Repair Manual En: Valid From Serial Number: 6051502

Repair Manual en
RRE140/160/180/200/250
Valid from serial number: 6051502
Order number: 261828-040

Issued: 2008-08-21 ITS
© BT
Document revisions:
Issue date Publication Changes

No.
2008-08-21 261828-040 Completely new issue.
This manual covers following truck models:
T-code Model Serial number

815 RRE140, RRE140C, (RRE140CC), 6051502-
RRE140E,RRE140EC, (RRE140ECC),
RRE160, RRE160C, (RRE160CC)
RRE160E, RRE160EC, (RRE160ECC)
816 RRE180, RRE180C, (RRE180CC), 6051502-
RRE180E, RRE180EC, (RRE180ECC),
RRE200, RRE200C, (RRE200CC),
RRE200E, RRE200EC, (RRE200ECC),
RRE250, RRE250C, (RRE250CC),
RRE250E, RRE250EC, (RRE250ECC)
© BT Repair Manual RRE140/160/180/200/250

Contents
Publication No. Date Valid from serial number T-code
261828-040 2008-08-21 6051502 815, 816
1 – Contents
1 – Contents ............................................................................................. 1-1
2 – General introduction ......................................................................... 2-1

2.1 How to use the manual................................................................... 2-1
2.2 Warning symbols ........................................................................... 2-2
2.3 Pictograms ..................................................................................... 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 – Functions and parameters ................................................................ 4-1

4.1 Chassis 0000 ................................................................................. 4-1
4.1.1 Driver protection (0840) ................................................... 4-1
Tilt stops .......................................................................... 4-1
Overhead guard ............................................................... 4-2
4.2 Motors 1000 ................................................................................... 4-3
4.2.1 General ............................................................................ 4-3
4.2.2 Electric pump motor (1710) ............................................. 4-3
General ............................................................................ 4-3
Design ............................................................................. 4-3
4.2.3 Electric steering motor (1730) ......................................... 4-4
General ............................................................................ 4-4
Design ............................................................................. 4-4
4.2.4 Fan motor/fan (1740) ....................................................... 4-5
4.2.5 Electric drive motor (1760) .............................................. 4-6
General ............................................................................ 4-6
Design ............................................................................. 4-6
4.3 Drive gear – 2000........................................................................... 4-7
4.3.1 General ............................................................................ 4-7
4.3.2 Design ............................................................................. 4-8
4.4 Brake system 3100 ........................................................................ 4-9
4.4.1 General ............................................................................ 4-9
Travel brake ..................................................................... 4-9
Parking brake .................................................................. 4-9
Emergency brake ............................................................ 4-9
4.4.2 Drive motor brake (travel brake) .................................... 4-10
Accelerator released ...................................................... 4-10
Changing the direction of travel ..................................... 4-10
4.4.3 Multiple disc brake, support arm (travel brake) ............. 4-11
General .......................................................................... 4-11
Design ........................................................................... 4-11
4.4.4 Disc brake on the drive motor (parking brake) .............. 4-12
General .......................................................................... 4-12
Design ........................................................................... 4-12
4.5 Steering system 4000 .................................................................. 4-13
4.5.1 General .......................................................................... 4-13
Design ........................................................................... 4-13
4.6 Operator compartment................................................................. 4-14
4.6.1 Truck control, overview .................................................. 4-14
© BT Repair Manual RRE140/160/180/200/250 1– 1

Contents
T-code Valid from serial number Date Publication No.
815, 816 6051502 2008-08-21 261828-040
Right-hand control panel, single control ........................ 4-14

Right-hand control panel, multi-control .......................... 4-14
Emergency switch off .................................................... 4-14
Steering module ............................................................ 4-15
Pedals ............................................................................ 4-16
4.6.2 Single control ................................................................. 4-17
4.6.3 Multi-control ................................................................... 4-18
4.6.4 Central Information Display – CID ................................. 4-19
CID LED symbols .......................................................... 4-19
CID information symbols in the display area ................. 4-20
CID disable indications in the display area .................... 4-21
CID service symbols in the display area ........................ 4-22
Driver parameter symbols ............................................. 4-23
Navigation ...................................................................... 4-24
4.6.5 Load Information Display – LID (option) ........................ 4-27
LID LED symbols ........................................................... 4-27
LID symbols in the display area ..................................... 4-28
4.7 Operation and connection sequences.......................................... 4-29
4.8 Functions ..................................................................................... 4-43
4.8.1 General overview ........................................................... 4-43
Key ................................................................................ 4-43
Components .................................................................. 4-43
4.8.2 MCU – Main Control Unit ............................................... 4-44
General .......................................................................... 4-44
System communication ................................................. 4-44
4.8.3 ACT/ACH transistor regulators ...................................... 4-44
General .......................................................................... 4-45
4.8.4 Start-up .......................................................................... 4-45
4.8.5 Shutdown ....................................................................... 4-45
4.8.6 Driving ........................................................................... 4-46
Introduction .................................................................... 4-46
Acceleration and speed reduction ................................. 4-46
Reversing ...................................................................... 4-47
Brake ............................................................................. 4-47
Travel speed .................................................................. 4-48
4.8.7 Steering ......................................................................... 4-49
Steering position check ................................................. 4-49
Steering speed .............................................................. 4-49
Steering reference ......................................................... 4-50
Travel speed limitation ................................................... 4-50
Compass card ............................................................... 4-50
4.8.8 Hydraulic system ........................................................... 4-51
Definitions ...................................................................... 4-51
Controls ......................................................................... 4-51
Lift .................................................................................. 4-51
Reach movement .......................................................... 4-52
Lift height limitation ........................................................ 4-52
Maximum height limitation ............................................. 4-52
Auxiliary/Extra functions (option) ................................... 4-53
4.9 Height preselector, description of function ................................... 4-54
4.9.1 Using the height preselector .......................................... 4-54
4.9.2 Symbols ......................................................................... 4-54
4.9.3 Buzzer ........................................................................... 4-54
4.9.4 Height preselector levels ............................................... 4-55
4.9.5 Level selection ............................................................... 4-55
4.9.6 Height programming ...................................................... 4-56
1– 2 Repair Manual RRE140/160/180/200/250 © BT

Contents
261828-040 2008-08-21 6051502 815, 816
4.9.7 Height preselector and TruckCom ................................. 4-57

4.9.8 Lift/lowering movement .................................................. 4-57
4.10 Hydraulic system 6000................................................................. 4-58
4.10.1 General .......................................................................... 4-58
4.10.2 Tank ............................................................................... 4-58
4.10.3 Filter ............................................................................... 4-58
Return filter .................................................................... 4-58
Dehumidification filter .................................................... 4-58
4.10.4 Hydraulic pump .............................................................. 4-59
4.10.5 Valve block .................................................................... 4-59
Main valve block ............................................................ 4-59
Other valve blocks ......................................................... 4-60
4.10.6 Cylinders ........................................................................ 4-61
Main lift cylinder ............................................................. 4-61
Free lift cylinder ............................................................. 4-61
Cylinders for the reach movement, cabin tilt, sideshift and fork
tilt ................................................................................... 4-61
4.10.7 Lift and lowering function ............................................... 4-62
Lifting and lowering of free lift ........................................ 4-62
Transition from free lift to main lift ................................. 4-62
Lifting and lowering of main lift ...................................... 4-62
Reach movement, in and out ......................................... 4-62
Simultaneous operation of mast lift and reach movement . 4-
63
4.10.8 Extra functions ............................................................... 4-63
4.10.9 Cabin tilt (RRE Ergo) ..................................................... 4-63
Hydraulic priority system ............................................... 4-63
Cabin tilt (RRE Ergo) during servicing ........................... 4-64
Cabin tilt in the event of hydraulic or electrical power loss 4-
64
4.11 Mast 7000 .................................................................................... 4-65
4.11.1 Mast and reach carriage ................................................ 4-65
4.12 Lifting devices .............................................................................. 4-66
4.12.1 Fork extensions ............................................................. 4-66
4.12.2 Telescopic forks ............................................................. 4-66
4.13 Parameters .................................................................................. 4-68
4.13.1 General .......................................................................... 4-68
4.13.2 Displaying/changing parameters ................................... 4-69
4.13.3 Parameters .................................................................... 4-69
Operator parameters, overview ..................................... 4-69
Service parameters, overview ....................................... 4-70
Factory parameters, overview ....................................... 4-75
Calibration parameters, overview .................................. 4-77
5 – Installation ......................................................................................... 5-1

5.1 Transporting the truck .................................................................... 5-1
Method 1 .......................................................................... 5-1
Method 2 .......................................................................... 5-1
5.2 Initial operation............................................................................... 5-2
5.2.1 Placing the battery ........................................................... 5-2
5.2.2 Parameters on initial operation ........................................ 5-3
Battery ............................................................................. 5-3
Load indicator .................................................................. 5-3
Ergo cabin ....................................................................... 5-3
Cold store cabin ............................................................... 5-4

Contents
815, 816 6051502 2008-08-21 261828-040
5.2.3 Parameters for optional equipment ................................. 5-4

Height measurement (option) .......................................... 5-4
Travel speed limitation, height-dependent ....................... 5-4
Travel speed limitation, reach movement dependent ...... 5-4
Travel speed limitation, parameter-dependent ................ 5-5
Collision sensor (BT) ....................................................... 5-5
5.2.4 Mast, fitting ...................................................................... 5-5
6 – Maintenance ....................................................................................... 6-1

6.1 Introduction, maintenance.............................................................. 6-1
6.2 Periodic maintenance .................................................................... 6-2
6.2.1 Every 500 B-hours/180 days ........................................... 6-2
6.2.2 Every 1000 B-hours/360 days ......................................... 6-4
6.2.3 Every 2000 B-hours/720 days ......................................... 6-9
6.2.4 Every 3000 B-hours/1080 days ....................................... 6-9
6.2.5 Every 5000 B-hours/1800 days ..................................... 6-11
6.2.6 Annual status inspection ................................................ 6-11
6.3 Maintenance instructions ............................................................. 6-12
6.3.1 Cleaning and washing ................................................... 6-12
High-pressure washers .................................................. 6-12
Degreasing agents ........................................................ 6-12
Cleaning the exterior ..................................................... 6-12
Cleaning the chain ......................................................... 6-13
Cleaning the motor compartment .................................. 6-13
Electrical components ................................................... 6-13
7 – Troubleshooting ................................................................................ 7-1

7.0.1 Error log menu ................................................................. 7-1
Error information menu .................................................... 7-1
7.1 Service diagnostics menu .............................................................. 7-2
7.1.1 General ............................................................................ 7-2
7.1.2 Diagnostics states ........................................................... 7-3
State 1 – Voltage from levers .......................................... 7-3
State 2 – Digital signals from truck controls to MCU ....... 7-4
State 3 – Voltages to MCU .............................................. 7-5
State 4 – Digital input signals to MCU ............................. 7-6
State 5 – Digital output signals from MCU ....................... 7-7
State 6 – PWM outputs from MCU .................................. 7-8
State 7 – FCU (not used) ................................................. 7-8
State 8 – FCU (not used) ................................................. 7-8
State 9 – GFU (not used) ................................................ 7-8
State 10 – GFU (not used) .............................................. 7-8
State 11 – Temperature signals ...................................... 7-9
State 12 – Voltage levels ................................................. 7-9
State 13 – Travel information ........................................ 7-10
State 14 Steering information ........................................ 7-11
State 15 – Lift/lowering information ............................... 7-12
State 16 – Reach movement ......................................... 7-13
State 17 – Hydraulic information ................................... 7-14
7.2 Warning and error codes.............................................................. 7-15
Abbreviations used in this section ................................. 7-15
Error code structure ....................................................... 7-15
7.2.1 Error codes ................................................................... 7-17
7.3 ACT/ACH transistor regulators .................................................... 7-34
7.3.1 Cable connections and pole bolts .................................. 7-34

