
X22 Q7 X22
1 2 61
X131:41 OUT. (PWM) REACH OUT
X22 Q8 X22
6070557
1 2 62
X131:37 OUT. AUX DIRECTION A
Repair manual
X22 Q9 X22
1 2 63
X131:11 OUT. AUX DIRECTION B
X22 X37 X40 Q18 X40 X37 X22

1 2 66
X131:38 OUT. TILT / SIDESHIFT / AUX
X25 X49 Q12 X49 X25

1 2 65
X131:21 OUT. FORK SPREAD / AUX
X25 X49 Q14 X49 X25

Date
1 2 67
X131:10 OUT. AUX VALVE
X25 X49 Q15 X49 X25

1 2 68
2012-10-03

CABIN TILT DOWN
X22 X56 Q21 X56 X22
1 2 41
Sh. 4
CABIN TILT UP
X22 X56 Q11 X56 X22
1 2 64
RRE140/160/180/200/250
Sh. 4
55/RD 55/RD OUT. +5VDC

Sh. 8 23 X130:1
X22 B4
X22
3 P 2 69
X130:3 INP. LIFT PRESSURE
1
X22
56 56
7510399-020
Publication no.
255534
255534
11/25 PROD I
11/25 PROD H
© BT
© BT
7510399-020
Publication no.
WITH HEIGHT MEASURING

A5
Date
Repair manual
29 OUT. +15VDC
X130:37
B19
2012-10-03
X22 X38 X38 X22

1 3 75
X130:12 INP. HEIGHT SENSOR MAIN LIFT, PULSE A
A
+
X38 X38 X22
4 2 76
X130:26 INP. HEIGHT SENSOR MAIN LIFT, PULSE B
|R B
-
X22
30 30 OUT. GND, DIGITAL
Sh. 9 13 X130:20
B18
X22 X37 X40 X40 X37 X22
1 3 130
X22 X130:40 INP. HEIGHT SENSOR FREELIFT, PULSE A
A
+
X37 X40 X40 X37 X22
6070557
4 2 131
X130:13 INP. HEIGHT SENSOR FREELIFT, PULSE B
|R B
-
B58
RRE140/160/180/200/250
X22 X37 X40 X40 X37 X22
27 1 2 141
Sh. 11 13 X131:2 INP. FREE LIFT HEIGHT REF.
3
B46
X38 X38 X22
1 2 73
X130:39 INP. MAIN LIFT HEIGHT REF
3
X38
B57
X38 X38 X22
139
X130:27 INP. MAIN LIFT HEIGHT REF.
T code
X38
815, 816
255534
12/25 PROD I
255534
Wiring diagram
12/25 PROD H
20 – 71
20 – 72
T code
815, 816
Wiring diagram
6070557
Repair manual

A5
B33
X22 X22
27 1 2 75
Sh. 12 14 X130:12 INP. HEIGHT REF. MAST NEAR LOWER POS.
Date
X22
3
30
Sh. 12 16
B25
X37 X40 X40 X37 X22
2012-10-03
1 2 141
X131:2 INP. FORKS NEAR MAST TOP
X37 X40
3
X38 X38
B46
X38 X22
1 2 73
X130:39 INP. MAST LOWER POS. A
RRE140/160/180/200/250
3
B57
X38 X22
1 2 139
X130:27 INP. MAST LOWER POS. B
3
255534
13/25 PROD I
7510399-020
255534
Publication no.
13/25 PROD H
© BT
© BT
7510399-020
Publication no.
SEAT BACK REST

E10:1 E10:2
Date
Repair manual
X47 X61 X62 S126 X62 X63 X63
129 138 429 ELECTRONIC CARD, MAIN CONTROL UNIT
Sh. 2 A5
2012-10-03
B49
X47 X47
27 1 2 83
Sh. 13 15 X130:41 INP. SEAT SWITCH
3
X47 X61
40
Sh. 6 15
P4
+ - 88
X131:25 OUT. HORN
6070557
RRE140/160/180/200/250

ELECTRONIC CARD, SENSORS A1
A6
39/RD 39/RD B35 93/VT

Sh. 10 17 1 INP. +5VDC OUT. HORN REQUEST 2 X505:5 INP. HORN REQUEST
Sig.
B36
T code
49/BU 49/BU Sig. 94/GY

Sh. 10 17 4 INP. GND OUT. TRAVEL DIR. CHANGE REQUEST 3 X505:4 INP. TRAVEL DIR. CHANGE REQUEST
815, 816
255534
255534
14/25 PROD I
Wiring diagram
14/25 PROD H
20 – 73
20 – 74
T code
815, 816
Sh. 2 A5
Q1
27 1 2 95
Sh. 14 16 X131:20 OUT. PARKING BRAKE
X18 Q16 X18

1 2 96
X131:39 OUT. (PWM) BRAKE, LEFT
SUPPORT ARM
Wiring diagram
X19 Q17 X19

1 2 97
X131:12 OUT. (PWM) BRAKE, RIGHT
SUPPORT ARM
X20 X21 P5 X21 X20
6070557
3 1 98
X131:36 OUT. WARNING LAMP
Repair manual
X34 X21 X20
118
X130:34 GND, SERVICE KEY
X34 X21 X20

117
X130:23 +15VDC SUPPLY, SERVICE KEY
SERVICE KEY INTERFACE

X41
117 1
Date
118 2
X20 X21
119/RD 119/RD 3
Sh. 3 16
2012-10-03
R102 120
X20 X21 ELECTRONIC CARD, LOAD INFORMATION DISPLAY
120/WH 120/WH 4 P6
Sh. 3 16
X34
119/RD
X202:3 CAN 1 HIGH
RRE140/160/180/200/250
X34
120/WH
X202:4 CAN 1 LOW
X20 X21 X34

100 100
Sh. 2 X202:2 INP. +48VDC POWER
X20 X21 X34

40 40
Sh. 14 16 X202:1 INP. GND
7510399-020
Publication no.
255534
255534
15/25 PROD I
15/25 PROD H
© BT
© BT
7510399-020
Publication no.

A5
B26
X22 X22
27 1 2 78
Sh. 15 17 X130:38 INP. REACH CARRIAGE SENSOR 1
3
B27
X22 X22
1 2 79
X130:11 INP. REACH CARRIAGE SENSOR 2
Date
Repair manual
3
X22
30
Sh. 13 17
2012-10-03
B28
X17 X17
1 2 80
X130:24 INP. CABIN TILT, LOWER POSITION
3
B29
X17 X17
1 2 81
X130:10 INP. CABIN TILT, UPPER POSITION
3
X17
6070557
OPTION
GENERAL FUNCTION UNIT
RRE140/160/180/200/250
CONNECTOR - GFU
X26
X20
99 99 1
Sh. 2
X20
40 40 2
Sh. 15 17
X20
119/RD 119/RD 3
Sh. 15 22
T code
815, 816
X20
120/WH 120/WH 4
Sh. 15 22
255534
PROD I
16/25255534
Wiring diagram
16/25 PROD H
20 – 75
20 – 76
T code
815, 816
OPTION A1
B40
39/RD 3
Sh. 14 23
1 103/OG
X503:3 INP. FORK TILT, ZERO DEGREE POSITIONING
49/BU 2
Sh. 14 23

Wiring diagram
A5
X22 X37 X40 X53 X53 X40 X37 X22

27 27/WH 74/GN 74
Sh. 16 22 X130:16 INP. FORK TILT ANGLE
6070557
X22 X37 X40 X53

30 30/BN
Repair manual
Sh. 16 ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
A1
B41
3
1 104/YE
X503:9 INP. SIDESHIFT, CENTRAL POSITION REQUEST

2
SIDE SHIFT SENSOR

B47
27/BN 1 ELECTRONIC CARD, MAIN CONTROL UNIT

Date
A5
SOUTH SENSING
X40 X37 X22
2 111/WH 111
X131:18 INP. SIDESHIFT SENSOR, LEFT SIDE
2012-10-03
NORTH SENSING
X40 X37 X22
3 112/BK 112
X131:32 INP. SIDESHIFT SENSOR, RIGHT SIDE
RRE140/160/180/200/250
30/BU
WORKING LIGHT
E5 E6
193
FRONT LEFT FRONT RIGHT

X20 X21 X32 S99 E3 E4
190 3 4 191 192
Sh. 2
X20 X21 X32

40
Sh. 16 18
7510399-020
Publication no.
255534
255534
17/25 PROD I
© BT
17/25 PROD H
© BT
DC/DC CONVERTER
OPTION T3
7510399-020
X20 X30 STEREO/CD

Publication no.
113 113
Sh. 2 6 INP. +48VDC
X20 X30
40 40
Sh. 17 20 3 INP. GND
114 114
Sh. 19 4 OUT. +12VDC
Date
Repair manual
115 115
Sh. 19 5 OUT. GND (GALV. SEPARATED)
2012-10-03
X23 X30
340
2 OUT. GND (GALV. SEPARATED)
X23 X30
312
1 OUT. +12VDC
STEREO/CD
A11
312
A:7 INP. +12VDC
6070557
A:4 +12V KEY
RRE140/160/180/200/250
340
A:8 INP. GND
P10
LEFT +
B:5 OUT. LEFT (+)
LEFT -
B:6 OUT. LEFT (-)
P11
RIGHT +
B:3 OUT. RIGHT (+)
RIGHT -
T code
B:4 OUT. RIGHT (-)

815, 816
T4
255534
255534
Wiring diagram
18/25 PROD I
20 – 77
18/25 PROD H
20 – 78
T code
815, 816
Wiring diagram
OPTION
FORK COLOUR CAMERA
6070557
FORK CAMERA TV-MONITOR

B50 P14
Repair manual
X50 X40 X48 X25 X23 X28
110 110/WH 110 110
VIDEO SIGNAL 101 A:1 VIDEO SIGNAL
X50 X40 X48 X25 X23 X28

156 156
SCREEN 104 A:2 SCREEN
X50 X40 X48 X25 X23 X28

114 114/BN 114 114

+12VDC 102 B:1 +12VDC
Date
X50 X40 X48 X25 X23 X28

115 115/GY-PK 115 115
GND 103 B:2 GND
2012-10-03
RRE140/160/180/200/250
X30
114
Sh. 18
X30
115
Sh. 18
7510399-020
255534
Publication no.
19/25 PROD I
255534
19/25 PROD H
© BT
© BT
AUX 48VDC BATTERY VOLTAGE CONNECTOR
X42
X20
7510399-020
116 116 1
Sh. 2
Publication no.
40 2
Date
DC/DC CONVERTER
Repair manual
OPTION T5
X20 X45 DC/DC CONVERTERS

109 109
2012-10-03
Sh. 2 22 6 INP. +48VDC
X20 X45
40 40
X43
12VDC OUTLET
X36 X45
+ 128
4 OUT. +12VDC
X36 X45
- 140
6070557
DC/DC CONVERTER
T6
RRE140/160/180/200/250
109
6 INP. +48VDC
40
3 INP. GND
X44
24VDC OUTLET
X36 X45
+ 224
4 OUT. +24VDC
X36 X45
240
T code
- 5 OUT. GND (GALV. SEPARATED)

815, 816
255534
255534
20/25 PROD I
Wiring diagram
20/25 PROD H
20 – 79
20 – 80
T code
815, 816
Wiring diagram
6070557
OPTION
Repair manual
ELECTRONIC START KEY ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
K1 A1
132/PK 132/PK
1 X506:1 OUT. +5VDC
133/WK-BK 133/WK-BK
2 X506:2 OUT. GND
Date
134/WH-BN 134/WH-BN
3 X506:3 OUT. ENABLE
2012-10-03
135/WH-RD 135/WH-RD
4 X506:4 OUT. SCK (SPI CLOCK)
136/WH-OG 136/WH-OG
5 X506:5 INP. MISO (SPI DATA MASTER IN)
RRE140/160/180/200/250
137/WH-YE 137/WH-YE
6 X506:6 OUT. MOSI (SPI DATA MASTER OUT)
7510399-020
255534
Publication no.
21/25 PROD I
255534
© BT
21/25 PROD H
© BT
7510399-020
Publication no.
OPTION
DATA HANDLING UNIT ELECTRONIC CARD, DATA HANDLING UNIT
A82
X52
109 109
Sh. 20 1 INP. +48VDC SUPPLY
X52
Date
40 40
Sh. 20 8 INP. GND
Repair manual
X52
119/RD 119/RD
2012-10-03
Sh. 16 2 INP. CAN 1 HIGH
X52
120/WH 120/WH
Sh. 16 3 INP. CAN 1 LOW
T20
6070557
OPTION
SHOCK SENSOR
SHOCK SENSOR
RRE140/160/180/200/250
B90
X52
27 27
Sh. 17 23 1 INP. +48VDC SUPPLY
40
2 INP. GND
119/RD
3 INP. CAN 1 HIGH
T code
120/WH
4 INP. CAN 1 LOW
815, 816
255534
Wiring diagram
22/25 PROD H
20 – 81
20 – 82
T code
815, 816