Contents
261828-040 2008-08-21 6051502 815, 816
7.3.2 Connections on the MCU .............................................. 7-36

7.4 Symptom tables ........................................................................... 7-38
7.4.1 Brake ............................................................................. 7-38
7.4.2 Telescopic forks ............................................................. 7-39
8 – Frame/Chassis 0000 .......................................................................... 8-1

8.1 General .......................................................................................... 8-1
8.2 Motor hood (0340).......................................................................... 8-1
8.2.1 Opening the motor compartment ..................................... 8-1
RRE 160-RRE 250 .......................................................... 8-1
8.3 Operator cabin (0500) .................................................................... 8-2
Cabin tilting RRE 160-250 Ergo ...................................... 8-2
8.4 Operator compartment (0600)........................................................ 8-3
8.4.1 Internal fittings (0680) ...................................................... 8-3
8.5 Safety equipment (0800)................................................................ 8-4
8.5.1 Checking the overhead guard (0810) .............................. 8-4
8.5.2 Adjusting the tilt stops (0840) .......................................... 8-5
9 – Motors 1000 ........................................................................................ 9-1

9.1 Motor sensors ................................................................................ 9-1
9.1.1 Temperature sensor ........................................................ 9-1
Retrofitting of external temperature sensor ..................... 9-1
9.1.2 Replacing the motor speed sensor .................................. 9-2
9.2 Pump motor (1710) ........................................................................ 9-3
9.2.1 General ............................................................................ 9-3
The pump motor dismantled ............................................ 9-3
9.2.2 Replacing the bearing on the pump motor ...................... 9-4
Dismantling the pump motor ............................................ 9-4
Assembling the pump motor ............................................ 9-6
9.3 Steering motor and steering unit (1730)......................................... 9-7
9.3.1 General ............................................................................ 9-7
9.3.2 Layout of the flange holes ............................................... 9-7
9.3.3 Removing the steering motor from the truck ................... 9-8
9.3.4 Placing the steering motor in the truck ............................ 9-8
9.4 Fan motor/fan (1740) ..................................................................... 9-9
9.4.1 General ............................................................................ 9-9
9.4.2 Replacing the frequency converter cooling fan ............... 9-9
Standard truck ................................................................. 9-9
Ergotruck ......................................................................... 9-9
9.4.3 Replacing the motor compartment cooling fan .............. 9-11
9.5 Drive motor (1760) ....................................................................... 9-12
9.5.1 General .......................................................................... 9-12
The drive motor dismantled ........................................... 9-12
9.5.2 Removing the drive motor from the truck ...................... 9-13
9.5.3 Dismantling the drive motor ........................................... 9-15
9.5.4 Cleaning ........................................................................ 9-16
9.5.5 Assembling the drive motor ........................................... 9-17
9.5.6 Fitting the drive motor to the truck ................................. 9-19
10 – Drive gear 2000 .............................................................................. 10-1

10.1 General ........................................................................................ 10-1
10.1.1 Leakage from the bottom cap ........................................ 10-1
10.1.2 Replacing the drive gear ................................................ 10-2
Special tools .................................................................. 10-2

Contents
815, 816 6051502 2008-08-21 261828-040
Exposing the drive gear ................................................. 10-2

Removing a drive motor from the truck ......................... 10-2
Removing a steering motor from the truck .................... 10-2
Removing the drive gear from the truck ........................ 10-3
10.1.3 Replacing the pinion gear, input shaft ........................... 10-5
Remove the pinion gear ................................................ 10-5
Placing a new ball bearing ............................................. 10-6
Fitting the sealing ring ................................................... 10-6
Inserting the pinion gear in the drive gear ..................... 10-6
10.1.4 Placing the drive gear in the truck ................................. 10-7
Placing the steering motor in the truck .......................... 10-8
Placing the drive motor in the truck ............................... 10-8
10.1.5 Refitting ......................................................................... 10-8
11 – Brake and wheel 3000 ................................................................... 11-1

11.1 Travel brake system (3100) ......................................................... 11-1
11.1.1 Removing the support arm's multiple disc brake ........... 11-1
11.1.2 Dismantling the multiple disc brake ............................... 11-1
Inspection ...................................................................... 11-2
Adjusting play ................................................................ 11-2
Assembling the multiple disc brake ............................... 11-3
11.1.3 Placing the multiple disc brake in the truck ................... 11-3
11.2 Parking brake (3300) ................................................................... 11-4
11.2.1 General .......................................................................... 11-4
11.2.2 Emergency release of the parking brake ....................... 11-5
11.2.3 Checking the brake force ............................................... 11-5
11.2.4 Removing the parking brake from the truck ................... 11-6
Dismantling and checking wear ..................................... 11-6
Assembling the parking brake ....................................... 11-7
Adjusting play ................................................................ 11-7
11.2.5 Placing the parking brake in the truck ........................... 11-8
11.3 Drive wheel (3530) ....................................................................... 11-9
11.3.1 General .......................................................................... 11-9
11.3.2 Removing the drive wheel from the truck ...................... 11-9
11.3.3 Placing the drive wheel on the truck .............................. 11-9
11.4 Wheel bolt (3530)....................................................................... 11-10
General ........................................................................ 11-10
11.4.1 Replacing wheel bolts .................................................. 11-10
11.5 Support arm wheel (3550).......................................................... 11-11
11.5.1 Removing the support arm wheel from the truck ......... 11-11
11.5.2 Replacing a wheel bearing – braked wheel (A) ........... 11-12
11.5.3 Replacing a wheel bearing – unbraked wheel (B) ....... 11-13
11.5.4 Placing the support arm wheel in the truck .................. 11-14
12 – Steering system 4000 .................................................................... 12-1

12.1 Electric steering wheel (4310)...................................................... 12-1
12.1.1 General .......................................................................... 12-1
12.1.2 Replacing the pulse transducer on the steering wheel module
12-1
12.1.3 Removing the operating console from the truck ............ 12-2
12.1.4 Replacing the wiring harness in the operating console . 12-3
12.1.5 Placing the operating console in the truck ..................... 12-5
12.2 Steering reference sensor (4350) ................................................ 12-6
General .......................................................................... 12-6
12.2.1 Replacing the reference sensor ..................................... 12-6

Contents
261828-040 2008-08-21 6051502 815, 816
12.3 Steering bearings (4380).............................................................. 12-7

12.3.1 Removing a steering bearing from the drive gear ......... 12-7
12.3.2 Placing a steering bearing on the drive gear ................. 12-7
13 – Electrical system 5000 .................................................................. 13-1

13.1 Battery (5110) .............................................................................. 13-1
13.1.1 Battery recommendation ............................................... 13-1
Exide gel batteries (Sonnenschein, for example) .......... 13-1
Hawker Evolution gel batteries ...................................... 13-1
13.1.2 Battery installation ......................................................... 13-2
13.1.3 Setting battery parameters ............................................ 13-2
Parameter settings for valve-controlled batteries (VRLA) 13-
2
Instructions for verifying parameter settings .................. 13-2
13.2 Control console (5510)................................................................. 13-3
13.2.1 General .......................................................................... 13-3
13.2.2 Replacement/installation of a control ............................. 13-3
13.2.3 Removing the control console from the truck ................ 13-4
13.2.4 Replacing the access card's circuit board ..................... 13-5
13.2.5 Dismantling the control console ..................................... 13-6
General .......................................................................... 13-6
Installing an extra push button ....................................... 13-8
Replacing the travel direction selector with signal button 13-
8
Replacing the display .................................................... 13-9
13.2.6 Assembling the control console ..................................... 13-9
13.2.7 Placing the control console in the truck ....................... 13-10
13.3 Parameter settings..................................................................... 13-11
13.3.1 Configuration menu ..................................................... 13-11
Calendar/hour counter menu ....................................... 13-11
Parameter menu (PAR) ............................................... 13-11
Driver parameter modification ..................................... 13-12
PIN menu ..................................................................... 13-13
13.4 Calibrations ................................................................................ 13-14
13.4.1 Valve calibration .......................................................... 13-14
Free lift and main lift valve calibration ......................... 13-14
Free lowering and main lowering valve calibration ...... 13-14
Reach movement valve calibration .............................. 13-15
13.4.2 Joystick calibration ...................................................... 13-16
13.4.3 Weight calibration ........................................................ 13-16
Calibrating the weight indicator ................................... 13-16
13.4.4 Height measurement/reach movement length calibration 13-
17
Calibrating height measurement (option) .................... 13-17
Calibrating reach movement length ............................. 13-18
13.4.5 Transition/mast separation calibration ......................... 13-19
14 – Hydraulic system 6000 .................................................................. 14-1

14.1 Hydraulic unit (6100) .................................................................... 14-1
14.1.1 Hydraulic tank, draining ................................................. 14-2
14.1.2 Hydraulic system, bleeding ............................................ 14-3
14.1.3 Removing the pump motor from the truck ..................... 14-4
14.1.4 Replacing the hydraulic pump ....................................... 14-5
14.1.5 Fitting the pump motor in the truck ................................ 14-6
14.2 Main valve (6210)......................................................................... 14-7

Contents
815, 816 6051502 2008-08-21 261828-040
14.2.1 Emergency lowering of forks ......................................... 14-7

14.2.2 Replacing the complete main valve block ..................... 14-8
14.2.3 Adjustment of maximum opening point ....................... 14-10
14.3 Hydraulic connections (6230) .................................................... 14-11
14.3.1 Tightening torque for hydraulic connections ................ 14-11
Conical connection with O-ring .................................... 14-11
Tredo seal .................................................................... 14-11
Pipe coupling ............................................................... 14-12
14.3.2 Quick change connector .............................................. 14-14
Assembling the quick change connector ..................... 14-14
Dismantling the quick change connector ..................... 14-15
14.4 Hydraulic system, mast (6300)................................................... 14-16
14.4.1 Mast-mounted hose reel (6370) .................................. 14-16
General ........................................................................ 14-16
14.4.2 Fitting the hose reel ..................................................... 14-16
Spring preloading (turns) ............................................. 14-16
14.4.3 Checks after fitting ....................................................... 14-17
14.5 Main lift cylinder (6610) .............................................................. 14-18
General ........................................................................ 14-18
14.5.1 Removing the air cylinder from the mast ..................... 14-18
14.5.2 Replacing the hose rupture valve ................................ 14-18
14.5.3 Fitting the cylinder to the mast ..................................... 14-19
14.6 Free lift cylinder (6620) .............................................................. 14-20
General ........................................................................ 14-20
14.6.1 Removing the free lift cylinder from the truck .............. 14-20
14.6.2 Replacing the hose rupture valve, free lift cylinder ...... 14-20
14.6.3 Placing the free lift cylinder in the truck ....................... 14-21
14.7 Reach cylinder (6650) ................................................................ 14-22
14.7.1 General ........................................................................ 14-22
14.7.2 Removing the reach cylinder from the truck ................ 14-22
14.7.3 Placing the reach cylinder in the truck ......................... 14-22
14.8 Fork tilt cylinder (6660)............................................................... 14-23
14.8.1 General ........................................................................ 14-23
14.8.2 Removing the tilt cylinder from the fork carriage ......... 14-23
15 – Mast/Lift system 7000 ................................................................... 15-1

15.1 Main mast 1.6-2.5 t (7100) ........................................................... 15-1
15.1.1 Replacing the full mast .................................................. 15-1
15.1.2 Replacing the mast damper plates ................................ 15-2
15.1.3 Removing the mast from the truck ................................. 15-3
15.1.4 Adjusting mast play ....................................................... 15-6
General .......................................................................... 15-6
Preparations .................................................................. 15-6
Adjusting lateral play ..................................................... 15-9
Adjustment of radial play ............................................. 15-10
Adjusting the damper parts .......................................... 15-10
Adjusting the damper plate .......................................... 15-11
Refitting the mast ......................................................... 15-11
15.1.5 Placing the mast on the truck ...................................... 15-12
15.2 Main lift chain system (7120) ..................................................... 15-16
15.2.1 General ........................................................................ 15-16
15.2.2 Inspecting the chain ..................................................... 15-16
Noise ........................................................................... 15-16
Surface rust ................................................................. 15-16
Rusty links ................................................................... 15-16

Contents
261828-040 2008-08-21 6051502 815, 816
Stiff links ...................................................................... 15-17

Bolt rotation ................................................................. 15-17
Loose bolts .................................................................. 15-17
Plate wear .................................................................... 15-18
Elongation .................................................................... 15-19
Damage ....................................................................... 15-19
Damaged plates .......................................................... 15-20
Damaged bolts ............................................................ 15-20
Dirty chain .................................................................... 15-20
15.2.3 Lubricating the chain ................................................... 15-20
15.2.4 Main lift chain system, adjusting the fork-to-floor distance ....
15-21
15.3 Reach carriage (7190) ............................................................... 15-22
15.3.1 Adjusting radial play in the reach carriage ................... 15-22
15.3.2 Adjusting axial play in the reach carriage .................... 15-24
15.4 Lifting devices (7400) ................................................................. 15-25
15.4.1 Forks ............................................................................ 15-25
General ........................................................................ 15-25
Inspection .................................................................... 15-25
Inspection intervals ...................................................... 15-25
Surface cracks ............................................................. 15-25
Difference in height between the fork tips ................... 15-26
Position locks ............................................................... 15-26
Legible markings ......................................................... 15-26
Fork blades and shafts ................................................ 15-26
Mounting fixings on the fork ......................................... 15-26
15.4.2 Forks, repairs and testing ............................................ 15-27
Repairs ........................................................................ 15-27
Testing the yield point .................................................. 15-27
Fork ............................................................................. 15-27
15.5 Fork carriage.............................................................................. 15-28
15.5.1 Checking the fork carriage’s wear strip ....................... 15-28
15.5.2 Lubricating the fork carriage ........................................ 15-29
15.6 Fork spread unit ......................................................................... 15-30
15.6.1 Servicing the fork spread unit ...................................... 15-30
Replacing bearings ...................................................... 15-31
Replacing the rollers .................................................... 15-31
15.7 Fork extensions with adjustable fork length ............................... 15-32
15.8 Manual telescopic forks.............................................................. 15-34
15.8.1 Fitting ........................................................................... 15-34
15.8.2 Maintenance ................................................................ 15-35
15.9 Hydraulic telescopic forks .......................................................... 15-36
15.9.1 Telescopic forks with separate flow dividers ............... 15-37
Fitting instructions ........................................................ 15-38
Initial operation of telescopic forks with separate flow dividers
15-38
15.9.2 Telescopic forks with integrated flow dividers ............. 15-39
Fitting instructions ........................................................ 15-40
Initial operation of telescopic forks with integrated flow divid-
ers ................................................................................ 15-40
15.9.3 Maintenance of telescopic forks .................................. 15-41
15.9.4 Dismantling telescopic forks ........................................ 15-42
15.9.5 Assembling telescopic forks ........................................ 15-43

Contents
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16 – External Equipment 8000 .............................................................. 16-1

16.1 Introduction .................................................................................. 16-1
17 – Options 9000 .................................................................................. 17-1

17.1 Introduction .................................................................................. 17-1
18 – Appendix “Destruction instructions” .......................................... 18-1

18.1 General ........................................................................................ 18-1
18.2 Marking of plastics ....................................................................... 18-1
18.2.1 General marking of products and packaging material ... 18-1
18.2.2 Marking according to our standard ................................ 18-2
Abbreviations ................................................................. 18-2
Marking examples ......................................................... 18-2
18.3 Pressure vessels.......................................................................... 18-3
18.3.1 Gas dampers ................................................................. 18-3
18.4 Sorting categories ........................................................................ 18-4
19 – Wiring diagrams ............................................................................ 19-1

19.1 Components ................................................................................ 19-1
19.2 Overview ...................................................................................... 19-6
19.3 Wiring diagrams ........................................................................... 19-7
20 – Hydraulics schematics ................................................................. 20-1

20.1 Main valve.................................................................................... 20-1
20.1.1 RRE Std. ....................................................................... 20-1
20.1.2 RRE Ergo ..................................................................... 20-2
20.2 Hydraulics schematics ................................................................. 20-3
20.2.1 Schematics designations ............................................... 20-3
20.2.2 List of symbols ............................................................... 20-4
20.2.3 Wiring diagrams RRE/RRE Ergo ................................... 20-5
21 – Tool ................................................................................................. 21-1

21.1 AMP connectors........................................................................... 21-1
21.2 AMP microtimer ........................................................................... 21-2
21.3 MQS contacts .............................................................................. 21-3
21.4 Other tools ................................................................................... 21-5
22 – Appendix “Service data and grease specifications” .................. 22-1

22.1 General tightening torques........................................................... 22-1
22.1.1 Galvanised non-oiled bolts ............................................ 22-1
22.1.2 Untreated oiled bolts ...................................................... 22-2
22.2 Oil and grease specifications ....................................................... 22-3
23 – Technical data ............................................................................... 23-1
1 – 10 Repair Manual RRE140/160/180/200/250 © BT

General introduction
How to use the manual
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2 – General introduction
2.1 How to use the manual

The service manual is divided into chapters containing the following
information:
• Functions and parameters – This chapter contains a basic descrip-
tion of the main functions of the truck and the control system para-
meters.
• Installation and initial operation – This chapter describes the work
that needs to be done before the truck is used for the first time.
• Maintenance – This chapter contains a general periodic mainte-
nance 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.
• Step by step – This chapter describes the various parts of the truck,
for example the hydraulic system, including what the parts look like
and the service activities that need to be carried out. The various de-
scriptions 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 service manual:
DANGER!
The word DANGER! means there is a risk of accident potentially lead-
ing to death or serious injury and material loss or damage. Always ac-
companied by the warning symbol.
WARNING!
The word WARNING! means that there are components sensitive for
electro-static discharges.
Follow applicable ESD-routines to protect the device.
IMPORTANT
The word IMPORTANT means there is a risk of material loss or dam-
age if the instructions are not followed. Also used to draw attention to
a non-standard torque.
2.3 Pictograms
Where suitable, pictograms are used to describe some actions. Mainly
this applies to the release and fastening of screws:
×n
s mm
The pictogram gives information about type of screw head and turning
direction indicated with an arrow.
Additional text below the pictogram gives information about
‘s’: key size, ‘n’: number of screws and, where applicable, recommend-
ed torque.
One example of another pictogram type is “Cut tie wrap”:
The pictogram might have additional information below, saying how

many ties to 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.

Functions and parameters
Chassis 0000
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4 – Functions and parameters
4.1 Chassis 0000
4.1.1 Driver 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, however, permissible to temporarily remove tilt stops when trans-
porting the truck, between different warehouses, for instance; but the
truck may not in this case be used to transport loads.
WARNING!
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 con-
sist 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
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Overhead guard
The cabin is protected from falling objects by a casing with bars (c) bolt-
ed into the roof of the cabin 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
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4.2 Motors 1000
4.2.1 General
The truck motors are the drive motor, the pump motor for the hydrau-
lics, 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
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 pump motor for the trucks.
On RRE140—RRE160, TSA170-200-106 is used.
On RRE180—RRE250, TSA170-180-072 is used.
Design

Motors 1000
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4.2.3 Electric steering motor (1730)

General
The steering motor is located on the drive unit housing. It receives sig-
nals from the pulse generator located in the steering column. The steer-
ing motor is equipped with a gear wheel working directly on the gear rim
of the drive gear.
There are two sizes of steering motor.
On RRE140–RRE160, 247454-001 is used.
On RRE180–RRE250, 208014-003 is used.
Design
The steering motor has the EPS electronics fitted directly on top of it
(a).
The motor (b) is a brushless synchronous motor with permanently mag-
netised 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.

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 compart-
ment.

Motors 1000
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4.2.5 Electric drive motor (1760)

General
The drive motor is a three-phase AC motor. In the motor, there is a ther-
moelement 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 com-
plete drive unit that can be steered through 360°.
The gear is a two-stage 90 degree gear and comes in two different siz-
es, 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 by means of 6 bolts. The steering
bearings and a gear rim for the steering motor are fitted in the top edge
of the gear.
The drive unit has a sensor for measuring the steering wheel direction
and direction of travel.

Drive gear – 2000
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4.3.2 Design
The drive gear is a two-stage 90 degree gear with conical roller bear-
ings on the drive shaft and pinion. The bearings are pretensioned to
reduce the risk of play in them.
The input shaft has splines that are engaged by the drive motor's output
shaft.
The steering bearing is screwed into the drive gear and can easily 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 should not normally be changed.
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 motor 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 and which is engaged by means of
spring pressure. The parking brake is released electrically (DC volt-
age).
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 de-
lay 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.
Motor 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. Motor braking can be obtained in three different ways.
These are:
• Releasing the accelerator when the truck is in motion
• Changing the direction of travel using the travel direction selector, at
the same time as depressing the accelerator
• Depressing the brake pedal
Accelerator released
The regenerative motor brake is automatically engaged when the
accelerator is released. The brake force can be adjusted using an oper-
ator parameter - see section "2 – Parameters".
The motor brake 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 half released, 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
motor 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 for a change in direction of travel can be adjusted using
a service parameter - see section "2 – Parameters".

Brake system 3100
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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 motor 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.
© BT Repair Manual RRE140/160/180/200/250 4 – 11

Brake system 3100
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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 emer-
gency and secondary travel brake at the end (final 10 %) of brake pedal
travel.
Design
Item 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 steer-
ing 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 sig-
nal, 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 man-
ner.
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, incom-
ing 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 gear.
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, cables or electronic unit result in automatic shut-
down of the truck drive function.

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 dif-
ferently.
Emergency switch off

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When the emergency switch off is depressed, the main contactor [Q10]
is opened, and this is indicated on the truck central information display.
Warning!
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 mechani-
cally 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 module
The steering module is used to steer the truck.

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Pedals
a
b
c
The truck has three pedals: a – Accelerator, b – Brake pedal,

c – Safety pedal for presence checks.