OPTION A1
B38
39/RD 3
Sh. 17
1 101/BK
X503:2 INP. HEIGHT PRE SELECTION, NEXT
49/BU 2 LEVEL
Sh. 17
Wiring diagram
B39
3
1 102/BN
X503:8 INP. HEIGHT LIMITATION, OVERRIDE
2
6070557
B43
3
Repair manual
1 106/VT
X503:10 INP. CABIN TILT REQUEST
2
B44
3
1 107/GY
X503:5 INP. SPARE FUNCTION 1
2
B45
3
1 108/WH
2
Date

A5
2012-10-03
X20 X23 X29 X29 X23 X20

27 121
Sh. 22 X131:8 OUT. TRAFFICATOR LEFT
680~E/2W
X29 X23 X20
122
X131:35 OUT. TRAFFICATOR RIGHT
RRE140/160/180/200/250
X24 X24
126
X131:23 OUT. TRAVEL ALARM
X20 X25 X25 X20

123
X131:17 INP. SPEED REDUCTION
B6
3 P 2 89
X130:30 INP. LIFT PRESSURE MAIN LIFT
1
7510399-020
Publication no.
255534
255534
23/25 PROD I
© BT
23/25 PROD H
© BT
7510399-020

Publication no.
OPTION A1
B40
39/RD 3
Sh. 14 23
1 103/OG
49/BU 2
Sh. 14 23

A5
Date
X22 X37 X40 X53 X53 X40 X37 X22
Repair manual
27 27/WH 74/GN 74
2012-10-03
X22 X37 X40 X53

30 30/BN
A1
B41
3
1 104/YE
2
SIDE SHIFT SENSOR

B47

A5
SOUTH SENSING
6070557
X40 X37 X22

2 111/WH 111
NORTH SENSING
RRE140/160/180/200/250
X40 X37 X22
3 112/BK 112
X131:32INP. SIDESHIFT SENSOR, RIGHT SIDE
30/BU 4
WORKING LIGHT
E5 E6
193

X20 X21 X32 S99 E3 E4
190 3 4 191 192
Sh. 2
T code
815, 816
X20 X21 X32

40
Sh. 16 18
255534
255534
24/25 PROD I
Wiring diagram
24/25 PROD H
20 – 83
OPTION SHOCKSWITCH, MAIN UNIT RF ID
A72
X42
20 – 84
T code
27 116
Sh. 24 1 INP. SUPPLY +48 VDC 815, 816
40 X42
40
Sh. 24 4 INP. SUPPLY 0 VDC
116
2 INP. KEY RELAY
Wiring diagram
142
3 OUT KEY RELAY
INP. SUPPLY
6070557
116
5
WARNING LIGHT +VDC
Repair manual
P17
143
6 OUT WARNING LIGHT
KEY READER
Date
KEY READER
2012-10-03
RRE140/160/180/200/250
A5
X65
142
X131:19 INP. KEY
7510399-020
Publication no.
255534
255534
25/25
25/25PROD
PROD IH
© BT
© BT
BATTERY CONNECTOR
X3 SHUNT BAR
1 40
7510399-020
Sh. 2 Sh. 2
Publication no.

A5
40
X131:14 GND, POWER
X1 G1 X1
+ -
Date
72
X130:32
Repair manual
INP. BATT. MEASURE 1
48V
2012-10-03
71
70
MEASURING WIRES
21 21
Sh. 2 X131:5 INP. EMERGENCY SWITCH OFF STATUS
EMERGENCY SWITCH OFF
X20 S21 X20 Q10
20 1 2 21 A1 A2 31
F90
160 2 1
6070557
Sh. 17
100A
8
Sh. 2
RRE140/160/180/200/250
23 23
Sh. 2 X131:15 INP. MAIN CONTACTOR / OUT. CAP. CHARGE
22 22
28 28
119/RD 119/RD
T code
R101 120Ω
815, 816
120/WH 120/WH
Sh. 3 CAN 1 LOW
20.7 Detailed diagram cold-store cab
260844
Detailed diagram cold-store cab
Wiring diagram
20 – 85
20 – 86
T code
815, 816
FUSE CENTRAL MODULE

A9
32 X15:2 F73 X15:29 27

Sh. 3 Sh. 4 +48VDC SUPPLY
7,5A
F74 X15:10 28
Sh. 1 3 KEY POWER RELAY STATUS
Wiring diagram
K20 3A
21 X15:4 A1 A2 F75 - OPTION X15:8 190
10A
F76 - OPTION X15:6 113
7,5A
1 X16:2 1 2 26 F77 - OPTION X15:3 129
6070557

10A
Repair manual
F60 X15:1 20
3A
F61 X15:5 22
7,5A
F62 X15:7
24
7,5A
F63 X15:9 100
7,5A
F64 X15:19 9
3A
F65 - OPTION X15:28
5A
F66 - OPTION X15:25 109
7,5A
Date
X15:15
X15:14
2012-10-03
F69 X15:23 116

10A

2 1 X15:11
RRE140/160/180/200/250
5 4 X15:20 95
X15:22 40
Sh. 1 3 B-
8 X16:1 F71 X15:21 23

7,5A
F72 X15:26 250
30A
X15:27
X15:17
7510399-020
Publication no.
260844
2/25 PROD B
© BT
© BT
7510399-020
Publication no.
Date
Repair manual
A1
2012-10-03
X20 X499
24 24 24/BN
X20 X499
40 40 40/WH
Sh. 2 4 X504:3 INP. GND
X20 X499
21 21 21/GN
X20 X499
32 32 32/GY
Sh. 2 X504:17 OUT. KEY POWER RELAY
6070557
X20 X499
28 28 28/YE
X20 X500
RRE140/160/180/200/250
119/RD 119/RD 119/YE-BN
Sh. 1 15 X504:15 CAN 1 HIGH
119/WH-GY
X504:9
X20 X500
120/WH 120/WH 120/GY-BN
Sh. 1 15 X504:6 CAN 1 LOW
120/RD-BU
X504:8
T code
815, 816
260844
Wiring diagram
3/25 PROD B
20 – 87
20 – 88
T code
MOTOR CONTROLLER, DRIVE 815, 816
T1
F1
8 2
325A M1
U
40 3 V
Sh. 3 5 B- V
W M
Wiring diagram
3~
14 4
K1:1 W
B1
6070557

K1:6
Repair manual
A5
10 218/BU
B11
1 2 12 219/RD
K1:13 K1:8 X130:22 CAN 2 HIGH
B
+
4 3 13 220/WH
K1:14 K1:16 X130:8 CAN 2 LOW
A
-
Date
64 64
2012-10-03
41 41
218/BU
Sh. 5
27 27
219/RD
RRE140/160/180/200/250
Sh. 5

A5 220/WH
Sh. 5
G3
1 2 33
G4
+ - 34
M X131:34 OUT. FAN, CHASSIS
7510399-020
Publication no.
260844
4/25 PROD B
© BT
© BT
7510399-020
Publication no.
MOTOR CONTROLLER, PUMP

T2
Date
Repair manual
F3
8 5
325A M3
2012-10-03
U
40 6 V
Sh. 4 6 B- V
W M
3~
19 7
K1:1 W
B2
16
K1:6
16 218/BU
6070557
15 219/RD
B12
RRE140/160/180/200/250
1 2 17
K1:13 K1:15
B
+ 120Ω
4 3 18 220/WH
K1:14 K1:16 Sh. 4 6
A
-
27 27
X22 Q5 X22
1 2 35
Q3 X22
T code
1 2 36
815, 816
260844
Wiring diagram
5/25 PROD B
20 – 89
20 – 90
T code
815, 816

A2
Wiring diagram
40 40
40
6070557
X901:15 GND POWER
Repair manual
250 250
M6
250
X901:16 +48VDC POWER SUPPLY
M
9 9
Date
219/RD 219/RD
R202 120Ω
2012-10-03
220/WH 220/WH
Sh. 5 X901:10 CAN 2 LOW
203
X901:3 OUT. 12VDC FOR REFERENCE SENSOR
B59
1 2 211
X901:11 INP. STEERING WHEEL REFERENCE POSITION
RRE140/160/180/200/250
3
212
7510399-020
Publication no.
260844
6/25 PROD B
© BT
© BT
7510399-020
Publication no.
PEDALS BASIC MODEL

Date
Repair manual
2012-10-03

A5
X39
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X39
85/WH
X39
86/BK
3
6070557
X130:18 INP. BRAKE REFERENCE 2
X39
55/RD 87/GY
Sh. 8 1 4 X130:17 INP. ACCELERATOR SIGNAL
RRE140/160/180/200/250
X39 S29 X39

27 5 7 91
Sh. 5 8 X131:16 INP. TRACTOR DIRECTION TRAVEL REQ.
S27 X39
8 92
T code
815, 816
260844
Wiring diagram
7/25 PROD B
20 – 91
20 – 92
T code
815, 816
Wiring diagram
PEDALS ERGO MODEL

6070557
Repair manual

A5
X20
90/BU
X130:6 GND, ANALOG
PEDALS
B32
Date
X20
85/WH
2012-10-03
X20
86/BK
X20 X20
55/RD 87/GY
Sh. 7 11 1 4 X130:17 INP. ACCELERATOR SIGNAL
RRE140/160/180/200/250
X20 X58 S29 X58 X20
27 5 7 91
S27 X58 X20

8 92
7510399-020
Publication no.
260844
© BT
8/25 PROD B
© BT
7510399-020
Publication no.

A1
B13
X27 X499
Date
42/BK 42 42/BU
X504:14
Repair manual
+5VDC, STEER SENSOR 1
X27 X499
2012-10-03
1 3 43/RD 43 43/RD
A
+
X27 X499
45/OR 4 2 44/BN 44 44/BK
B
-
X27 X499
45 45/VT
X27 X499
46/YE 46 46/GY-PK
X27 X500
5 7 47/BU 47 47/BN-GN
6070557
A
+
X27 X500
45/VT 8 6 48/GN 48 48/WH-YE
B
-
RRE140/160/180/200/250

A5
B17
27 1 2 57
T code
3
815, 816
30
Sh. 12
260844
Wiring diagram
9/25 PROD B
20 – 93
20 – 94
T code
815, 816

A1
39/RD 39/RD
Sh. 14 X505:1 OUT. +5VDC, SOFTWARE CONTROLLED
Wiring diagram
X503:1
6070557
49/BU 49/BU
Repair manual
X503:7
B20
1
3 50/BK
2
B21
1
3 51/BN
Date
B22
1
2012-10-03
3 52/OG
X505:17 INP. TILT
2
B23
1
3 53/YE
2
RRE140/160/180/200/250
B24
1
3 54/GN
2
B42
3
1 105/GN
X503:4 INP. FIFTH LEVER B24, FUNCTION SHIFT
2
7510399-020
Publication no.
260844
© BT
10/25 PROD B
© BT
A5
X22 Q4 X22
27 1 2 58
7510399-020
Q2
Publication no.
X22 X22
1 2 59
X22 Q6 X22
1 2 60
X22 Q7 X22
1 2 61
Date
Repair manual
X22 Q8 X22
1 2 62
2012-10-03
X22 Q9 X22
1 2 63
X22 X37 X40 Q18 X40 X37 X22

27/VT 27 1 2 66 66/GY 66
X131:38 OUT. TILT / SIDESHIFT / AUX 1
X25 X49 Q12 X49 X25

1 2 65
X131:21 OUT. FORK SPREAD / AUX 2
X25 X49 Q14 X49 X25

1 2 67
X131:10 OUT. AUX VALVE 3
6070557
X25 X49 Q15 X49 X25

1 2 68
CABIN TILT DOWN
Q21
RRE140/160/180/200/250
X22 X56 X56 X22
1 2 41
Sh. 4
CABIN TILT UP
X22 X56 Q11 X56 X22
1 2 64
Sh. 4
55/RD 55/RD
Sh. 8 X130:1 OUT. +5VDC
X22 B4
X22
3 P 2 69
1
X22
T code
56
X130:29
815, 816
GND, ANALOG
260844
Wiring diagram
11/25 PROD B
20 – 95
20 – 96
T code
815, 816

Wiring diagram
A5
29
X130:37 OUT. +15VDC
6070557
B19
X22 X38 X38 X22
1 3 75
Repair manual

A
+
X38 X38 X22
4 2 76
B
-
X22
30 30
Sh. 9 13 X130:20 OUT. GND, DIGITAL
B18
X22 X37 X40 X40 X37 X22
29/YE 29 1 3 130 130/BK 130
A
+
Date
X37 X40 X40 X37 X22

30/BU 30 4 2 131 131/RD 131
B
-
2012-10-03
B58
X22 X37 X40 X40 X37 X22
27 27/VT 27 1 2 141 141/PK 141
RRE140/160/180/200/250
B46
X38 X38 X22
1 2 73
3
X38
X38 X38 X22

139
X38
7510399-020
Publication no.
260844
© BT
12/25 PROD B
© BT
7510399-020
Publication no.
Date
Repair manual
2012-10-03

A5
B33
X22 X22
27 1 2 75
X22
3
30
Sh. 12 16
B25
X37 X40 X40 X37 X22
27/VT 27 1 2 141 141/PK 141
6070557
X37 X40
3
30/BU 30
X38 X38
B46
X38 X22
RRE140/160/180/200/250
1 2 73
3
B57
X38 X22
1 2 139
3
T code
815, 816
260844
Wiring diagram
13/25 PROD B
20 – 97
20 – 98
T code
815, 816
SEAT BACK REST

E10:1 E10:2
X47 X61 X62 S126 X62 X63 X63
129 138 429
Sh. 2
Wiring diagram

A5
6070557
B49
X47 X47
27 1 2 83
Repair manual
X130:41
Sh. 13 15 INP. SEAT SWITCH
3
X47 X61
40
Sh. 6 15
B31
X20 X20
1 2 84
X130:31 INP. DOOR SWITCH
3
X20
P4
Date
2 1 88
X131:25 OUT. HORN
2012-10-03

A6
39/RD 39/RD B35 93/VT
RRE140/160/180/200/250
Sig.
B36

Sh. 10 19 4 INP. GND OUT. TRAVEL DIR. CHANGE 3 X505:4 INP. TRAVEL DIR. CHANGE REQUEST
REQUEST
7510399-020
Publication no.
260844
© BT
14/25 PROD B
© BT
Sh. 2 A5
7510399-020
Q1
Publication no.
27 1 2 95
X18 Q16 X18

1 2 96
X131:39 OUT. (PWM) BRAKE, LEFT SUPPORT ARM
X19 Q17 X19

1 2 97
X131:12 OUT. (PWM) BRAKE, RIGHT SUPPORT ARM
Date
Repair manual
X20 P5 X20
3 1 98
2012-10-03
X20
118
X20
117

X41
117 1
118 2
X20
6070557
119/RD 119/RD 3
Sh. 3 24
R102 120Ω
X20 ELECTRONIC CARD, LOAD INFORMATION DISPLAY
120/WH 120/WH 4
RRE140/160/180/200/250
Sh. 3 24 P6
X34
119/RD
X202:3 CAN 1 HIGH
X34
120/WH
X202:4 CAN 1 LOW
X20 X34
100 100
X20 X34
40 40
Sh. 14 17 X202:1 INP. GND
T code
815, 816
260844
Wiring diagram
15/25 PROD B
20 – 99
T code
20 – 100
815, 816

Wiring diagram
A5
B26
X22 X22
27 1 2 78
6070557
3
B27
X22 X22
Repair manual
1 2 79
3
X22
30
Sh. 13 19
B28
X17 X17
1 2 80
3
B29
X17 X17
1 2 81
Date
3
X17
2012-10-03
RRE140/160/180/200/250
7510399-020
Publication no.
260844
© BT
16/25 PROD B
© BT
7510399-020
Publication no.
ELECTRONIC CARD
T30
HEATER
40 40
Sh. 15 18 INP. 0VDC, SUPPLY VOLTAGE
R300 R301
Date
Repair manual
HEATER POWER INITIAL HEATER
X46 Q30 Q31
27 GY WH 167 A1 A2 A1 A2 177
Sh. 16 19 IGN INP. PWM ENABLE
2012-10-03
X46
X46
BK 174
POS OUT. POT. SUPPLY
R5
WH
180 1 X46
RD 175
PWM INP. SET TEMPERATURE
2
X46 3
GY
162 162
Sh. 18 X46
BU 176
NEG OUT. POT. GND.
160 161
Sh. 1
6070557
F91 7.5A F92 20A F93 20A F94 20A F95 20A F96 20A
RRE140/160/180/200/250
183
PTC - OUT. PWM OUTPUT "A" FOR HEATER
FAN 182
PTC -
40
OUT. PWM OUTPUT "B" FOR HEATER
162
ASSY.
G5
163
164
165
166
A1 A2
M
X46 400W 400W 400W 400W 400W 400W 400W 400W
BK 168 OUT POT SUPPLY
1
2
3
4
5
1
3
5
2
4
E30:1 E30:2 E30:3 E30:4 E31:1 E31:2 E31:3 E31:4

R4 1 X46
RD 169 INP. SET SPEED
2
3 X46
BU 170 OUT POT GND
T code
815, 816
171
Sh. 18
PWM-REGULATED HEATER E30:2, E30:3, E30:4, E31:2, E31:3, E31:4

INITIAL HEATER E30:1, E31:1
260844
Wiring diagram
FUNCTION SEGMENTS
17/25 PROD B
20 – 101
T code
20 – 102
815, 816
TIMER
OPTION
Wiring diagram
X57 K54 HEATED WINDOWS X57

162 A1 A2 40
Sh. 17 Sh. 17 19
B1
R550
6070557
Repair manual
R55 Q55
15 18 173 178 85 86
16 270R/3W
HEATED WINDOWS
S181
162 3 4 188
R560
R181 R56 Q56

Date
40 1 6 189 179 85 86
2K2/1W 270R/3W
2012-10-03
LEFT SIDE 150W

X57 E40
171 30 87 186
Sh. 17
87a
RIGHT SIDE 90W
E41
RRE140/160/180/200/250
DOOR 250W
E42
FRONT 380W
E43
30 87 187
87a
ROOF 125W
E44
7510399-020
Publication no.
260844
© BT
18/25 PROD B
© BT
7510399-020
Publication no.

OPTION A1
B40
39/RD 3
Sh. 14 25
1 103/OG
49/BU 2
Sh. 14 25
Date
Repair manual
A5
X22 X37 X40 X53 X40 X37 X22

27 27/VT 27 27/WH 74/GN 74 74/GN 74
2012-10-03
X22 X37 X40

30 30/BU 30 30/BN
A1
B41
3
1 104/YE
2
SIDE SHIFT SENSOR

B47
1
6070557
27/BN ELECTRONIC CARD, MAIN CONTROL UNIT

A5
NORTH SENSING
X40 X37 X22
2 111/WH 111/BN 111
RRE140/160/180/200/250
SOUTH SENSING
X40 X37 X22
3 112/BK 112/WH 112
30/BU 4
WORKING LIGHT
E5 E6
193

T code
815, 816
X20 S99 E3 E4
190 3 4 191 192
Sh. 2
X20
40
Sh. 18 20 260844
Wiring diagram
19/25 PROD B
20 – 103
DC/DC CONVERTER
T code
20 – 104
OPTION T3 815, 816
X20 STEREO/CD
113 113
Sh. 2 6 INP. +48VDC
X20
40 40
114 114
Wiring diagram
115 115
6070557
Repair manual
340
312
1 OUT. +12VDC
STEREO/CD
A11
Date
312
A:7 INP. +12VDC
2012-10-03
312
A:4 +12V KEY
340
A:8 INP. GND
P10
LEFT +
RRE140/160/180/200/250
B:5 OUT. LEFT (+)
LEFT -
B:6 OUT. LEFT (-)
P11
RIGHT +
B:3 OUT. RIGHT (+)
RIGHT -
B:4 OUT. RIGHT (-)
T4
7510399-020
Publication no.
260844
© BT
20/25 PROD B
© BT
7510399-020
Publication no.
OPTION
FORK COLOUR CAMERA

B50 P14
X50 X40 X48 X25 X28

Date
110 110/WH 110 110

101 A:1
Repair manual
VIDEO SIGNAL VIDEO SIGNAL
X50 X40 X48 X25 X28

2012-10-03
156 156
X50 X40 X48 X25 X28

114 114/BN 114 114
+12VDC 102 B:1 +12VDC
X50 X40 X48 X25 X28

115 115/GY-PK 115 115
GND 103 B:2 GND
6070557
114
RRE140/160/180/200/250
Sh. 20
115
Sh. 20
T code
815, 816
260844
Wiring diagram
21/25 PROD B
20 – 105
T code
20 – 106
815, 816
X42
X20
116 116 1
Sh. 2
40 2
Wiring diagram
DC/DC CONVERTER
6070557
OPTION T5
DC/DC CONVERTERS
Repair manual
X20
109 109
Sh. 2 24 6 INP. +48VDC
X20
40 40
X43
12VDC OUTLET
+ 128
4 OUT. +12VDC
Date
- 140
2012-10-03
DC/DC CONVERTER
T6
109
6 INP. +48VDC
RRE140/160/180/200/250
40
3 INP. GND
X44
24VDC OUTLET
+ 224
4 OUT. +24VDC
- 240
7510399-020
Publication no.
260844
22/25 PROD B
© BT
© BT
7510399-020
Publication no.
OPTION

K1 A1
Date
132/PK 132/PK
Repair manual
1 X506:1 OUT. +5VDC
2012-10-03
133/WK-BK 133/WK-BK
2 X506:2 OUT. GND
134/WH-BN 134/WH-BN
135/WH-RD 135/WH-RD
136/WH-OG 136/WH-OG
6070557
137/WH-YE 137/WH-YE
RRE140/160/180/200/250
T code
815, 816
260844
Wiring diagram
23/25 PROD B
20 – 107
T code
20 – 108
815, 816
OPTION
A82
X52
109 109
Wiring diagram
X52
40 40
Sh. 22 8 INP. GND
6070557
X52
119/RD 119/RD
2 INP. CAN 1 HIGH
Repair manual
Sh. 15
X52
120/WH 120/WH
T20
Date
OPTION
2012-10-03
SHOCK SENSOR
SHOCK SENSOR
B90
X52
27 27
1 INP. +48VDC SUPPLY
RRE140/160/180/200/250
Sh. 19 25
40
2 INP. GND
119/RD
3 INP. CAN 1 HIGH
120/WH
4 INP. CAN 1 LOW
7510399-020
Publication no.
260844
24/25 PROD B
© BT
© BT
7510399-020
Publication no.

A1
B38 OPTION
39/RD 3
Sh. 19
1 101/BK
X503:2 INP. HEIGHT PRE SELECTION, NEXT LEVEL
49/BU 2
Sh. 19
B39
Date
Repair manual
1 102/BN
2
2012-10-03
B43
3
1 106/VT
2
B44
3
1 107/GY
2
B45
3
1 108/WH
2
6070557

A5
X20 X29 R10 P12 X29 X20

27 121
RRE140/160/180/200/250
680Ω/2W
P13 X29 X20

122
P7
X24 X24
126
X20 X25 X25 X20

123
T code
815, 816
260844
Wiring diagram
25/25 PROD B
20 – 109
Wiring diagram
815, 816 6070557 2012-10-03 7510399-020
20.8 Details up to and including serial

no. 6206800

© BT
BATTERY CONNECTOR
X3 SHUNT BAR
1 40
Sh. 2 Sh. 2
7510399-020
Publication no.