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4.6.2 Single control

a b c
d
e
f
g
h
j
a: CID Central Information Display.
b: Fork lift/lower.
c: Fork carriage reach/retraction.
d: Tilt.
e: Extra function 1 (sideshift, for example).
f: Extra function 2 and 3 (forkspread, for example).
g: 8 buttons for selectable functions (parameter settings).
Function examples:
- Height preselector.
- Height limitation override. The function is active for 5 seconds,
and if the the first height limitation is passed, the next one applies.
- Horizontal tilt position.
- Sideshift zero position.
- Selection of extra hydraulic function 3 (active as long as the func-
tion is used and for 15 seconds afterwards) or switching detected
by service parameter.
- Operator cabin tilt.
- Turn signal lights.
h: Travel direction selector.
j: Horn.

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4.6.3 Multi-control
a d
c cb
g
cd
cc
j j ca
h
e
f
a: CID Central Information Display
c: Multi-control
ca: Fork lift
cb: Fork lowering
cc: Reach carriage - in
cd: Reach carriage - out
d: Tilt
e: Extra function 1 (sideshift, for example)
f: Extra function 2 and 3 (forkspread, for example)
g: 8 buttons for selectable functions (parameter-based)
Function examples:
- Height preselector.
- Height limitation override. The function is active for 5 seconds,
and if the the first height limitation is passed, the next one applies.
- Horizontal tilt position.
- Sideshift zero position.
- Selection of extra hydraulic function 3 (active as long as the func-
tion is used and for 15 seconds afterwards) or switching detected
by service parameter.
- Operator cabin tilt.
- Turn signal lights.
h: Travel direction selector.
j: Horn.

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4.6.4 Central Information Display – CID

The Central Information Display, referred to from now on 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 graphics
display. At 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 the display backlighting is switched off if there has
been no activity for 5 minutes. Once the keypad is activated, the light-
ing is switched on again.
In logged-in mode, the display is always lit.
CID 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 driving 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 fault.
e. Cabin tilt.
Cabin tilting is possible (RRE Ergo)
f. Warning.
Comes on when a warning is active.
g. Low battery.
Battery capacity is low: flashing lamp when 10 % remaining, comes
on permanently at 0 %.
h. Extra.
Comes on when an extra hydraulic function is selected.

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CID information symbols in the display area
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 mode Hour meter. Time.
Date, time and
hour meter.
Operator. Program version.
Indicates the
active operator
profile.
Login
Login method Login method Login method
Login with PIN PIN code login Login via ID unit
code verified by or unit connected
T.W.I.S. to the MCU
Reading ID unit.
Waits for identifi-
cation via ID unit
Height preselector.
Height preselector Pick up Deposit
active
Delete height

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CID disable indications in the display area
Sym- Description Sym- Description

bol bol
Height limit. The travel speed has
The lift height limit has been reduced via the
been reached. input to the MCU.
The reduction is param-
eter-based.
Function reactivation. Seat switch.
Reactivation of the The truck cannot be
requested function is used as the seat switch
required to be able to has not been activated.
use the truck.
Safety pedal. Temperature.
The truck cannot be The temperature in the
operated as the pres- transistor regulator for
ence check has not the drive or hydraulics
been activated. is over 85°C.
ESO (Emergency Service.
Switch Off) Time until the next serv-
The emergency stop ice.
button has been The service interval is
depressed. set with parameter 101.
Looking for reference Looking for lower refer-
sensor. ence sensor.
None of the reference Sensor [B58] for lower
sensors read. lift reference not read.
Looking for upper refer- Main lift started.
ence sensor. The indication is dis-
Sensor [B46]/[B57] for played when attempt-
upper lift reference not ing to drive at >4 km/h
read. with the main lift mast
raised.
Travel speed is limited
to 4 km/h.
Cold store cabin – Door
open.
Driving disabled or lim-
ited to 2.5 km/h.
Controlled by parameter
116.

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CID service symbols in the display area

Service symbols may be displayed either as a possible selection for
accessing a service function or as an indication of an active service
function.
Most service symbols require connection of the CAN key or TruckCom
for them to be displayed.
The "Service" icon is selected in information mode, and it is indicated

by a double border. The function is activated by pressing the green but-
ton.
Once the "Service" function has been activated, the service symbol
appears in the top left-hand corner of the display.

bol bol
Bleeding Cabin tilt
Service function for Service function for tilt-
main cylinder bleeding. ing the cabin.
Configuration Impact sensor
Setting the calendar/ Read-out of the impact
time, parameters and sensor log.
PIN functions
Diagnostics Error log
Service and fault finding Read-out of the error
log.
Factory setting Fan test
Resets the operator Service function for
parameters to their testing the fans
basic settings
PIN code Calibration
Programming PIN Service function for cali-
codes brating sensors, etc.
Joystick Mast
Calibration of joysticks Service function for
operating the mast.

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bol bol
Parameters PIN code, disable
Settings of the operator Enable or disable PIN
and service parameters. code blocks.
PIN code Pressure relief
Changing PIN codes. Service function for
manual relief of hydrau-
lic pressure.
Sensor Service
Service function for cali- Access to service mode
brating sensors. or indication that the
truck is in service mode.
Transition Valve
Calibration of the transi- Calibration of propor-
tion function between tional valves.
free lift and main lift.
Load
Calibration of the fork
load measurement.
Driver parameter symbols

bol bol
Steer progressiveness Top speed – Drive
wheel direction
Top speed – Fork direc- Acceleration

tion
Auto brake Cabin tilt

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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 func-
tion you require is highlighted by having a bolder border around it. 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 informa-
tion 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 func-
tions are displayed.

261828-040 2008-08-21 6051502 815, 816
a
Login
c
i c
j
Info Startup
i i
User
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

815, 816 6051502 2008-08-21 261828-040
a
Login
c
i c
j
Info Startup
User
c i c
Driver
i i info
i c
i
Teach
c
In
| c
Error
info
c c
| c
Error
info
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

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4.6.5 Load Information Display – LID (option)

The Load Information Display, referred to from now on as “LID”, is avail-
able 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 graphics

display.
In logged-out mode, the display is switched off.
LID 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 driving mode, all the symbols
flash simultaneously.

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LID symbols in the display area
1125 kg: Load weight, 10.89 m: Load height, Right-hand half: Height
preselector (option).

Operation and connection sequences
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4.7 Operation and connection

sequences
Event: 1. Battery is connected

Action(s) The battery [G1] is connected [X3] or, with battery replacement cables,
[X1]
Contributing factors 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.

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Event: 2a. Login via unit connected to the MCU

Previous 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.
Contributing factors Parameter 503 = ‘1’ or ‘2’
"Central Information Display (CID)" displays a key symbol when the
truck is in logged-out mode:
Resulting conditions Login approved:

“Central Information Display (CID)” displays a status image for
approximately 2 seconds:
Main contactor [Q10] on

Key relay [K20] on
Login rejected:
“Central Information Display (CID)” displays:
Main contactor [Q10] off

Key relay [K20] off

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Event: 2b. Login via keypad

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



Key relay [K20] on
Login rejected:

Key relay [K20] off

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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.
"Central Information Display (CID)" displays a key symbol when the
truck is in logged-out mode:
Once the green button has been pressed, it is possible during a 5 sec-
ond period to log in with the ID key. The following is displayed:


Key relay [K20] on
Login rejected:

Key relay [K20] off

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Event: 2d. Login to emergency driving mode

Action(s) From the login screen, 'i' is pressed, so that the CID displays the "Infor-
mation screen". On the information screen, select:
and then press the green button

Contributing factors –
Resulting conditions “Central Information Display (CID)” displays a status image for

Key relay [K20] on

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Event: 3. Basic control criteria

Previous 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 driving mode
2a, 2b & 2c – CID displays the standard screen:
2d – CID displays the standard screen for emergency driving:
2d – During emergency driving and if a LID is installed and activated,

this displays the following:
At the same time, 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”
Contributing factors The emergency stop button [S21] is not depressed.
Resulting conditions It is possible to drive the truck, 2a, 2b & 2c, according to the parame-
ters for the current operator profile and emergency driving, 2d, with
greatly reduced speed for all functions.

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Event: 4. Driving in fork direction

Previous 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.
Contributing factors Operator parameter 3: Maximum speed in fork direction.
Operator parameter 4: Acceleration.
Emergency login.
Resulting conditions CID 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.
In terms of 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 drive wheel direction

Previous event 3. Basic control criteria.
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 approxi-
mately 0.6 V.
The accelerator [B32] is depressed and this has an effect on input A5-
X130:17.
Contributing factors Operator parameter 2: Maximum speed in drive wheel direction.
Operator parameter 4: Acceleration.
Emergency login.
Resulting conditions CID 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.
In terms of 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: 6. Braking in neutral

Previous 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.
Contributing factors Operator parameter 5: Automatic braking.
Resulting conditions The frequency of the drive motor three-phase voltage is reduced.

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Event: 7. Reverse braking

or
5. Driving in 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 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.
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 for more than 5 % of its possible travel,
the voltage at output A5-X131:20 is reduced, and the mechanical brake
[Q1] is activated.
In terms of the support arm brake:
When the pedal is depressed 50 - 90 % of its possible travel, PWM out-
puts A5-X131:39 and A5-X131:12. are modulated so that the brakes
[Q16] and [Q17] are released.

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Event: 9. Steering
Previous event 3. Basic control criteria
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 A telegram 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 opera-
tor, 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 transis-
tor regulator [T2].
Output A5:OUT.(PWM) REACH OUT lowers the voltage
Current flows through the proportional valve [Q7]
The proportional valve [Q7] is opened in proportion to the current that
flows through.
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 approxi-
mately 0.6 V at the end position of the control.
tor regulator [T2].
Output A5:OUT.(PWM) REACH IN lowers the voltage
Current flows through the proportional valve [Q6]
flows through.

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Event: 12. Fork lift

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.
Contributing factors Service parameter 1261: Transition flows during raising.
tor regulator [T2].
Free lift:
Output T2-K1:10 “OUT.(PWM) INITIAL MAST LIFT” reduces the volt-
age.
Output A5-131:26 “OUT(PWM) MAIN MAST LIFT” retains the full volt-
age.
Current flows through the proportional valve [Q3].
flows through.
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 propor-
tional 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 the full volt-
age.
flows through.

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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 4.7 V
at the end position of the control.
Contributing factors Service parameter 1262: Transition flows during lowering.
Resulting conditions Main lift:
Output A5-131:40 “OUT(PWM) MAIN MAST LOWER” reduces the volt-
age
Output T2-K1:2 “OUT.(PWM) INITIAL MAST LOWER” retains the full
voltage
flows through
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 propor-
tional valve [Q5] begins to open.
Initial lift:
Output T2-K1:2 “OUT.(PWM) INITIAL MAST LOWER” reduces the volt-
age.
Output A5-131:40 “OUT(PWM) MAIN MAST LOWER” retains the full
voltage.
flows through.

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Event: 14. Fork tilt, backwards/upwards

Action(s) The control for the fork lift [B22] is moved towards the operator and
input A1-X505:17 is reduced from approximately 2.6 V to approxi-
mately 0.6 V at the end position of the control.
tor regulator [T2].
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].
Event: 15. Fork tilt, backwards

Action(s) The control for fork lift [B22] is moved away from the operator, and
input A1-X505:17 increases from approximately 2.6 V to approximately
Resulting conditions Output A5-X131:37 “OUT.AUX DIRECTION A” remains high.
Output A5-X131:11 “OUT.AUX DIRECTION B” reduces the voltage.
The tilt 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].