A5
40
X131:14 GND, POWER
X1 G1 X1
+ -
72
Date
48V
Repair manual
71
2012-10-03
70
MEASURING WIRES
21 21
EMERGENCY SWITCH OFF
X20 S21 X20 Q10
20 1 2 21 A1 A2 31
2 1
6070557
8
Sh. 2
RRE140/160/180/200/250
23 23
Sh. 2 X131:15 INP. MAIN CONTACTOR / OUT. CAP.
CHARGE
22 22
27 27
119/RD 119/RD
R101
T code
120/WH 120/WH
X131:42 CAN 1 LOW
815, 816
Sh. 3
255534
Wiring diagram
1/25 PROD J
20 – 111
T code
FUSE CENTRAL MODULE
20 – 112
A9 815, 816
32 X15:2 F73 X15:29 27

Sh. 3 Sh. 1 4 +48VDC SUPPLY
7,5A
K20 3A
21 X15:4 A1 A2 F75 - OPTION X15:8 190
10A
F76 - OPTION X15:6 113
7,5A
1 X16:2 1 2 26 F77 - OPTION X15:3 129
Wiring diagram
10A
F60 X15:1 20
3A
F61 X15:5 22
+48VDC MCU SUPPLY
6070557
Sh. 1
7,5A
F62 X15:7 24
Repair manual
7,5A
F63 X15:9 100
7,5A
F64 X15:19 9
3A
F65 - OPTION X15:28 99
Sh. 16 +48VDC GFU SUPPLY

5A
F66 - OPTION X15:25 109
7,5A
X15:15

X15:14
F69 X15:23 116

Date

10A
EMERGENCY BRAKE RELEASE 2 S133 1 X15:11

2012-10-03
5 4 X15:20 95
X15:22 40
Sh. 1 3 B-
8 X16:1 F71 X15:21 23
RRE140/160/180/200/250
h. 1 4 Sh. 1 +48VDC CAP. CHARGE
7,5A
F72 X15:26 250
30A
X15:27
X15:17
255534
7510399-020
2/25 PROD J
Publication no.
© BT
© BT
7510399-020
Publication no.

A1
Date
X20 X499
24 24 24/BN
Repair manual
X20 X499
2012-10-03
40 40 40/WH
Sh. 2 4 X504:3 INP. GND
X20 X499
21 21 21/GN
X20 X499
32 32 32/GY
X20 X500
6070557
119/RD 119/RD 119/YE-BN

Sh. 1 15 X504:15 CAN 1 HIGH
119/WH-GY
X504:9
RRE140/160/180/200/250
X20 X500
120/WH 120/WH 120/GY-BN
Sh. 1 15 X504:6 CAN 1 LOW
120/RD-BU
X504:8
T code
815, 816
255534
3/25 PROD J
Wiring diagram
20 – 113
T code
20 – 114
T1
F1
8 2
325A M1
U
40 3 V
Sh. 3 5 B- V M
W 3~
Wiring diagram

14 4
K1:1 W
B1
6070557

K1:6
A5
Repair manual
10 218/BU
B11
1 2 12 219/RD
K1:13 K1:8 X130:22 CAN 2 HIGH
+ B
4 3 13 220/WH
K1:14 K1:16 X130:8 CAN 2 LOW
- A
Date
X22 X56 Q21 X56 X22

27 1 2 64
Sh. 2 5 K1:10 OUT. (PWM) CABIN TILT UP
2012-10-03
X22 X56 Q11 X56 X22

1 2 41
K1:2 OUT. (PWM) CABIN TILT DOWN
218/BU
Sh. 5
27
K1:9 +48VDC LOGIC SUPPLY
219/RD
RRE140/160/180/200/250
Sh. 5

A5 220/WH
Sh. 5
G3
1 2 33
G4
+ - 34
255534
4/25 PROD J
7510399-020
Publication no.
© BT
© BT
7510399-020
Publication no.
MOTOR CONTROLLER, LIFT

T2
F3
8 5
Date
325A M3
Repair manual
U
40 6 V
Sh. 4 6 B- V
M
2012-10-03
W
3~A
19 7
K1:1 W
B2
16
K1:6
16 218/BU
15 219/RD
6070557
B12
1 2 17
K1:13 K1:15
B
+ 120
RRE140/160/180/200/250
4 3 18 220/WH
K1:14 K1:16 Sh. 4 6
A
-
27 27
X22 Q5 X22
1 2 35
Q3 X22
1 2 36
T code
815, 816
255534
5/25 PROD J
255534
5/25 PROD H
Wiring diagram
20 – 115
T code
20 – 116
815, 816

A2
40 40
Wiring diagram
40
X901:15 GND POWER
250 250
6070557
M6
Repair manual
250
M
9 9
219/RD 219/RD
R202 120
Date
220/WH 220/WH
Sh. 5 X901:10 CAN 2 LOW
2012-10-03
203
X901:3 OUT. 12VDC FOR REFERENCE
SENSOR
211
X901:11 INP. STEERING WHEEL REFERENCE
POSITION
212
X901:12
RRE140/160/180/200/250
OUT. GND FOR REF. SENSOR
255534
255534
6/25 PROD J
7510399-020
6/25 PROD H
Publication no.
© BT
© BT
7510399-020
Publication no.
PEDALS BASIC MODEL

A5
Date
X39 B31
Repair manual
55/RD 1
Sh. 8 X39
2 84
3
2012-10-03
X39
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X39
85/WH
X39
86/BK
6070557
X39
87/GY
RRE140/160/180/200/250
X39 S29 X39
27 5 7 91
TRAVEL REQ.
S27 X39
8 92
T code
815, 816
255534
255534
7/25 PROD J
7/25 PROD H
Wiring diagram
20 – 117
T code
20 – 118
815, 816
PEDALS ERGO MODEL

Wiring diagram
A5
X20 X35 B31
55/RD 1
Sh. 7 11 X35 X20
2 84
6070557
X35 X20
Repair manual
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X35 X20
85/WH
X35 X20
86/BK
Date
X35 X20
87/GY
2012-10-03
X20 X58 S29 X58 X20

27 5 7 91
TRAVEL REQ.
RRE140/160/180/200/250
S27 X58 X20
8 92
255534
255534
8/25 PROD J
7510399-020
8/25 PROD H
Publication no.
© BT
© BT
7510399-020
A1
Publication no.
B13
X27 X499
42/BK 42 42/BU
X27 X499
1 3 43/RD 43 43/RD
A
+
Date
X27 X499
45/OR 4 2 44/BN 44 44/BK
Repair manual
B
-
X27 X499
2012-10-03
45 45/VT
X27 X499
46/YE 46 46/GY-PK
X27 X500
5 7 47/BU 47 47/BN-GN
A
+
X27 X500
45/VT 8 6 48/GN 48 48/WH-YE
B
-
6070557
RRE140/160/180/200/250

A5
B17
27 1 2 57
3
30
Sh. 12
T code
815, 816
255534
9/25 PROD J
255534
9/25 PROD H
Wiring diagram
20 – 119
T code
20 – 120
815, 816
A1
39/RD 39/RD
Sh. 14 X505:1 OUT. +5VDC, SOFTWARE
CONTROLLED
X503:1
Wiring diagram
49/BU 49/BU
6070557
Repair manual
X503:7
B20
1
3 50/BK

2
B21
1
3 51/BN

2
Date
B22
1
3 52/OG
X505:17 INP. TILT / AUX 1
2
2012-10-03
B23
1
3 53/YE
2
B24
RRE140/160/180/200/250
1
3 54/GN
2
B42
3
1 105/GN
X503:4 INP. AUX 4 / FIFTH LEVER B24,
2 FUNC. SHIFT
255534255534
7510399-020
10/25 PROD J
Publication no.
10/25 PROD H
© BT
© BT
A5
X22 Q4 X22
27 1 2 58
7510399-020

Publication no.
X22 Q2 X22
1 2 59 X131:26 OUT. (PWM) MAIN MAST LIFT
X22 Q6 X22
1 2 60
X22 Q7 X22
1 61
Date
2 X131:41 OUT. (PWM) REACH OUT
Repair manual
X22 Q8 X22
1 2 62
2012-10-03
X22 Q9 X22
1 2 63
X22 X37 X40 Q18 X40 X37 X22

1 2 66
X131:38 OUT. TILT / SIDESHIFT / AUX
X25 X49 Q12 X49 X25

1 2 65 X131:21 OUT. FORK SPREAD / AUX
X25 X49 Q14 X49 X25

1 2 67
6070557
X25 X49 Q15 X49 X25

1 2 68 X131:24 OUT. AUX VALVE
RRE140/160/180/200/250
*
X22 X37 X40 Q15 X40 X37
1 2
55/RD 55/RD
Sh. 8 23 X130:1 OUT. +5VDC
X22 B4 X22
3 P 2 69
1
X22
56 56
T code

815, 816
* WHEN KOOI FORKS
255534
11/25 PROD J
Wiring diagram
20 – 121
T code
20 – 122
815, 816

Wiring diagram
A5
29 OUT. +15VDC
X130:37
6070557
B19
X22 X38 X38 X22
Repair manual
1 3 75
A
+
X38 X38 X22
4 2 76

|R B
-
X22
30 30 OUT. GND, DIGITAL
Sh. 9 13 X130:20
B18
X22 X37 X40 X40 X37 X22
1 3 130
Date
A
+
X37 X40 X40 X37 X22
4 2 131
B
2012-10-03
- |R
B58
X22 X37 X40 X40 X37 X22
27 1 2 141
RRE140/160/180/200/250
B46
X38 X38 X22
1 2 73
X130:39 INP. MAIN LIFT HEIGHT REF
3
X38
B57
X38 X38 X22
139
X38
255534
7510399-020
Publication no.
12/25 PROD J
255534
12/25 PROD H
© BT
© BT
7510399-020
Publication no.

Date
Repair manual
2012-10-03
A5
B33
X22 X22
27 1 2 75
X22
3
30
Sh. 12 16
B25
X37 X40 X40 X37 X22
1 2 141
X37 X40
3
X38 X38
B46
X38 X22
6070557
1 2 73
RRE140/160/180/200/250
B57
X38 X22
1 2 139
3
255534
13/25 PROD H
T code
815, 816
255534
13/25 PROD J
Wiring diagram
20 – 123
T code
20 – 124
815, 816
SEAT BACK REST

E10:1 E10:2
X47 X61 X62 S126 X62 X63 X63

129 138 429 ELECTRONIC CARD, MAIN CONTROL UNIT
Wiring diagram
Sh. 2 A5
B49
X47 X47
27 1 2 83
6070557
3
X47 X61
Repair manual
40
Sh. 6 15
P4
+ - 88
X131:25 OUT. HORN
Date
2012-10-03

A6
39/RD 39/RD B35 93/VT

Sig.
RRE140/160/180/200/250
B36

Sh. 10 17 4 INP. GND OUT. TRAVEL DIR. CHANGE REQUEST 3 X505:4 INP. TRAVEL DIR. CHANGE REQUEST
255534
255534
14/25 PROD
7510399-020
14/25 PROD
J H
Publication no.
© BT
© BT
Sh. 2 A5
7510399-020
Q1
Publication no.
27 1 2 95
X18 Q16 X18

1 2 96
X131:39 OUT. (PWM) BRAKE, LEFT
SUPPORT ARM
X19 Q17 X19
1 2 97
X131:12 OUT. (PWM) BRAKE, RIGHT
Date
SUPPORT ARM
Repair manual
X20 X21 P5 X21 X20
3 1 98
2012-10-03
X34 X21 X20

118
X34 X21 X20

117

X41
117 1
118 2
6070557
X20 X21
119/RD 119/RD 3
Sh. 3 16
R102 120
X20 X21 ELECTRONIC CARD, LOAD INFORMATION DISPLAY
120/WH 120/WH 4
RRE140/160/180/200/250
Sh. 3 16 P6
X34
119/RD
X202:3 CAN 1 HIGH
X34
120/WH
X202:4 CAN 1 LOW
X20 X21 X34

100 100
X20 X21 X34

40 40
Sh. 14 16 X202:1 INP. GND
T code
815, 816
255534
15/25 PROD
255534J
Wiring diagram
15/25 PROD H
20 – 125
T code
20 – 126
815, 816
A5
B26
X22 X22
27 1 2 78
3
B27
X22 X22
1 2 79
Wiring diagram
3
X22
30
Sh. 13 17
B28
X17 X17
6070557
1 2 80
Repair manual
3
B29
X17 X17
1 2 81
3
X17
Date
OPTION
GENERAL FUNCTION UNIT
2012-10-03
CONNECTOR - GFU
X26
X20
99 99 1
Sh. 2
RRE140/160/180/200/250
X20
40 40 2
Sh. 15 17
X20
119/RD 119/RD 3
Sh. 15 22
X20
120/WH 120/WH 4
Sh. 15 22
255534
16/25 PROD
255534J
7510399-020
Publication no.
16/25 PROD H
© BT
© BT
7510399-020
A1
Publication no.
B40
OPTION
39/RD 3
Sh. 14 23
1 103/OG
49/BU 2
Sh. 14 23

A5
Date
X22 X37 X40 X53 X53 X40 X37 X22
Repair manual
27 27/WH 74/GN 74
X22 X37 X40 X53

2012-10-03
30 30/BN
A1
B41
3
1 104/YE
2
SIDE SHIFT SENSOR

B47

A5
SOUTH SENSING
6070557
X40 X37 X22

2 111/WH 111
NORTH SENSING
RRE140/160/180/200/250
X40 X37 X22
3 112/BK 112
30/BU 4
WORKING LIGHT
E5 E6
193

X20 X21 X32 S99 E3 E4
190 3 4 191 192
Sh. 2
T code
815, 816
X20 X21 X32

40
Sh. 16 18
255534
255534
Wiring diagram
17/25 PROD J
17/25 PROD H
20 – 127
T code
20 – 128
DC/DC CONVERTER 815, 816
OPTION T3
X20 X30 STEREO/CD

113 113
Sh. 2 6 INP. +48VDC
X20 X30
40 40
Wiring diagram
114 114
115 115
5
6070557
Sh. 19 OUT. GND (GALV. SEPARATED)
Repair manual
X23 X30
340
X23 X30
312
1 OUT. +12VDC
STEREO/CD
A11
312
Date
A:7 INP. +12VDC
A:4
2012-10-03
+12V KEY
340
A:8 INP. GND
P10
LEFT +
B:5 OUT. LEFT (+)
RRE140/160/180/200/250
LEFT -
B:6 OUT. LEFT (-)
P11
RIGHT +
B:3 OUT. RIGHT (+)
RIGHT -
B:4 OUT. RIGHT (-)
T4
7510399-020
Publication no.
255534
255534
18/25 PROD J
© BT
18/25 PROD H
© BT
7510399-020
Publication no.
OPTION
Date
FORK COLOUR CAMERA
Repair manual
2012-10-03
B50 P14
X50 X40 X48 X25 X23 X28

110 110/WH 110 110
VIDEO SIGNAL 101 A:1 VIDEO SIGNAL
X50 X40 X48 X25 X23 X28

156 156
X50 X40 X48 X25 X23 X28

114 114/BN 114 114
+12VDC 102 B:1 +12VDC
X50 X40 X48 X25 X23 X28

115 115/GY-PK 115 115
GND 103 B:2 GND
6070557
RRE140/160/180/200/250
X30
114
Sh. 18
X30
115
Sh. 18
T code
815, 816
255534
19/25 PROD J
255534
Wiring diagram
19/25 PROD H
20 – 129
T code
20 – 130
AUX 48VDC BATTERY VOLTAGE CONNECTOR 815, 816
X42
X20
116 116 1
Sh. 2
40 2
Wiring diagram
DC/DC CONVERTER
OPTION T5
6070557
X20 X45 DC/DC CONVERTERS

109 109
Sh. 2 22 6 INP. +48VDC
Repair manual
X20 X45
40 40
X43
12VDC OUTLET
X36 X45
+ 128
4 OUT. +12VDC
X36 X45
- 140
5
Date
OUT. GND (GALV. SEPARATED)

2012-10-03
DC/DC CONVERTER
T6
109
6 INP. +48VDC
RRE140/160/180/200/250
40
3 INP. GND
X44
24VDC OUTLET
X36 X45
+ 224
4 OUT. +24VDC
X36 X45
- 240
7510399-020
Publication no.
255534
255534
20/25 PROD J
20/25 PROD H
© BT
© BT
7510399-020
Publication no.
OPTION
Date
Repair manual
K1 A1
2012-10-03
132/PK 132/PK
1 X506:1 OUT. +5VDC
133/WK-BK 133/WK-BK
2 X506:2 OUT. GND
134/WH-BN 134/WH-BN
135/WH-RD 135/WH-RD
6070557
136/WH-OG 136/WH-OG
RRE140/160/180/200/250
137/WH-YE 137/WH-YE
T code
815, 816
255534255534
21/25 PROD J
21/25 PROD H
Wiring diagram
20 – 131
T code
20 – 132
815, 816
OPTION
A82
X52
109 109
Wiring diagram
X52
40 40
Sh. 20 8 INP. GND
6070557
X52
119/RD 119/RD
Repair manual
X52
120/WH 120/WH
T20
Date
OPTION
2012-10-03
SHOCK SENSOR
SHOCK SENSOR
B90
X52
27 27
Sh. 17 23 1 INP. +48VDC SUPPLY
RRE140/160/180/200/250
40
2 INP. GND
119/RD
3 INP. CAN 1 HIGH
120/WH
4 INP. CAN 1 LOW
7510399-020
Publication no.
255534
255534
PROD
22/2522/25 PROD
J H
© BT
© BT
7510399-020
Publication no.

OPTION A1
B38
39/RD 3
Sh. 17
1 101/BK
X503:2 INP. HEIGHT PRE SELECTION, NEXT
49/BU 2 LEVEL
Sh. 17
B39
3
Date
1 102/BN
Repair manual
2
B43
3
2012-10-03
1 106/VT
2
B44
3
1 107/GY
2
B45
3
1 108/WH
2

6070557
A5
X20 X23 X29 X29 X23 X20

27 121
680~E/2W
RRE140/160/180/200/250
X29 X23 X20
122
X24 X24
126
X20 X25 X25 X20

123
T code
B6
815, 816
3 P 2 89
X130:30 INP. LIFT PRESSURE MAIN LIFT
1
255534
255534
Wiring diagram
23/25 PROD J
23/25 PROD H
20 – 133
T code
20 – 134
815, 816

OPTION A1
B40
39/RD 3
Sh. 14 23
1 103/OG
49/BU 2
Sh. 14 23

Wiring diagram
A5
X22 X37 X40 X53 X53 X40 X37 X22

27 27/WH 74/GN 74
6070557
X22 X37 X40 X53
Repair manual
30 30/BN
A1
B41
3
1 104/YE
2
SIDE SHIFT SENSOR

B47

Date
A5
SOUTH SENSING
X40 X37 X22
2 111/WH 111
2012-10-03
NORTH SENSING
X40 X37 X22
3 112/BK 112
X131:32INP. SIDESHIFT SENSOR, RIGHT SIDE
30/BU 4
RRE140/160/180/200/250
WORKING LIGHT
E5 E6
193

X20 X21 X32 S99 E3 E4
190 3 4 191 192
Sh. 2
X20 X21 X32

40
Sh. 16 18
7510399-020
Publication no.
255534
255534
24/25 PROD J
24/25 PROD H
© BT
OPTION SHOCKSWITCH, MAIN UNIT RF ID
A72
© BT
X42
27 116
Sh. 24 1 INP. SUPPLY +48 VDC
7510399-020
40 X42
Publication no.
40
Sh. 24 4 INP. SUPPLY 0 VDC
116
2 INP. KEY RELAY
142
3 OUT KEY RELAY
Date
Repair manual
116 INP. SUPPLY
5
WARNING LIGHT +VDC
2012-10-03
P17
143
6 OUT WARNING LIGHT
KEY READER
KEY READER
6070557
RRE140/160/180/200/250

A5
X65
T code
142
X131:19
815, 816
INP. KEY
255534
255534
Wiring diagram
25/25 PROD J
25/25 PROD H
20 – 135
Wiring diagram
Details cold store cab starting with 6206800
815, 816 6070557 2012-10-03 7510399-020
20.9 Details cold store cab starting with

6206800

© BT
BATTERY CONNECTOR
X3 SHUNT BAR
1 40
Sh. 2 Sh. 2
7510399-020
Publication no.

A5
40
X131:14 GND, POWER
X1 G1 X1
+ -
72
Date
48V
Repair manual
71
2012-10-03
70
MEASURING WIRES
21 21
EMERGENCY SWITCH OFF STATUS
X20 S21 X20 Q10
20 1 2 21 A1 A2 31
F90
160 2 1
Sh. 17
100A
6070557
8
Sh. 2
RRE140/160/180/200/250
23 23
Sh. 2 X131:15 INP. MAIN CONTACTOR /
OUT. CAP. CHARGE
22 22
27 27
119/RD 119/RD
R101 120 Ω
120/WH 120/WH
T code
Sh. 3 X131:42 CAN 1 LOW

815, 816
260844
1/25 PROD C
Wiring diagram
20 – 137
T code
20 – 138
815, 816
FUSE CENTRAL MODULE

A9
32 X15:2 F73 X15:29 27

Sh. 3 Sh. 1 4 +48VDC SUPPLY
Wiring diagram
7,5A F74 - NOT USED

X15:10
K20 3A
21 X15:4 A1 A2 F75 - OPTION X15:8 190
10A F76 - OPTION X15:6 113
6070557
1 X16:2 1 2 26 F77 - OPTION 7,5A X15:3 129

10A
Repair manual
F60 X15:1 20
F61 3A
X15:5 22
7,5A F62 X15:7 24

F63 7,5A
X15:9 100
7,5A
F64 X15:19 9
F65 - OPTION 3A X15:28
5A F66 - OPTION X15:25 109
Date
Sh. 22 +48VDC AUX CONVERTERS SUPPLY,

7,5A DHU SUPPLY
X15:15
2012-10-03
X15:14
F69 X15:23 116
Sh. 22 +48VDC BATTERY VOLTAGE, AUX EQUIPMENT
10A SUPPLY
2 1 X15:11
RRE140/160/180/200/250
5 4 X15:20 95
X15:22 40
Sh. 1 3 B-
8 X16:1 F71 X15:21 23

7,5A F72 X15:26 250
30A
X15:27
X15:17
260844
7510399-020
2/25 PROD C
Publication no.
© BT
© BT
7510399-020
Publication no.
Date
Repair manual
A1
X20 X499
24 24 24/BN
2012-10-03
X20 X499
40 40 40/WH
Sh. 2 4 X504:3 INP. GND
X20 X499
21 21 21/GN
STATUS
X20 X499
32 32 32/GY
6070557
X20 X500
119/RD 119/RD 119/YE-BN
Sh. 1 15 X504:15 CAN 1 HIGH
RRE140/160/180/200/250
119/WH-GY
X504:9
X20 X500
120/WH 120/WH 120/GY-BN
Sh. 1 15 X504:6 CAN 1 LOW
120/RD-BU
X504:8
T code
260844
815, 816
3/25 PROD C
Wiring diagram
20 – 139
T code
20 – 140
T1
F1
8 2
325A M1
U
40 3 V
Sh. 3 5 B- V
W M
Wiring diagram
3~
14 4
K1:1 W
B1
6070557

K1:6
Repair manual
A5
10 218/BU
B11
1 2 12 219/RD
K1:13 K1:8 X130:22 CAN 2 HIGH
B
+
4 3 13 220/WH
K1:14 K1:16 X130:8 CAN 2 LOW
A
-
Date
64 64
2012-10-03
41 41
218/BU
Sh. 5
27 27
219/RD
RRE140/160/180/200/250
Sh. 5

A5 220/WH
Sh. 5
G3
1 2 33
G4
+ - 34
260844
7510399-020
Publication no.
4/25 PROD C
260844
4/25 PROD B
© BT
© BT
7510399-020
Publication no.
MOTOR CONTROLLER, PUMP

T2
Date
Repair manual
F3
8 5
325A M3
2012-10-03
U
40 6 V
Sh. 4 6 B- V
W M
3~
19 7
K1:1 W
B2
16
K1:6
16 218/BU
6070557
15 219/RD
B12
RRE140/160/180/200/250
1 2 17
K1:13 K1:15
B
+ 120Ω
4 3 18 220/WH
K1:14 K1:16 Sh. 4 6
A
-
27 27
X22 Q5 X22
1 2 35
Q3 X22
T code
1 2 36
815, 816
260844
5/25 PROD C
260844
Wiring diagram
5/25 PROD B
20 – 141
T code
20 – 142
815, 816