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Event: 16. Sideshift, right

Action(s) The control for the fork lift [B23] is moved towards the operator, and
input A1-X505:3 is reduced from approximately 2.6 V to approximately
Contributing factors Sideshift as an optional function.
tor regulator [T2].
Output A5-X131:37 “OUT.AUX DIRECTION A” remains high.
Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” reduces the volt-
age.
The piston rod end of the sideshift cylinder is drained to the tank.
Event: 17. Sideshift, left

Action(s) The control for fork lift [B23] is moved away from the operator, and
input A1-X505:3 increases from approximately 2.6 V to approximately
Contributing factors Sideshift as an optional function.
tor regulator [T2].
Output A5-X131:37 “OUT.AUX DIRECTION A” remains high.
Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” reduces the volt-
age.
The piston rod end of the sideshift cylinder is pressurised.

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Event: 18. Ergo cabin, tilt up

Previous event 12. Fork lift
Action(s) –
Contributing factors 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.
Event: 18. Ergo cabin, tilt down

Previous event 13. Fork lowering
Action(s) –
Contributing factors 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
to it.
The cabin tilt cylinder is drained to the tank.
Event: 19. Logout

Previous 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.

Functions
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4.8 Functions
4.8.1 General overview

Key
[ ] = 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

Functions
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4.8.2 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 ser-
vo 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 steer-
ing, driving, braking, hydraulics, communication and various other
things.
The TruckCom service program must be used for downloading new
software.
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 transistor regulators (ACT and
ACH).
4.8.3 ACT/ACH transistor regulators

Functions
261828-040 2008-08-21 6051502 815, 816
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 var-
ious 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.
4.8.4 Start-up
The truck checks the system by testing the inputs, outputs, voltage and
communication, etc.
4.8.5 Shutdown
Shutdown is initiated by pressing the red "Logout" button. Subsequent-
ly, 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.

Functions
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4.8.6 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 acceler-
ator depressed.
If the operator seat is not loaded and the safety pedal is depressed, a
disable indication will be displayed in the CID.
If no direction has been selected, the two green arrows that indicate
direction alternate.
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.
The maximum speed is parameter-based.
Pressing hard on the accelerator results in sudden acceleration, and
pressing lightly results in more restrained acceleration.
The acceleration is parameter-based.
Once the accelerator is released the motor brake will be activated and
the speed will be reduced. The more the pedal is released, the greater
the retardation.
The retardation is parameter-based.
Monitoring
Acceleration is reduced when battery voltage is low, as well as in emer-
gency driving mode.
Retardation is reduced in emergency driving mode.
Speed is monitored so that actual speed is reduced when retardation is
requested.

Functions
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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 equip-
ment, 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 to the MCU. These are reciprocally
inverted. 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 MCUand 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.

Functions
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Travel speed
The travel speed in both drive wheel and fork direction can be adjusted
separately using parameters.
If it is not equipped with support arm brakes, the truck can drive at 10
km/h in the drive wheel direction and at 7 km/h in the fork direction.
If the truck has support arm brakes installed, it may drive at 14 km/h in
the drive wheel direction. In the fork direction, 10 km/h is permitted if the
truck is unladen and 8 km/h with a load of more than 1000 kg on the
forks.
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 adjusted by means of a parameter.
Other speeds are also possible depending on the limitations, warnings
and errors that are specified.
There are three digital inputs that can generate special speeds; these
are parameter-based, provided as special options.

Functions
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4.8.7 Steering
Steering position check
The truck has position steering that is speed-controlled. The pulse gen-
erator 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 val-
ue into a variance reading from the current position and sends a new
setpoint to the EPS, which controls the steering motor.
Monitoring
The pulse generatoris a twin generator and two separate pulse trains
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 steering speed is high so that large wheel
manoeuvres can be carried out using 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 with an 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 output.
In the case of a low steering value, the speed must be under a given
speed, otherwise an error code is output.
When the steering servo is deactivated, the actual steering speed must
be 0, otherwise an error code is output.

Functions
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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 steer-
ing 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 toler-
ance 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 card
In the truck symbol on the CID, a compass card with 8 arrows is dis-
played. 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 direc-
tion of the drive wheel.

Functions
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4.8.8 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.

Functions
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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 car-
riage 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 cir-
cuits 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 lim-
itations, and parameters 387 – 393 are used for activation and to spec-
ify 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 "Obligatory" may be
overridden with a cancel button. Pressing the button removes the limi-
tation 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 pre-
vented. 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 hydrau-
lic functions.
All extra functionscan be calibrated by means of a number of parame-
ters.
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.
Sideshift
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.
Forkspread and telescopic 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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4.9 Height preselector, description of

function
4.9.1 Using the height preselector

To be able to use the height preselector functions, the factory parame-
ter 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 depress-
ing and holding down the preselector button on the CID for 3 seconds.
4.9.2 Symbols
Height preselector mode is indicated in the CID by the following sym-
bols:
Symbol Description Symbol Description

Height preselector Pick up
active
Delete height Deposit
4.9.3 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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4.9.4 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 for-
mat "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.
4.9.5 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 of a
second later.
When a 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 select-
ed, 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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4.9.6 Height programming

IMPORTANT:
Height programming requires that parameter 510 allow free access or
that the CAN key/TruckCom is connected.
There is storage space for 200 different pick up 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 heightpreselector 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 pro-
grammed 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 pick up height, and the deposit height
is saved automatically as the difference for the current height as deter-
mined by service parameter 378 for the Pick up/Deposit difference.
The new heights will be displayed under the pick up and deposit sym-
bols.
The deposit height can be programmed individually using the arrow
buttons. Using the arrow buttons, you can select the icon for deposit
height. Then you press the green button.
The deposit height must be within the minimum and maximum values
specified by service parameter 378. If the height is outside this interval,
it will not be saved and the buzzer emits a warning sound.
To leave the programming screen, press the C-button.

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4.9.7 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.
4.9.8 Lift/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 the specification of
parameters 375/376, Braking Distance Lift/Lower, the movement slows
in three stages to the height set by parameters 373/374, Creep Dis-
tance 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 byparameter 377, Max. StopHeight Error, a
warning code is displayed at the same time as the CID emits a warning
sound.

Hydraulic system 6000
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4.10 Hydraulic system 6000
4.10.1 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 car-
riage.
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.
4.10.2 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 hydraulic oil from the hydraulic system and the breathing air are fil-
tered by the return filter. There is no filter between the tank and the
pump.
A separate plug for oil level checking is located on the tank.
4.10.3 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 ele-
ment 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 fil-
tered. 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 combina-
tion with a special return filter with a specially adapted breather filter
connection for connecting to the dehumidification filter.

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4.10.4 Hydraulic pump

The pump is of gear wheel type (inner gear wheel) with fixed displace-
ment 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.
4.10.5 Valve block

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 pres-
sure-compensated proportional valves. By means of pressure compen-
sation, 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 indi-
vidually 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 sys-
tem 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 and adjustment of lowering 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 opti-
mum.
For the lowering valves Q4 and Q5, the opening point must be calibrat-
ed, using CID in servicemode, see “ Free lowering and main lowering
valve calibration” on page 13 – 14. The opening point determines the
lowest lowering speed.
For the lowering valves Q4 and Q5, also the maximum opening point
that determines the maximum lowering speed, must be mechanically
adjusted , see “14.2.3 Adjustment of maximum opening point” on
page 14 – 10.
For the lift valves Q2 and Q3, the opening point must be calibrated. For
the lift valves the opening point is very important for maintaining opti-
mum 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 con-
nected to the emergency lowering valve.
The emergency lowering valve is opened by loosening a 3 mm allen
screw in the valve block. The screw only needs opening 1½ turns to
activate emergency lowering.
IMPORTANT!
The screw must only be tightened to 2.5 Nm on closing.
Other valve blocks

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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4.10.6 Cylinders
Main lift cylinder
The main lift cylinders are single-action cylinders without pistons. The
diameter of the rod determines the pressure area and the rod is control-
led in the cylinder tube by a control belt. Hydraulic oil surrounds the
whole rod up to the top sleeve. Sealing against leaks is 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, side-

shift 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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4.10.7 Lift and lowering function

Lifting and lowering of free lift
The free lift is controlled by a proportional valve, Q3/Q5, of replaceable
cartridge design.
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

Main lift is controlled by a proportional valve, Q2/Q4, of replaceable car-
tridge design.
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, non-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 move-
ment 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.
4.10.8 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.
4.10.9 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, which is the service position.
Warning!
Risk for personnel injuries, crushing.
The hydraulics does not stop the tilt motion beyond the balancing
point.
Make sure that the area that will house a tilted cab is free from person-
nel and objects prior to the commencement of tilt motion.
To raise the 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 pow-

er 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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4.11 Mast 7000
4.11.1 Mast and reach carriage
The mast and reach carriage are available in a number of different siz-
es and these can be combined in a specific way. The reach carriages
and masts 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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4.12 Lifting devices
4.12.1 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 suita-
ble for fitting to a standard truck fork (see the details on the identifica-
tion 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.
IMPORTANT!
Please note that load capacity is reduced once the fork extensions
are attached.
IMPORTANT!
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 down-
wards. Daily visual inspection is recommended.
4.12.2 Telescopic forks

KOOI forks, manufactured by the Meijer Special Equipment Company
in the Netherlands are a specially designed fork 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 provide important
information on the fork’s technical data, e.g. the maximum load capaci-
ty of the fork.
The telescopic forks are operated using a closed, self-lubricating oil cir-
cuit. These forks come supplied with oil that meets an ISO 4406 clean-
liness 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 stand-
ard 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).

Parameters
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4.13 Parameters
4.13.1 General
The trucks control system can store a number of different parameters.
These are used to configure the truck according to the task to be per-
formed. The parameters are split into two groups:
• Operator parameters – The operator parameters (range 1 – 100) are
used to adapt the trucks response to a specific operator or task. Up
to ten operator parameters can be stored.
• Service parameters – The service parameters (range 101 – 1000)
are used to adapt the trucks performance/response; they cover all
other parameters not covered by the operator parameters.
• Factory parameters – (range 1001 – 1250). Truck-specific parame-
ters.
• Calibration parameters – (range 1251 – 1500) are used to calibrate
valves, weight indication, etc.
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.

Parameters
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4.13.2 Displaying/changing parameters

See the "Settings menu (SET)" for instructions on how to display and
change the parameter settings.
4.13.3 Parameters
Operator parameters, overview
No. Min. Max. Increments Default Unit Description

1 1 6 1 3 Steering, speed-depend-
ent deflection
2 1 10 1 10 10 % Maximum speed, drive
wheel direction
3 1 10 1 8 10 % Maximum speed, fork
direction
4 3 10 1 8 10 % Acceleration
5 3 10 1 8 10 % Automatic brake
6 500 10 000 100 1000 mm Height above free lift
once the Ergo cabin
starts tilting.
Operator Parameter number

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
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Service parameters, overview
No. Min. Max. In- De- Unit Description

cre- fault
ment
General parameters
101 0 5000 100 0 h Service interval. Time till next service in B-
time.
0 = deactivated
104 0 120 1 20 min Log-off timer
0 = 4 hours
107 1 20 1 12 Battery size
108 0 20 5 5 % Limit for start of reduction in performance as
% of BDI
109 0 2 1 0 Delete data on login
0 = Do not clear data
1 = Clear histogram log
2 = Clear crash log
110 0 100 1 0 Impact sensor X
0 = deactivated
1–100 sensitivity setting
111 0 100 1 0 Impact sensor Y
0 = deactivated
1–100 sensitivity setting
112 0 1 1 0 Impact sensor, action after collision
0 = Login with special PIN code to reset sen-
sor
1 = Restart the truck to reset
113 50 1000 1 246 Shunt resistance for BDI (resistance for the
shunt resistance in question)
114 0 7 1 0 Travel alarm 1 (X) setting
115 0 3 1 0 Travel alarm 2 (Y) setting
116 0 1 1 0 Door open action (cold store cabin)
0 = Disable operation
1 = Speed limited to 2.5 km/h
Driving parameters
201 50 100 10 100 % Reversing speed
202 30 100 10 100 % Creep speed
203 30 100 10 100 % Half speed
204 30 100 10 100 % Safety speed
205 0 100 10 100 % Speed limitation 1

Parameters
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cre- fault
ment
208 0 1 1 1 Creep speed activated
209 0 15000 1 100 mm Height limit for speed reduction
210 0 140 5 140 0.1 Speed limitation above selected height (see
km/h 209)
211 0 840 1 10 mm Reach length for speed reduction
212 0 140 5 140 0.1 Speed limitation after selected reach length
km/h (see 211)
Hydraulic parameters
301 0 31 1 0 Extra (Aux.) function valve 1
305 10 100 1 100 Extra (Aux) max. current strength, direction
A1
A2
A3
A4
B1
B2
B3
312 10 100 1 100 Extra (Aux) current strength, direction B4
313 0 50 1 25 Extra (Aux.) draining 1
317 12 300 1 57 Extra (Aux) max. flow, direction A1
321 12 300 1 47 Extra (Aux) max. flow, direction B1

Parameters
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cre- fault
ment
325 101 9999 1 505 Extra (Aux.) overlapping time, direction A1
329 101 9999 1 505 Extra (Aux.) overlapping time, direction B1
341 30 100 10 100 % Lift speed
342 30 100 10 100 % Lowering speed
343 30 100 10 100 % Reach speed
344 0 1 1 1 Fork speed reduction enable
345 0 20000 10 0 mm Special height 1
346 0 20000 10 0 mm Special height 2
347 0 140 5 140 0.1 Raise/lower function not possible above this
km/h speed
355 500 10000 100 500 mm Starting point for Ergo cabin to tilt down
371 0 100 1 5 % Height preselector, creep speed lift before
stop
372 0 100 1 5 % Height preselector, creep speed lowering
before stop
373 0 100 1 25 mm Height preselector, creep distance lift
374 0 100 1 25 mm Height preselector, creep distance lowering
375 0 1000 10 350 mm Height preselector, braking distance lift
376 0 1000 10 350 mm Height preselector, braking distance lower-
ing
377 0 100 1 10 mm Height preselector, max. variation in stop
heighit
378 40 250 1 120 mm Height preselector, p+d height, difference
379 0 500 5 200 kg Height preselector,automatic load detection
limit
380 10 15000 10 10 mm Lift height limitation 1

Parameters
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cre- fault
ment
387 0 2 1 0 Lift height limitation 1, function selection
0 = deactivated
1 = Can be overridden
2 = Cannot be overridden
388 0 2 1 0 Height limitation 2, function selection, see
387
387
387
387
387
387
387
395 0 15000 10 0 mm Height limitation 1 controlled by external sig-
nal
0 = deactivates the limit
nal
nal
CID1 parameters
501 0 0 1 0 Display illumination
503 0 8 1 3 Operator access
1, 2 = Key/button (controlled from the MCU)
3, 4 = Keypad using 100 PIN codes
5, 6 = Keypad using DHU
7, 8 = ID unit
Odd number = Access to operator parameter
Even number = No access to operator
parameter

Parameters
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cre- fault
ment
504 0 255 1 255 ID card setting, department low
505 0 255 1 255 ID card setting, department high
506 0 255 1 255 ID card setting, truck type low
507 0 255 1 255 ID card setting, truck type high
508 0 1 1 0 Load information
509 0 15 1 15 Summer activation
0 = Disabled
1 = Write to parameter sound
2 = Safety pedal and option buttons
3=1+2
4 = Press button
5=1+4
6=2+4
7=1+2+4
510 0 1 1 0 Height preselector available
511 1 8 1 7 Height preselector, number of rows
Truck type
512 0 0 1 0 RRE = 0
Date format
513 0 1 1 0 0 = yyyy-mm-dd
1 = dd-mm-yyyy

Parameters
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Factory parameters, overview
No. Min. Max. Increm Default Unit Description

ent
General parameters
1001 0 5 1 0 Truck type
0 = Unknown truck type
1 = RRE140
2 = RRE160
3 = RRE180
4 = RRE200
5 = RRE250
1002 0 1 1 0 Drive motor
0 = Small
1 = Large
1003 0 1 1 0 Pedal type
0 = Standard pedals
1 = Direction switch on pedals
1004 0 1 1 0 Steering servo
0 = Small
1 = Large
1005 0 1 1 0 Pump motor
0 = Small
1 = Large
1006 0 1 1 0 Hydraulic pump
0 = Small
1 = Large
1007 0 4 1 0 Steering lever configuration
0 = Lift, reach
1 = Lift, reach, Aux1
2 = Lift, reach, Aux1, Aux2
3 = Lift, reach, Aux1, Aux2, Aux3
4 = Lift, reach, Aux1, Aux2, Aux3, Aux4 (fifth
lever with button depressed)
1008 0 2 1 0 Type of mast
0 = 1.6 t
1 = 2.0 t
2 = 2.5 t
1009 0 1 1 0 Type of height measurement
0 = Base (only digital sensors)
1 = Full (with rotating encoder)
1010 0 20000 2 6000 mm Max lift height
1016 0 1 1 0 Type of weight measurement
0 = Base version. Only in the free lift range.

Parameters
815, 816 6051502 2008-08-21 261828-040
No. Min. Max. Increm Default Unit Description

ent
Option, activate (on/off) parameters, 0 = Deactivated 1 = Activated
1101 0 1 1 0 Support arm brakes
1102 0 1 1 0 Reverse steering
1103 0 1 1 0 HPS, height preselector
1104 0 1 1 0 Cabin tilt activated (Ergo)
1105 0 1 1 0 Cold store cabin
1106 0 1 1 0 LID
1107 0 1 1 0 Height limitation
1108 0 1 1 0 Travel alarm available
1109 0 1 1 0 Travel direction indicators (flashers) availa-
ble

Parameters
261828-040 2008-08-21 6051502 815, 816
Calibration parameters, overview
No. Incre Defaul Description

Min. Max. Unit
ment t
Hydraulic parameters
1252 –200 200 5 0 mA Free lift calibration
1253 –200 200 5 0 mA Free lowering calibration
1254 –200 200 5 0 mA Lift calibration for main mast
1255 –200 200 5 0 mA Lowering calibration for main mast
1256 –200 200 5 0 mA Calibration of reach out
1257 –200 200 5 0 mA Calibration of reach in
1258 0 30 1 10 % Extra flow for reach mast valve. Extra flow in
% used for reach mast valve. In this way the
reach mast function is controlled by the
pump and not limited by the valve.
1259 –200 200 5 0 mA Ergo cabin, tilt up calibration
1260 –200 200 5 0 mA Ergo cabin, tilt down calibration
1261 15 40 1 30 % Flow on upward transition. Specifies the flow
in % when the free lift valve should close
during lift transition from free lift to main lift.
For smooth transition between the two mast
sections.
1262 15 40 1 30 % Flow during downward transition. Specifies
the flow in % when the main lowering valve
should close during lowering transition from
main lift to free lift. For smooth transition
between the two mast sections.
1263 0 1000 10 240 kg Weight of the fork carriage in kg, for calcula-
tion of the load on the forks.
1264 0 2000 10 990 kg Weight of the mast + fork carriage in kg, for
calculation of the load on the forks.
1265 120 840 12 564 mm Reach length. The total length of the reach
movement (in mm) so that the movement
can be dampened in the end positions.
1266 –300 300 5 0 kg Weight 1 calibration
1267 500 3000 5 1000 kg Reference weight 2
1268 –300 300 5 0 kg Weight 2 calibration
1269 –200 200 5 0 mA Calibration of free lift lowering speed.
1270 –200 200 5 0 mA Calibration of main lift lowering speed.
1271 0 9000 2 800 mm Free lift, height reference
1272 0 100 2 30 mm Main lift, height reference
1273 0 6000 2 3000 mm Free lift height

Parameters
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Installation
Transporting the truck
261828-040 2008-08-21 6051502 815, 816
5 – Installation
5.1 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 minimum 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.
Method 2
To move the truck over short distances, you can use an extension cable
from an adjacent battery.

Installation
Initial operation
815, 816 6051502 2008-08-21 261828-040
5.2 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.
5.2.1 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!
Risk of centre of gravity shifting.
Battery weight that is too low results in a deterioration in stability
and braking capacity.
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. Start the truck.
11. 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 locking has occurred.
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.

Installation
Initial operation
261828-040 2008-08-21 6051502 815, 816
5.2.2 Parameters on initial operation

Full calibration of the functions is described in section “13.3 Parameter
settings”.
Battery
The size (capacity) of the battery fitted in the truck must be
specified using parameter 107
.
Parameter RRE140 RRE160 RRE180 RRE200 RRE250

no. 450 600 450 450 750 600 600 750 600 750 450 600
107
So as not to run the battery down completely, a limit is set beyond which
a reduction in truck performance must be initiated
Battery capacity limit for reduction in Parameter no.

truck performance 108
Limit as a % of BDI 5
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.
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 free lift once the Ergo cabin 1000
starts tilting
Height when the Ergo cabin starts to tilt 500
down

Installation
Initial operation
815, 816 6051502 2008-08-21 261828-040
Cold store cabin

When the cabin door is not shut, the truck is braked by the motor until it
stops.
An option is available that allows the truck to be driven (2.5 km/h) with
the door open; this may be deselected.
.
Door open action (cold store cabin) Parameter no. 116

Disable operation (driving) 0
Speed limited to 2.5 km/h 1
5.2.3 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 given 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
predetermined 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
261828-040 2008-08-21 6051502 815, 816
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, restart of truck without collision 1–99 1–99 0
PIN code not possible
Activated, restart of truck without collision 1–99 1–99 1
PIN code possible
5.2.4 Mast, fitting

See section "15.1.5 Placing the mast on the truck".

Installation
Initial operation
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Maintenance
Introduction, maintenance
261828-040 2008-08-21 6051502 815, 816
6 – Maintenance
6.1 Introduction, maintenance

To maintain a high level of truck safety, and to minimise downtimes, all
the points specified in the service program should be carried out.
The intervals specified are those meeting the truck manufacturer's
requirements for a truck – RRE160/180/200/250 – in standard applica-
tion at approximately 1000 operating hours/year. The local operating
environment may require service intervals that differ from those speci-
fied.
Once a truck's service interval has been determined, the hour meter is
used in the first instance to determine when servicing is to be carried
out.
To maintain truck safety, only spare parts approved by the manufactur-
er may be used for servicing and repairs.
During the truck warranty period: If repairs or servicing have been
carried out by non-authorised personnel, or if non-approved spare parts
are used, the truck warranty ceases to be valid.
IMPORTANT:
At each service, checks must be made that the truck functions as
usual and is safe. These checks are to be performed in accordance
with the instructions for daily care that are in the operator's manual.