A2
Wiring diagram
40 40
40
6070557
X901:15 GND POWER
Repair manual
250 250
M6
250
M
9 9

Date
219/RD 219/RD
R202 120Ω
2012-10-03
220/WH 220/WH
Sh. 5 X901:10 CAN 2 LOW
203
X901:3 OUT. 12VDC FOR REFERENCE SENSOR
B59
1 2 211
X901:11 INP. STEERING WHEEL REFERENCE POSITION
RRE140/160/180/200/250
3
212
260844
7510399-020
Publication no.
6/25 PROD C
260844
6/25 PROD B
© BT
© BT
7510399-020
Publication no.
PEDALS BASIC MODEL

Date
Repair manual
2012-10-03

A5
X39
90/BU
X130:6 GND, ANALOG
PEDALS
B32
X39
85/WH
X39
86/BK
3
6070557
X130:18 INP. BRAKE REFERENCE 2
X39
55/RD 87/GY
Sh. 8 1 4 X130:17 INP. ACCELERATOR SIGNAL
RRE140/160/180/200/250
X39 S29 X39

27 5 7 91
S27 X39
8 92
T code
815, 816
260844
7/25 PROD C
260844
Wiring diagram
7/25 PROD B
20 – 143
T code
20 – 144
815, 816
Wiring diagram
PEDALS ERGO MODEL

6070557
Repair manual
A5
X20
90/BU
X130:6 GND, ANALOG
PEDALS
B32
Date
X20
85/WH
2012-10-03
X20
86/BK
X20 X20
55/RD 87/GY
Sh. 7 11 1 4 X130:17 INP. ACCELERATOR SIGNAL
RRE140/160/180/200/250
X20 X58 S29 X58 X20
27 5 7 91
S27 X58 X20

8 92
260844
7510399-020
8/25 PROD C
Publication no.
260844
© BT
8/25 PROD B
© BT
7510399-020
Publication no.

A1
B13
X27 X499
Date
42/BK 42 42/BU
X504:14
Repair manual
+5VDC, STEER SENSOR 1
X27 X499
2012-10-03
1 3 43/RD 43 43/RD
A
+
X27 X499
45/OR 4 2 44/BN 44 44/BK
B
-
X27 X499
45 45/VT
X27 X499
46/YE 46 46/GY-PK
X27 X500
5 7 47/BU 47 47/BN-GN
6070557
A
+
X27 X500
45/VT 8 6 48/GN 48 48/WH-YE
B
-
RRE140/160/180/200/250

A5
B17
27 1 2 57
T code
3
815, 816
30
Sh. 12
260844
9/25 PROD C
260844
Wiring diagram
9/25 PROD B
20 – 145
T code
20 – 146
815, 816

A1
39/RD 39/RD
Sh. 14 X505:1 OUT. +5VDC, SOFTWARE CONTROLLED
Wiring diagram
X503:1
6070557
49/BU 49/BU
Repair manual
X503:7
B20
1
3 50/BK
2
B21
1
3 51/BN
Date
B22
1
2012-10-03
3 52/OG
X505:17 INP. TILT
2
B23
1
3 53/YE
2
RRE140/160/180/200/250
B24
1
3 54/GN
2
B42
3
1 105/GN
X503:4 INP. FIFTH LEVER B24, FUNCTION SHIFT
2
7510399-020
Publication no.
260844
10/25260844
PROD C
© BT
10/25 PROD B
© BT
A5
X22 Q4 X22
27 1 2 58
7510399-020
Q2
Publication no.
X22 X22
1 2 59
X22 Q6 X22
1 2 60
X22 Q7 X22
1 2 61
Date
Repair manual
X22 Q8 X22
1 2 62
2012-10-03
X22 Q9 X22
1 2 63
X22 X37 X40 Q18 X40 X37 X22

27/VT 27 1 2 66 66/GY 66
X131:38 OUT. TILT / SIDESHIFT / AUX 1
X25 X49 Q12 X49 X25

1 2 65
X131:21 OUT. FORK SPREAD / AUX 2
X25 X49 Q14 X49 X25

1 2 67
6070557
X25 X49 Q15 X49 X25

1 2 68
CABIN TILT DOWN
Q21
RRE140/160/180/200/250
X22 X56 X56 X22
1 2 41
Sh. 4
CABIN TILT UP
X22 X56 Q11 X56 X22
1 2 64
Sh. 4
55/RD 55/RD
Sh. 8 X130:1 OUT. +5VDC
X22 B4
X22
3 P 2 69
1
X22
T code
56
X130:29
815, 816
GND, ANALOG
260844
260844
Wiring diagram
PROD
11/25 11/25 PROD
C B
20 – 147
T code
20 – 148
815, 816

Wiring diagram
A5
29
X130:37 OUT. +15VDC
6070557
B19
X22 X38 X38 X22
1 3 75
Repair manual
A
+
X38 X38 X22
4 2 76
B
-
X22
30 30
Sh. 9 13 X130:20 OUT. GND, DIGITAL
B18
X22 X37 X40 X40 X37 X22
29/YE 29 1 3 130 130/BK 130
A
+
Date
X37 X40 X40 X37 X22

30/BU 30 4 2 131 131/RD 131
B
-
2012-10-03
B58
X22 X37 X40 X40 X37 X22
27 27/VT 27 1 2 141 141/PK 141
RRE140/160/180/200/250
B46
X38 X38 X22
1 2 73
3
X38
X38 X38 X22

139
X38
260844
7510399-020
Publication no.
12/25 PROD C
260844
© BT
12/25 PROD B
© BT
7510399-020
Publication no.
Date
Repair manual
2012-10-03

A5
B33
X22 X22
27 1 2 75
X22
3
30
Sh. 12 16
B25
X37 X40 X40 X37 X22
27/VT 27 1 2 141 141/PK 141
X37 X40
3
30/BU 30
6070557
X38 X38
B46
X38 X22
1 2 73
RRE140/160/180/200/250
3
B57
X38 X22
1 2 139
3
T code
815, 816
260844
13/25 PROD C
260844
13/25 PROD B
Wiring diagram
20 – 149
T code
20 – 150
815, 816
SEAT BACK REST

E10:1 E10:2
X47 X61 X62 S126 X62 X63 X63
129 138 429
Sh. 2
Wiring diagram

A5
6070557
B49
X47 X47
27 1 2 83
Repair manual
3
X47 X61
40
Sh. 6 15
B31
X20 X20
1 2 84
X130:31 INP. DOOR SWITCH
3
X20
P4
Date
2 1 88
X131:25 OUT. HORN
2012-10-03

A6
39/RD 39/RD B35 93/VT
RRE140/160/180/200/250
Sig.
B36

Sh. 10 19 4 INP. GND OUT. TRAVEL DIR. CHANGE 3 X505:4 INP. TRAVEL DIR. CHANGE REQUEST
REQUEST
260844
7510399-020
14/25 PROD C
Publication no.
260844
© BT
14/25 PROD B
© BT
Sh. 2 A5
7510399-020
Q1
Publication no.
27 1 2 95
X18 Q16 X18

1 2 96
X131:39 OUT. (PWM) BRAKE, LEFT SUPPORT ARM
X19 Q17 X19

1 2 97
X131:12 OUT. (PWM) BRAKE, RIGHT SUPPORT ARM
Date
Repair manual
X20 P5 X20
3 1 98
2012-10-03
X20
118
X20
117

X41
117 1
118 2
X20
6070557
119/RD 119/RD 3
Sh. 3 24
R102 120Ω
X20 ELECTRONIC CARD, LOAD INFORMATION DISPLAY
120/WH 120/WH 4
RRE140/160/180/200/250
Sh. 3 24 P6
X34
119/RD
X202:3 CAN 1 HIGH
X34
120/WH
X202:4 CAN 1 LOW
X20 X34
100 100
X20 X34
40 40
Sh. 14 17 X202:1 INP. GND
T code
815, 816
260844
15/25 PROD C
260844
Wiring diagram
15/25 PROD B
20 – 151
T code
20 – 152
815, 816

Wiring diagram
A5
B26
X22 X22
27 1 2 78
6070557
3
B27
X22 X22
Repair manual
1 2 79
3
X22
30
Sh. 13 19
B28
X17 X17
1 2 80
3
B29
X17 X17
1 2 81
Date
3
X17
2012-10-03
RRE140/160/180/200/250
260844
16/25 PROD C
7510399-020
Publication no.
260844
© BT
16/25 PROD B
© BT
7510399-020
Publication no.
ELECTRONIC CARD
T30
HEATER
40 40
Sh. 15 18 INP. 0VDC, SUPPLY VOLTAGE
R300 R301
Date
Repair manual
HEATER POWER INITIAL HEATER
X46 Q30 Q31
27 GY WH 167 A1 A2 A1 A2 177
Sh. 16 19 IGN INP. PWM ENABLE
2012-10-03
X46
X46
BK 174
POS OUT. POT. SUPPLY
R5
WH
180 1 X46
RD 175
PWM INP. SET TEMPERATURE
2
X46 3
GY
162 162
Sh. 18 X46
BU 176
NEG OUT. POT. GND.
160 161
Sh. 1
6070557
F91 7.5A F92 20A F93 20A F94 20A F95 20A F96 20A
RRE140/160/180/200/250
183
PTC - OUT. PWM OUTPUT "A" FOR HEATER
FAN 182
PTC -
40
OUT. PWM OUTPUT "B" FOR HEATER
162
ASSY.
G5
163
164
165
166
A1 A2
M
X46 400W 400W 400W 400W 400W 400W 400W 400W
BK 168 OUT POT SUPPLY
1
2
3
4
5
1
3
5
2
4
E30:1 E30:2 E30:3 E30:4 E31:1 E31:2 E31:3 E31:4

R4 1 X46
RD 169 INP. SET SPEED
2
3 X46
BU 170 OUT POT GND
T code
815, 816
171 260844
Sh. 18
PWM-REGULATED HEATER E30:2, E30:3, E30:4, E31:2, E31:3, E31:4

17/25 PROD C
INITIAL HEATER E30:1, E31:1
260844
Wiring diagram
FUNCTION SEGMENTS
17/25 PROD B
20 – 153
T code
20 – 154
815, 816
TIMER
OPTION
X57 K54 HEATED WINDOWS X57
162 A1 A2 40
Sh. 17 Sh. 17 19
B1
R550
Wiring diagram
R55 Q55
15 18 173 178 85 86
6070557
16 270R/3W
HEATED WINDOWS
Repair manual
S181
162 3 4 188
R560
R181 R56 Q56

40 1 6 189 179 85 86
2K2/1W 270R/3W
Date
LEFT SIDE 150W

X57 E40
171 30 87 186
Sh. 17
87a
2012-10-03
RIGHT SIDE 90W

E41
DOOR 250W
E42
RRE140/160/180/200/250
FRONT 380W
E43
30 87 187
87a
ROOF 125W
E44
260844
260844
18/25 PROD
18/25 PROD
C B
7510399-020
Publication no.
© BT
© BT
7510399-020
Publication no.