Maintenance
Periodic maintenance
815, 816 6051502 2008-08-21 261828-040
6.2 Periodic maintenance
6.2.1 Every 500 B-hours/180 days

Estimated duration: 39.5 min.
7120.1
7120.2
7120.3
5110.1
5110.2
5110.3

Maintenance
261828-040 2008-08-21 6051502 815, 816
Position Component Type of work Work to be carried out See Sec-

tion
5110.1 Battery Inspection Open all the battery's 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 Inspection Check that the connections of the power
cables to the battery, truck and charger are
not damaged or overheating.
5110.3 Battery Inspection Visual inspection to ensure that the battery
cell and terminal protectors are undam-
aged
7120.1 Mast Inspection Visual inspection of wear on lifting chains,
chain bolts, chain mountings and chain
wheels
7120.2 Mast Inspection Adjustment of lifting chains, check the
tightening torque of the lock nuts and
inspect the cotter pins
7120.3 Mast Lubrication Lifting chains

Maintenance
815, 816 6051502 2008-08-21 261828-040

<TBD>: Not 0390.5, 0390.6, 0390.9, 0390.10, 4310.1
0340.1
0620.1
0350.2 0350.1
3370.1
0340.2
3180.1
3180.2
3180.3 2550.1
3180.4
0840.1
0390.5
0390.2
0390.4
0390.9 0390.1
0390.10
0390.6

Maintenance
261828-040 2008-08-21 6051502 815, 816
Carry out the 500 hour service together with the following:

tion
0340.1 Motor hood Inspection Check the locking of the motor
hood
0340.2 Motor hood Lubrication Motor hood hinges
0350.1 Support arms Lubrication Beam contact surfaces for reach
carriage rollers
0350.2 Support arms Inspection Check wear and fixings of the
mechanical reach carriage stops
0390.1 Battery compartment Inspection Visual inspection of battery lock-
ing catch wear
0390.2 Battery compartment Lubrication The locking pin for the battery
catch
0390.4 Battery compartment Lubrication Support arm/roller bed sliding
surfaces
0390.5 Battery compartment Inspection Roller bed locking (Option)
0390.6 Battery compartment Inspection Wear on the roller bed sliding
blocks (Option)
0390.9 Battery compartment Inspection Inspect the sliding surfaces in
the unloading mechanism
0390.10 Battery compartment Lubrication The sliding surfaces in the
unloading mechanism
0620.1 Operator compartment Inspection Operator's seat mounting and
adjustment functions
0840.1 Chassis Inspection Tilt stop wear and sealing
2550.1 Gear Lubrication Chain gear rim (after careful
cleaning)
3180.1 Wheel brake Inspection Brake disc wear
3180.2 Wheel brake Adjustment Play in un-braked position
3180.3 Wheel brake Inspection Braking force
3180.4 Wheel brake Check on Locking screw of the wheel
tightening brake in the supporting arm (34
torque Nm)
3370.1 Parking brake Inspection Play in un-braked position

Maintenance
815, 816 6051502 2008-08-21 261828-040
7110.1
4310.1
5590.2
5590.3
6600.2
7400.1
5430.1
5430.2
3550.2
7190.2 7190.1 5000.4
3530.1
3530.2
6120.2 3530.3
7190.4 7190.7
7190.5 7190.8

Maintenance
261828-040 2008-08-21 6051502 815, 816

tion
3530.1 Wheel Cleaning Remove string and other debris
3530.2 Wheel Inspection Tread depth wear
3530.3 Wheel Check on Wheel bolts (140 Nm)
tightening
torque
3550.2 Wheels Inspection Tread wear
4310.1 Steering module Inspection Mounting and locking
5000.4 Electrical system Inspection Emergency operation functions,
and check that the power switch
on the fuse box releases the
parking brake
5430.1 Electrical system Inspection Wear and damage to copper
bars
5430.2 Electrical system Check on Copper bar mountings
tightening
torque
5590.2 Electrical system Inspection Wear to the mast cabling
5590.3 Electrical system Inspection Restrictions (strain) on mast
cabling
6120.2 Hydraulic system Inspection Wear on hoses in the reach car-
riage and mast
6600.2 Hydraulic system Inspection Mountings of the hydraulic cylin-
ders
7110.1 Mast Lubrication Play reducer and mast beams
7190.1 Mast Check on Mast fixing points, upper and
tightening lower
torque
7190.2 Mast Inspection 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 Inspection Cracks

Maintenance
815, 816 6051502 2008-08-21 261828-040
0000.2
5000.3
3370.2
0390.12
5110.7
5110.8
5110.9
3550.1
0390.11
7190.3
0390.7
2550.2
0390.3 5000.2

Maintenance
261828-040 2008-08-21 6051502 815, 816

<TBD>: Not 0390.3, 0390.7, 0390.11, 0390.12, 3550.1, 5000.2,
5110.7, 5110.8, 5110.9, 7190.3
Carry out the 500 and 1000 hour service together with the follow-
ing:

tion
0000.2 Chassis Inspection Cable fixings
0390.3 Battery compartment Check on Fixed component of the battery
tightening lock hook
torque
0390.7 Battery compartment Inspection Bearings of the battery rollers
0390.11 Battery compartment Inspection Battery changing function
0390.12 Battery compartment Inspection Wear on protective housing over
battery
3550.1 Wheels Inspection Rotation and bearing noise
5000.2 Electrical system Inspection The mountings of the electric
panel
5110.7 Battery Inspection Force required to withdraw the
battery connector
5110.8 Battery Inspection Connection of the battery con-
nector to the copper bars
5110.9 Battery Inspection Wear on battery tray guiding ele-
ments
7190.3 Reach carriage Inspection Wear and bearings of reach car-
riage guide rollers

Estimated duration: 171,8 min
<TBD>: Not 5000.3
Carry out the 500, 1000 and 2000 hour service together with the
following:

tion
2550.2 Drive gear Check on tightening The gear's mounting bolts in the
torque chassis
3370.2 Parking Inspection Braking force
brake
5000.3 Electrical Check on tightening Power cables on transistor regula-
system torque tors

Maintenance
815, 816 6051502 2008-08-21 261828-040
5200.1
0640.1
5110.4
5110.5
5110.6 6140.1
1700.1
5390.1
5590.1
5000.1

Maintenance
261828-040 2008-08-21 6051502 815, 816

Carry out the 500, 1000, 2000 and 3000 hour service together with
the following:

tion
6140.1 Hydraulic Replacement Oil and air filter
system
6.2.6 Annual status inspection

<TBD>: Not 5590.1

tion
0640.1 Operator Inspection Functions relating to control, steering
compart- wheel, brake, pedals, horn and emergency
ment switch off
1700.1 Motors Check on Power cable connections. Tightening
tightening torque.
torque
5000.1 Electrical Cleaning Electric panel
system
5110.4 Battery Inspection Measure the battery fluid density with a
density meter
5110.5 Battery Inspection Measure the battery temperature at the
centre of the battery
5110.6 Battery Cleaning Remove excess fluid from the battery tray
5200.1 Electrical Inspection Wear and damage to the truck displays
system
5390.1 Electrical Inspection Wiring harness wear
system
5590.1 Electrical Inspection Wear and damage to wiring harness,
system including protective covering, in the reach
carriage

Maintenance
Maintenance instructions
815, 816 6051502 2008-08-21 261828-040
6.3 Maintenance instructions
6.3.1 Cleaning and washing

Cleaning and washing the truck is important for reliability.
• Carry out general cleaning and washing each week.
IMPORTANT!
The electrical system can get damaged.
Pull out the battery connector to disconnect the battery before wash-
ing.
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 motor compartment.
When using a high-pressure washer, the jet must be directed in such a
way as not to 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 – may not
be exposed to the jet, as there is a risk that water may penetrate and
cause corrosion.
Once washing by high-pressure washer is completed, 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 are designed for general
vehicle cleaning, and which do not damage paintwork, plastic compo-
nents, cables, hydraulic hoses or decals.
Cleaning the exterior

• On a daily basis, remove rubbish, etc. from the wheels
• Degreasing agents can be used as needed, in line with the previous
section
• Rinse off loose dirt with tepid water.
IMPORTANT!
Jamming, corrosion.
Mechanical parts can be damaged.
After washing the truck it should be lubricated as set out in the main-
tenance instructions.

Maintenance
261828-040 2008-08-21 6051502 815, 816
Cleaning the chain

If a chain is very dirty you are recommended to replace it.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with a solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
IMPORTANT!
Take care with degreasing agents as these may contain abrasives.
Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing
IMPORTANT!
The electrical system can get damaged.
Electrical components must not be washed with high-pressure clean-
ers.
• Clean the motor compartment using a leading brand of degreasing
agent, diluted to a suitable concentration
• Rinse off loose dirt with tepid water.
Electrical components
• Blow electric motors clean using compressed air
• Clean electrical panels, PCBs, contactors, contacts, solenoid
valves, etc., with a moist cloth and a cleaning agent.
IMPORTANT!
The electrical components may become damaged.
Do not break the warranty seal on the PCBs.

Maintenance
815, 816 6051502 2008-08-21 261828-040
This page is intentionally left blank

Troubleshooting
261828-040 2008-08-21 6051502 815, 816
7 – Troubleshooting
7.0.1 Error log menu

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 high-
lighted 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 bot-
tom of the list, the menu rolls the list on, to display more errors if
there are any. Pressing the green button (I) displays a new menu, the
error information menu, which displays more information relating to
the error selected.
Error information menu

The error information menu displays more detailed information relating
to the logged error.
The error code (3:180) is shown on the left of 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; to obtain more values, the
arrow keys must be used.

Troubleshooting
Service diagnostics menu
815, 816 6051502 2008-08-21 261828-040
7.1 Service diagnostics menu
7.1.1 General
The service diagnostics menu can only be accessed when a service
key is connected to CAN. From the operator information menu, high-
light the symbol with a magnifying glass and press the green button (I).
Toggle between the numbered diagnostics states using the plus/minus

buttons, and select a state using the green button (I). You can also use
the numerical keys to access a given diagnostics state directly.