OPTION A1
B40
39/RD 3
Sh. 14 25
1 103/OG
49/BU 2
Sh. 14 25
Date
Repair manual
A5
X22 X37 X40 X53 X40 X37 X22

27 27/VT 27 27/WH 74/GN 74 74/GN 74
2012-10-03
X22 X37 X40

30 30/BU 30 30/BN
A1
B41
3
1 104/YE
2
SIDE SHIFT SENSOR

B47
1
6070557
27/BN ELECTRONIC CARD, MAIN CONTROL UNIT

A5
NORTH SENSING
X40 X37 X22
2 111/WH 111/BN 111
RRE140/160/180/200/250
SOUTH SENSING
X40 X37 X22
3 112/BK 112/WH 112
30/BU 4
WORKING LIGHT
E5 E6
193

T code
815, 816
X20 S99 E3 E4
190 3 4 191 192 260844
Sh. 2
19/25 PROD C
X20
40
Sh. 18 20 260844
Wiring diagram
19/25 PROD B
20 – 155
DC/DC CONVERTER T code
OPTION T3
20 – 156
815, 816
X20 STEREO/CD
113 113
Sh. 2 6 INP. +48VDC
X20
40 40
114 114
Wiring diagram
115 115
6070557
340
Repair manual
312
1
OUT. +12VDC
STEREO/CD
A11
312
A:7
Date
INP. +12VDC
312
A:4 +12V KEY
2012-10-03
340
A:8 INP. GND
P10
LEFT +
B:5 OUT. LEFT (+)
RRE140/160/180/200/250
LEFT -
B:6 OUT. LEFT (-)
P11
RIGHT +
B:3 OUT. RIGHT (+)
RIGHT -
B:4 OUT. RIGHT (-)
T4
7510399-020
Publication no.
260844
260844
20/25
20/25 PROD
PRODBC
© BT
© BT
7510399-020
Publication no.
OPTION
FORK COLOUR CAMERA

B50 P14
X50 X40 X48 X25 X28

Date
110 110/WH 110 110

101 A:1
Repair manual
VIDEO SIGNAL VIDEO SIGNAL
X50 X40 X48 X25 X28

2012-10-03
156 156
X50 X40 X48 X25 X28

114 114/BN 114 114
+12VDC 102 B:1 +12VDC
X50 X40 X48 X25 X28

115 115/GY-PK 115 115
GND 103 B:2 GND
6070557
114
RRE140/160/180/200/250
Sh. 20
115
Sh. 20
T code
260844
815, 816
21/25 PROD C
260844
Wiring diagram
21/25 PROD B
20 – 157
T code
20 – 158
815, 816
X42
X20
116 116 1
Sh. 2
40 2
Wiring diagram
DC/DC CONVERTER
6070557
OPTION T5
DC/DC CONVERTERS
Repair manual
X20
109 109
Sh. 2 24 6 INP. +48VDC
X20
40 40
X43
12VDC OUTLET
+ 128
4 OUT. +12VDC
Date
- 140
2012-10-03
DC/DC CONVERTER
T6
109
6 INP. +48VDC
RRE140/160/180/200/250
40
3 INP. GND
X44
24VDC OUTLET
+ 224
4 OUT. +24VDC
- 240
7510399-020
Publication no.
260844
22/25 PROD
260844C
22/25 PROD B
© BT
© BT
7510399-020
Publication no.
OPTION

K1 A1
Date
132/PK 132/PK
Repair manual
1 X506:1 OUT. +5VDC
2012-10-03
133/WK-BK 133/WK-BK
2 X506:2 OUT. GND
134/WH-BN 134/WH-BN
135/WH-RD 135/WH-RD
136/WH-OG 136/WH-OG
6070557
137/WH-YE 137/WH-YE
RRE140/160/180/200/250
T code
815, 816
260844
23/25 PROD C
260844
Wiring diagram
23/25 PROD B
20 – 159
T code
20 – 160
815, 816
OPTION
A82
X52
109 109
Wiring diagram
X52
40 40
Sh. 22 8 INP. GND
X52
6070557
119/RD 119/RD
Repair manual
X52
120/WH 120/WH
T20
Date
OPTION
2012-10-03
SHOCK SENSOR
SHOCK SENSOR
B90
X52
27 27
. 19 25 1 INP. +48VDC SUPPLY
RRE140/160/180/200/250
40
2 INP. GND
119/RD
3 INP. CAN 1 HIGH
120/WH
4 INP. CAN 1 LOW
7510399-020
260844
Publication no.
260844
24/25 PROD C
24/25 PROD B
© BT
© BT
7510399-020
Publication no.

A1
B38 OPTION
39/RD 3
Sh. 19
1 101/BK
X503:2 INP. HEIGHT PRE SELECTION, NEXT LEVEL
49/BU 2
Sh. 19
B39
Date
Repair manual
1 102/BN
2
2012-10-03
B43
3
1 106/VT
2
B44
3
1 107/GY
2
B45
3
1 108/WH
2
6070557

A5
X20 X29 R10 P12 X29 X20

27 121
RRE140/160/180/200/250
680Ω/2W
P13 X29 X20

122
P7
X24 X24
126
X20 X25 X25 X20

123
T code
815, 816
260844
25/25 PROD C
260844
Wiring diagram
25/25 PROD B
20 – 161
Wiring diagram
815, 816 6070557 2012-10-03 7510399-020

Hydraulics schematics
Main valve unit
7510399-020 2012-10-03 6070557 815, 816
21 – Hydraulics schematics
21.1 Main valve unit
21.1.1 RRE Std.

B1 A1 H3 H2 H1 P EL M2 A2 B2
MP
Q7 Q8 Dv1 Q4 Q5 T Q3 Q2 Q9 Q6
A1 Extra function P Pump connection

A2 Extra function Q2 Lift valve, main lift
B1 Extra function Q3 Lift valve, free lift (initial lift)
B2 Extra function Q4 Lowering valve, main lift
Dv1 Main pressure limiter 25 MPa (250 bar) Q5 Lowering valve, free lift (initial lift)
EL Emergency lowering Q6 Reach movement - In
H1 Free lift (initial lift) Q7 Reach movement - Out
H2 Main lift Q8 Extra function, pump pressure for A1
H3 Main lift Q9 Extra function, pump pressure for B1
M Pressure sensor H1 T Tank connection
M2 Measuring point H2-H3
MP Meter outlet, pump pressure P

Main valve unit
815, 816 6070557 2012-10-03 7510399-020
21.1.2 RRE Ergo

B1 A1 H3 H2 H1 P EL M2 A2 B2 A3 B3
MP
Q21 Q7 Q8 Dv1 Q4 Q5 T Q3 Q2 Q9 Q6 Q11

A1 Extra function P Pump connection
A2 Extra function Q2 Lift valve, main lift
A3 Cab tilt - down Q3 Lift valve, free lift (initial lift)
B1 Extra function Q4 Lowering valve, main lift
B2 Extra function Q5 Lowering valve, free lift (initial lift)
B3 Cab tilt - up Q6 Reach movement - In
Dv1 Main pressure limiter 25 MPa (250 bar) Q7 Reach movement - Out
EL Emergency lowering Q8 Extra function, pump pressure for A1
H1 Free lift (initial lift) Q9 Extra function, pump pressure for B1
H2 Main lift Q11 Cab tilt - up
H3 Main lift Q21 Cab tilt - down - and emergency
M Pressure sensor H1 lowering
M2 Measuring point H2-H3 T Tank connection
MP Meter outlet, pump pressure P

7510399-020 2012-10-03 6070557 815, 816
21.2 Hydraulics schematics
21.2.1 Schematics designations
Designa- Function Component

tion type
Dv1 Main pressure limitation Valve
Dv2 Reach pressure limitation Valve
Dv3 Cab tilt pressure limitation Valve
(Ergo)
M Pressure sensor, free lift (ini- Sensor
tial lift)
M2 Measuring point, main lift Input/output
M3 Pump motor Motor
MP Meter outlet, pump pressure Outlet
P Pump Pump
Q2 Main mast lift Magnetic valve
Q3 Free lift lifting (initial mast) Magnetic valve
Q4 Main mast lowering Magnetic valve
Q5 Free lift lowering (initial mast) Magnetic valve
Q6 Reach carriage - in Magnetic valve
Q7 Reach carriage - out Magnetic valve
Q8 Extra function, direction A Magnetic valve
Q9 Extra function, direction B Magnetic valve
Q11 Cab tilt - upwards Magnetic valve
Q21 Cab tilt - downwards Magnetic valve
T Tank Tank

815, 816 6070557 2012-10-03 7510399-020
21.2.2 List of symbols

Single-acting cylinder Double-acting cylinder
Shuttle valve Pressure sensor, analog
Choke Shut-off valve for emer-

gency lowering
Proportional valve, electro- Pressure compensation

magnetically controlled valve
Shunt valve Pressure reducing valve
Flow control valve Priority flow valve
Counter balance valve Directional valve 4/3

(above centre valve)
Directional valve 6/3 Proportional valve 4/3
Electric motor and pump Filter
Tank Non-return valve
Counter-balance valve Directional valve 6/2

7510399-020 2012-10-03 6070557 815, 816
21.2.3 Wiring diagrams RRE/RRE Ergo
Rev: Prod B
Dwg. No.:258981
Sheet/of: 1/6

815, 816 6070557 2012-10-03 7510399-020
Rev: Prod B
Dwg. No.:258981
Sheet/of: 2/6

7510399-020 2012-10-03 6070557 815, 816
Rev: Prod B
Dwg. No.:258981
Sheet/of: 3/6

815, 816 6070557 2012-10-03 7510399-020
Rev: Prod B
Dwg. No.:258981
Sheet/of: 4/6

7510399-020 2012-10-03 6070557 815, 816
Rev: Prod B
Dwg. No.:258981
Sheet/of: 5/6

815, 816 6070557 2012-10-03 7510399-020
Rev: Prod B
Dwg. No.:258981
Sheet/of: 6/6

Tools
AMP connectors
7510399-020 2012-10-03 6070557 815, 816
22 – Tools
22.1 AMP connectors

PT = Power Timer (4.8, 5.8, 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)
Tools Number Use

213296 (JPT, PT) Pin/sleeve removal tool
213298 (MPT) Pin/sleeve removal tool
1=163787 (JPT) Tool for crimping sleeves

2=163788 (JPT)
1=213336 (MPT)
1 2=213337 (MPT)
2
1=213336 (JPT) Tool for crimping pins
2=213549 (JPT) For 0.5–2.5 mm2
1
2

Tools
MQS contacts
815, 816 6070557 2012-10-03 7510399-020
22.2 MQS contacts
Tools Number Use

257841 MQS Basic toolbox.
The box contains:

1 pair crimping pliers
1 pair stripping pliers
25 x splice sleeves 0.5-1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
contacts (male and female) with
prewired cables and splicing sleeves.
Used to replace damaged contacts
on the truck.

Tools
MQS contacts
7510399-020 2012-10-03 6070557 815, 816
Tools Number Use

257842 MQS refill box.
Use to refill the “MQS 257843
complete toolbox”.
The refill box contains:

200 x sleeves 0.2-0.5 mm2
200 x SWS sleeves 0.2-0.5 mm2
400 x SWS sleeves 0.5-0.75 mm2
100 x Clean body sleeves 0.5-0.75
mm2
200 x SWS pins 0.2-0.5 mm2
400 x SWS pins 0.5-0.75 mm2
1200 x seals
200 x blind plugs
and connectors
257843 MQS complete toolbox.
Contains 4 pliers including tools:

MQS SWS 0.25-0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&Clean body 0.25-0.5 mm2,
MQS Std&Clean body 0.5-0.75 mm2
Puller for 2, 3, 4, 6, 8 and 12-pin male

and female contacts.

Tools
CPC contacts
815, 816 6070557 2012-10-03 7510399-020
22.3 CPC contacts
Tools Number Use

1=213336 (CPC) Crimping tool
2=213338 (CPC) (sleeves only)
1
2
183593 Pin/sleeve removal
tool

Tools
Miscellaneous tools
7510399-020 2012-10-03 6070557 815, 816
22.4 Miscellaneous tools

Tools Number Use
156263 Service instrument (CAN)
1=7521083 Service instrument

1 2=163973 (CASTOR USB)
for programming
Anti-static mat for electronic

work
808-413 Socket for support arm wheel

808-4XX
219730 Hydraulic pressure gauge

Tools
Miscellaneous tools
815, 816 6070557 2012-10-03 7510399-020
Tools Number Use

7504474 Adjustment of mast angle
1/4" — 254526 Plugs (male part) for valves with

3/8" — 254527 WEO type quick change
1/2" — 254528 connector
1/4" — 254529 Plugs (female part) for hydraulic

3/8" — 254530 hoses with WEO type quick
1/2" — 254531 change connector
11-1310 Lifting tool for batteries

Max. 1500 kg

Tools
Miscellaneous tools
7510399-020 2012-10-03 6070557 815, 816
Tools Number Use

11-1091 Lifting tool for mast 1.4 - 2.0 t
11/-1133/4 Lifting tool for mast 2.5 t
92
0

Tools
Miscellaneous tools
815, 816 6070557 2012-10-03 7510399-020
Tools Number Use

11-1020 Lifting tool for mast guide
7
41
11-1021 Lifting tool for mast guide

0
38
08-17526 Oil dipstick
7509180 Door latch

Appendix “Service data and grease specifications”
General tightening torques
7510399-020 2012-10-03 6070557 815, 816
23 – Appendix “Service data and

grease specifications”
23.1 General tightening torques

Millimetre threads M3 to M24.
The tables apply under good conditions, e.g. steel against steel.
23.1.1 Galvanised non-oiled bolts

Tightening torque (Nm)
Strength class:
8.8 10.9 12.9
M3 1.1 1.6 2.0
M4 2.8 3.8 4.7
M5 5.5 7.7 9.3
M6 9.5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075

General tightening torques
815, 816 6070557 2012-10-03 7510399-020
23.1.2 Untreated oiled bolts

Tightening torque (Nm)
Strength class:
8.8 10.9 12.9
M3 1.2 1.7 2.1
M4 2.9 4.0 4.9
M5 5.7 8.1 9.7
M6 9.8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
Note!
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will also achieve the correct torque value
for galvanised bolts. Do not tighten more than the values set out in
the table, otherwise the bolts may be damaged.

Oil and grease specification
7510399-020 2012-10-03 6070557 815, 816
23.2 Oil and grease specification

Ref: 236021 Rev. 5 (21-05-2008)
Lubricant type Specification Use

>-15? <-15?
A Grease S213366 S213366 Bearings and bushes
Q8 Rubens WB Q8 Rubens WB
C Transmission oil Synthetic hypoid oil Gears
SAE 75W-90
Class API-GL5
D Grease See table below See table below Chains
E Grease Grafloscon Grafloscon Gear rim
A-G1 (Klüber) A-G1 (Klüber)
F Grease S213366 S213366 Mast
Q8 Rubens WB Q8 Rubens WB
Pos Ambient tem- Viscosity class Use

perature
B 0°C - 40°C ISO VG32 Hydraulic system
ISO 6743-4 category HM
DIN 51524 part 2 = HLP
B -35°C - 40°C ISO VG 27.5 Hydraulic system
ISO 7643-4 category HV
DIN 51524 part 3 = HVLP
Pos Ambient tem- Viscosity class Recommended products*

perature
D > -40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< -30°C
D > -30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
Anticorit LBO 160 TT, Fuchs DEA
< +5°C
D > +5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
Anticorit LBO 160, Fuchs DEA
< +45°C
Rexoil, Rexnord Kette
D > +45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
< +80°C
* Equivalent products from another manufacturer may be used

Oil and grease specification
815, 816 6070557 2012-10-03 7510399-020

Technical data
7510399-020 2012-10-03 6070557 815, 816
24 – Technical data
Model RRE 140 RRE 160
Drive motor
Type TSA170-200-073
Output, kW S2 60 min 7.5
Transmission/gear
Designation GK25
Gear ratio 20.2:1
Oil volume, litres 3.3
Oil type Fully-synthetic hypoid oil
Viscosity class, ambient temperature SAE 75W-90 API GL 5
+40 to -35°C
Wheel and brakes
Parking brake, nominal braking torque 90 Nm
nominal play 0.3 ± 0.1 mm
maximum play 0.50 mm
minimum thickness for the friction disc 10.5 mm
coil resistance 48 ohms at 20°C
Support arm brake, nominal braking 1000 Nm
torque
number of inner discs 3
number of outer discs 5
Drive wheel, diameter x width, mm 350x140
Support arm wheel, diameter x width, 300x106
mm
Maximum weight on support arm wheels 1243/3982 1295/4131
without load/with load (kg)
Maximum weight on drive wheel without 1899/1577 1952/1875
load/with load (kg)
Maximum wheel pressure, support arm 43.8 46.0
(MPa)
Maximum wheel pressure, drive (MPa) 33.8 34.4

Technical data
815, 816 6070557 2012-10-03 7510399-020

Hydraulic system
Pump motor, type TSA170-140-072
Output, kW S3 15% 11
Pump displacement 16 cc
Tank volume, litres 25
Oil type:
0°C - 40°C ISO VG32

ISO 6743-4 category HM
DIN 51524 part 2 = HLP
-35°C - 40°C ISO VG 27.5

ISO 7643-4 category HV
DIN 51524 part 3 = HVLP
Hydraulic pressure
Overflow pressure, bar 250
Pressure limitation tilt/extra function/cab 150
tilt, bar
Steering motor
Output, continuous, max. W 300
Fuses
F1, Drive motor 325 A
F3, Pump motor 325 A
F60, ESO circuit 3A
F61, Main fuse MCU [A5] 7.5 A
F62, Main fuse CID [A1] 7.5 A
F63, Main fuse LID [P6] 7.5 A
F64, Steering servo EPS [A2] 3A
F65, GFU (option) 5A
F66, Converter [T5], [T6] (option) 7.5 A
F69, Extra equipment 10 A
F71, MCU [A5] 7.5 A
F72, Steering motor EPS [A2] 30 A
F73, Controls 48 V 7.5 A
F74, Key relay [A1], [A5] 3 A
F75, Working light (option) 10 A

Technical data
7510399-020 2012-10-03 6070557 815, 816

F76, Converter [T3] (option) 7.5 A
F77, Seat heater (option) 10 A
F90, Cab heater (cold store cab) 100 A
F91, Heater control (cold store cab) 7.5 A
F92, Heater element (cold store cab) 20 A
F96, Electrically-heated windows (cold 20 A
store cab)
Batteries
Capacity, Ah 450 – 750
Travel speed, km/h
Without support arm brake, drive wheel 11/11
direction, laden/unladen (km/h)
Without support arm brake, fork direc- 11/11
tion, laden/unladen (km/h)
With support arm brake, drive wheel 12/14
With support arm brake, fork direction, 12/14
laden/unladen (km/h)

Technical data
815, 816 6070557 2012-10-03 7510399-020
Model RRE 180 RRE 200 RRE 250

Drive motor
Type TSA200-180-100
Output, kW S2 60 min 9
Transmission/gear
Designation GK30
Gear ratio 22.4:1
Oil volume, litres 4.6
Oil type Fully-synthetic hypoid oil
Viscosity class, ambient temperature SAE 75W-90 API GL 5
+40 to -35°C
Wheel and brakes
Parking brake, nominal braking torque 90 Nm
nominal play 0.3 ± 0.1 mm
maximum play 0.50 mm
minimum thickness for the friction 10.5 mm
disc
coil resistance 48 ohms at 20°C
Support arm brake, nominal braking 1000 Nm
torque
number of inner discs 3
number of outer discs 5
Drive wheel, diameter x width, mm 400x160
Support arm wheel, diameter x width, 350x106
mm
Maximum weight on support arm 1523/4659 1512/4932 1932/6098
wheels without load/with load (kg)
Maximum weight on drive wheel without 2418/2403 2476/2415 2822/2736
load/with load (kg)
Maximum wheel pressure, support arm 49.8 53.6 55.9
(MPa)
Maximum wheel pressure, drive (MPa) 31.3 32.7 33.1

Technical data
7510399-020 2012-10-03 6070557 815, 816

Hydraulic system
Pump motor, type TSA170-200-106
Output, kW S3 15% 15.0
Pump displacement 19cc 19cc 16cc
Tank volume, litres 25
Oil type:
Normal temperature ISO VG32
<-15°C ISO VG27.5
Hydraulic pressure
Overflow pressure, bar 250
Pressure limitation tilt/extra function/ 150
cab tilt, bar
Steering motor
Output, continuous, max. W 400
Fuses
F1, Drive motor 325 A
F3, Pump motor 325 A
F60, ESO circuit 3A
F61, Main fuse MCU [A5] 7.5 A
F62, Main fuse CID [A1] 7.5 A
F63, Main fuse LID [P6] 7.5 A
F64, Steering servo EPS [A2] 3A
F65, GFU (option) 5A
F66, Converter [T5], [T6] (option) 7.5 A
F69, Extra equipment 10 A
F71, MCU [A5] 7.5 A
F72, Steering motor EPS [A2] 30 A
F73, Controls 48 V 7,5 A
F74, Key relay [A1], [A5] 3 A
F75, Working light (option) 10 A
F76, Converter [T3] (option) 7.5 A
F77, Seat heater (option) 10 A
F90, Cab heater (cold store cab) 100 A

Technical data
815, 816 6070557 2012-10-03 7510399-020

F91, Heater control (cold store cab) 7.5 A
F96, Electrically-heated windows (cold 20 A
store cab)
Batteries
Capacity, Ah 450 – 900
Travel speed, km/h
Without support arm brake, drive wheel 11/11
Without support arm brake, fork direc- 11/11
tion, laden/unladen (km/h)
With support arm brake, drive wheel 12/14
With support arm brake, fork direction, 12/14
laden/unladen (km/h)

Technical data
815, 816 6070557 2012-10-03 7510399-020

© BT
SE-595 81 Mjölby
Sweden
www.toyota-forklifts.eu
Technical data
815, 816 6070557 2012-10-03 7510399-020

Repair Manual En: Applies From Serial Number: 6070557

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Publishing Order Amendments

This manual contains information on the following trucks:

T-Code Model: Serial number

© BT Repair manual RRE140/160/180/200/250

3 – General safety rules .......................................................................... 3-1

4 – Descriptions of functions ................................................................. 4-1

© BT Repair Manual RRE140/160/180/200/250 1– 1

4.9.7 OTP ............................................................................... 4-88

© BT Repair Manual RRE140/160/180/200/250 1– 3

4.11.9 Cabin tilt (RRE Ergo) ................................................... 4-104

5 – Parameters ......................................................................................... 5-1

1– 4 Repair Manual RRE140/160/180/200/250 © BT

Parameter 209/210 – Reduced maximum travel

© BT Repair Manual RRE140/160/180/200/250 1– 5

5.8 General factory parameters ......................................................... 5-51

6 – Installation ......................................................................................... 6-1

7 – Maintenance ....................................................................................... 7-1

1– 6 Repair Manual RRE140/160/180/200/250 © BT

7.4.4 Every 3000 B-hours/1080 days ..................................... 7-13

8 – Troubleshooting ................................................................................ 8-1

© BT Repair Manual RRE140/160/180/200/250 1– 7

8.6 Troubleshooting without indications ............................................. 8-97

9 – Frame/Chassis 0000 .......................................................................... 9-1

10 – Motors 1000 ................................................................................... 10-1

1– 8 Repair Manual RRE140/160/180/200/250 © BT

Reassembling the pump motor ...................................... 10-6

11 – Drive gear 2000 .............................................................................. 11-1

12 – Brake and wheel 3000 ................................................................... 12-1

© BT Repair Manual RRE140/160/180/200/250 1– 9

Adjusting the air gap .................................................... 12-10

13 – Steering system 4000 .................................................................... 13-1

14 – Electrical system 5000 .................................................................. 14-1

1 – 10 Repair Manual RRE140/160/180/200/250 © BT

Replacing the travel direction selector with signal button 14-

15 – Hydraulic system 6000 .................................................................. 15-1

© BT Repair Manual RRE140/160/180/200/250 1 – 11

15.3.1 Emergency lowering of forks ....................................... 15-12

1 – 12 Repair Manual RRE140/160/180/200/250 © BT

16 – Mast/Lift system 7000 ................................................................... 16-1

© BT Repair Manual RRE140/160/180/200/250 1 – 13

16.2.2 Checking the chain ...................................................... 16-16

1 – 14 Repair Manual RRE140/160/180/200/250 © BT

16.9.4 Dismantling telescopic forks ........................................ 16-42

17 – Peripherals - 8000 .......................................................................... 17-1

18 – Extra equipment - 9000 ................................................................. 18-1

19 – Appendix “Destruction instructions” .......................................... 19-1

20 – Wiring diagram .............................................................................. 20-1

© BT Repair Manual RRE140/160/180/200/250 1 – 15

Figure 32 (Cab tilt wiring harness) ............................... 20-40

21 – Hydraulics schematics ................................................................. 21-1

22 – Tools ............................................................................................... 22-1

23 – Appendix “Service data and grease specifications” .................. 23-1

24 – Technical data ............................................................................... 24-1

1 – 16 Repair Manual RRE140/160/180/200/250 © BT

2.1 How to use the manual

© BT Repair Manual RRE140/160/180/200/250 2– 1

2.2 Warning symbols

Additional information under the Pictogram can, for example, indicate

2– 2 Repair Manual RRE140/160/180/200/250 © BT

3 – General safety rules

3.1 Safety while working