Troubleshooting
261828-040 2008-08-21 6051502 815, 816
7.1.2 Diagnostics states

IMPORTANT!
Please note that the updating frequency for data is slow, once a sec-
ond.
State 1 – Voltage from levers

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

1 A1 X505:2 Lift/lowering lever
2 A2 X505:11 Reach movement lever
3 A3 X505:17 Tilt lever
4 A4 X505:3 Sideshift lever
5 A5 X505:12 Forkspread lever
6 A6 X505:4 Travel direction selector
7 A7 X505:6 –
8 A8 X505:15 –
9–10 Not used

Troubleshooting
815, 816 6051502 2008-08-21 261828-040
State 2 – Digital signals from truck controls to MCU

State 2 displays 20 digital signals from the truck controls to the
CID.
No CID signal
.
1 PT0 X504:13 Steer sensor 1 A
2 PT1 X504:4 Steer sensor 1 B
3 PT2 X504:11 Steer sensor 2 A
4 PT3 X504:2 Steer sensor 2 B
5 DI5 X503:6 Free
6 DI6 X505:5 Horn
7 DI7 X503:2 Height pre-selector
8 DI8 X503:8 Height preselector override
9 DI9 X503:3 0-position tilt
10 DI10 X503:9 0-position sideshift
11 DI11 X503:4 Extra function 5th lever
12 DI12 X503:10 Cabin tilt
13 DI13 X503:5 Free
14 DI14 X503:11 Free
15 DI15 X504:10 Flashers, left
16 DI16 X504:1 Flashers, right
17 DI17 X505:14 (Multi/Single Keying)
18 DI18 X503:12 Free
19 ESOIN X504:16 Emergency stop (ESO)
20 KEYIN X504:7 Key signal

Troubleshooting
261828-040 2008-08-21 6051502 815, 816
State 3 – Voltages 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 plac-
es.
No. MCU signal

1 A1 X130:2 –
2 A2 X130:16 Fork tilt indicator
3 A3 X130:30 Hydraulic pressure, main lift
4 A4 X130:3 Hydraulic pressure, free lift
5 A5 X130:17 Accelerator
6 A6 X130:31 Safety pedal
7 A7 X130:4 Brake pedal 1
8 A8 X130:18 Brake pedal 2
9 A9 X130:32 Power consumption
10 A10 X130:5 Battery voltage +

Troubleshooting
815, 816 6051502 2008-08-21 261828-040
State 4 – Digital input signals to MCU

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

1 DI1 X130:10 Cabin tilt, upper position
2 DI2 X130:24 Cabin tilt, lower position
3 DI3 X130:38 Reach movement, position 1
4 DI4 X130:11 Reach movement, position 2
5 DI5 X130:25 Steering angle, 180 degrees
6 DI6 X130:39 Mast lowering mode A
7 DI7 X130:12 Main lift height A (with height indicator)/
Mast near bottom position (without
height indicator)
8 DI8 X130:26 Main lift height B
9 DI9 X130:40 Free lift height A
10 DI10 X130:13 Free lift height B
11 DI11 X130:27 Mast lowering mode B
12 DI12 X130:41 Seat switch
13 DI13 X131:2 Forks below 1 m (with height indicator)/
Forks near top of mast (without height
indicator)
14 DI14 X131:16 Travel direction pedal, drive wheel
direction
15 DI15 X131:30 Travel direction pedal, fork direction
16 DI16 X131:3 Free
17 DI17 X131:17 Speed limitation 1
20 DI20 X131:18 Sideshift, left
21 DI21 X131:32 Sideshift, right
22 DI22 X131:5 Emergency stop (ESO)
23 DI23 X131:19 Key (option)
24 DI24 X131:33 (production test)
25 DI25 X131:6 Key signal in

Troubleshooting
261828-040 2008-08-21 6051502 815, 816
State 5 – Digital output signals from MCU

State 5 displays 18 digital output signals from the MCU.
No MCU signal
.
1 DO1 X131:20 Parking brake
2 DO2 X131:34 Chassis fan
3 DO3 X131:7 Main contactor
4 DO4 X131:21 Extra (Aux) hydraulic function valve 2
5 DO5 X131:35 Flashers, right
6 DO6 X131:8 Flashers, left
7 DO7 X131:22 Travel alarm 2
8 DO8 X131:36 Warning lamp
9 DO9 X131:9 Fan inverter
10 DO10 X131:23 Travel alarm 1
11 DO11 X131:37 Extra (Aux), direction A
15 DO15 X131:11 Extra (Aux), direction B
16 DO16 X131:25 Horn
17 DO17 X131:39 Support arm brake, left
18 DO18 X131:12 Support arm brake, right

Troubleshooting
815, 816 6051502 2008-08-21 261828-040
State 6 – PWM outputs from MCU

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

.
1 PWM1 X131:26 V Main Lift
2 PWM2 X131:40 V Main lowering
3 PWM3 X131:13 V Reach movement, in
4 PWM4 X131:41 V Reach movement, out
5 DO17 X131:39 V Support arm brake, left
6 DO18 X131:12 V Support arm brake, right
ACH signal
7 PWM1 K1:10 A Free lift
8 PWM2 K1:2 A Free lowering
ACT signal
9 PWM1 K1:10 A Cabin tilt, up
10 PWM2 K1:2 A Cabin tilt, down
State 7 – FCU (not used)
State 8 – FCU (not used)
State 9 – GFU (not used)
State 10 – GFU (not used)

Troubleshooting
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State 11 – Temperature signals

State 11 displays the temperature signals in the truck, of which
there are 5 in total. 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
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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 enabled
3 Safety pedal/door switch
4 Seat switch
5 Parking brake enabled
6–8 Not used

Troubleshooting
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State 14 Steering information

State 14 displays steering information.
No. Unit
Position, target °
Position, actual °
Steering speed, target V/min
Steering speed, actual V/min
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
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State 15 – Lift/lowering information

State 15 displays lift/lowering information.
No. Unit
H1 Height, free lift mm
H2 Height, main lift mm
H Height, total (displayed) mm
L Lift/lowering lever V
P Requested hydraulic pump speed rpm
Basic version, height indicator (parameter 1009 = 0)
1 Mast lowered pos. A
2 Mast lowered pos. B
3
4 Mast near to lowered pos.
5 ACH power stage enabled
6
7
8 Forks near to mast top
Full height indication (parameter 1009 = 1)
1 Mast lowered pos. A
2 Mast lowered pos. B
3
4
5 ACH power stage enabled
6
7
8 Free lift, height reference

Troubleshooting
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State 16 – Reach movement

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
1 Reach carriage sensor 1
2 Reach carriage sensor 2
3-8 Not used

Troubleshooting
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State 17 – Hydraulic information

State 17 displays hydraulic information.
No. Unit
FT Fork tilt, angle 0.1 degrees
L1 Lever aux 1 V
L2 Lever aux 2 V
L3 Lever aux 3 V
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
Warning and error codes
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7.2 Warning and error codes

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)
Error code structure

The error codes consist of warnings and errors. An error code consists
of two parts, a group number and a code number, separated by a colon
(:), for instance: 1:181.
By studying the tables below we can read off that the error code origi-
nates from the CID (1:nnn), in the form of a warning (n:1nn) and relates
to a signal error from a sensor (n:n81). The sensor in question can be
identified using the error code tables in this section.
All codes start with a main group, 1–7, depending on the system they
belong to.
Group number, error codes

Group: Description
1:nnn CID
2:nnn MCU
3:nnn Traction force system
4:nnn Hydraulic system
5:nnn Steering system
6:nnn Wire guidance (does not apply to RRE trucks)
7:nnn GFU

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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 it. 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 motor brake until it
stops. Once the truck has stopped, or after 5 sec-
onds, the relays for the main power supply and key
are switched off.
n:5nn Critical error.
Main contactor and power relay for the key are
switched off.
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
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7.2.1 Error codes

Code Name Description/possible causes
Event Action
Group 1 CID warnings and errors
1:003 Minor program version The program versions in the MCU and CID do not match.
incompatibility The MCU does not support some of the functions used by
the CID, or vice versa.
Check that identical versions of the software are being used
in the CID and MCU.
1:004 Incompatibility in the dis- The program versions in the MCU and CID do not match.
play program software The MCU does not support some of the functions used by
Check that identical versions of the software are being used
in the CID and MCU.
1:010 CAN 1 communication The CID CAN module has received too many error mes-
warning sages.
1. Check that CAN 1 is intact in terms of wiring harness,
final resistance and contacts.
2. Withdraw the battery contact. Check that the resistance
between positions 3 and 4 in X41 is 54 – 66 ohms.
3. Uninstall and disconnect the LID.
1:120 LID status does not comply LID reports status that is not approved.
1:121 CAN 1 communication Communication with the LID lost. No message received
warning from the LID.
1:431 External +5 V error The external +5 V is outside the permitted voltage range.
1. Check the electrical supply in terms of wiring harness
and contacts.
2. Check that there is no short circuit between B31:1 and
B31:3.
3. Disconnect levers and buttons, one by one, from the wir-
ing harness connected to X505:1.
1:501 MCU error The CID detects an error in the MCU. The program counter
is not correct.
Look for the latest software, replace the MCU.
1:503 Emergency mode error The MCU and CID display different status if the truck is in
emergency driving mode.
Restart the truck.

Troubleshooting
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Event Action
1:504 Major program version The program versions in the MCU and CID do not match.
incompatibility The MCU does not support some of the functions used by
Login not permitted Check that identical versions of the software are being used
in the CID and MCU.
1:510 CAN 1 communication CID CAN BOF. CAN bus error.
error
1:512 CAN 1 communication The CID has problems sending a CAN message
error
3. Uninstall and disconnect the CID.
1:514- CAN 1 communication The MCU or CID have not received a response via CAN in
1:516 error 70 ms.
3. Uninstall and disconnect the CID.
1:520 Internal 5 V error The internal 5 V is outside the permitted voltage range.
Check the power supply, cables.
1:540 Key contactor interrupted
power circuit
1. Check that the wiring harness and contacts are intact
and correctly fitted.
2. Check the operation of the key contactor.
3. Replace the MCU.
1:580 Key contactor welded
3. Replace the MCU.
1:581 Key contactor off
3. Replace the MCU.

Troubleshooting
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Event Action
Group 2 - MCU and non-classified warnings and errors
2:002 Standard value warning The standard factory value has been loaded on the MCU.
Check that the truck settings suit the required application.
2:003 Internal MCU error Error on reading back-up data.
Possible error on hour Carry out back-up of data. Update to the latest program
meter and error log software. If necessary, replace the MCU unit.
2:004 The back-up parameters The back-up data does not match. Error when control value
do not match. is tested.
2:005 Time for service
2:006 LOG buffer overfull Only logged, not displayed. Errors that should have been
logged have disappeared from the error log.
2:010 CAN 1 communication The MCU CAN module has received too many error mes-
warning sages.
3. Uninstall and disconnect the CAN 1 modules, one after
the other.
2:011 CAN 2 communication The MCU CAN module has received too many error mes-
warning sages.
the other.
2:102 HPS stop height Error on height preselector, stop height.
2:103 Lift height limiting Lift height limiting is activated but no height measurement is
activated.
2:106 Collision locking Collision value registered over the level determined by the
service parameter, a collision has been registered.
Travel speed reduced

Troubleshooting
815, 816 6051502 2008-08-21 261828-040

Event Action
2:140 Error on digital output sig- Output signal for chassis fan short-circuited.
nal 2
1. Check the power supply, contacts and wiring harness
with regard to a short circuit.
2. Check the operation of the chassis fan.
2:141 Error on digital output sig- Output signal for fan voltage converter short-circuited.
nal 9
2. Check the operation of the voltage converter.
2:160 Error on digital output sig- Cable break output signal for chassis fan.
nal 2
2. Check the operation of the chassis fan.
2:161 Error on digital output sig- Cable break output signal for fan voltage converter.
nal 9
2. Check the operation of the voltage converter.
2:180 CAN 1 communication Impact sensor error. No contact with impact sensor.
warning
Travel speed reduced 1. If impact sensor is not present, change parameter 109/
110 to deactivate the impact sensor.
2. Check the power supply, contacts and wiring harness.
2:401 Internal program error Error in the MCU program.
MCU
Program software error, report to BT.
2:403 Read A/D time-out A/D reading is taking too long.
2:420 Incorrect battery voltage The battery voltage is below 33.6 V.

1. Check the battery status.
2. Check that the battery cables are intact and correctly fit-
ted.
3. Check that the battery status wiring harness is intact and
correctly fitted.
2:421 Incorrect battery voltage Battery voltage exceeds 72 V.
1. Check the battery status.
2. Check that the battery cables are intact and correctly fit-
ted.
3. Check that the battery status wiring harness is intact and
correctly fitted.

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Event Action
2:431 External + 5 V error 5 V electrical supply for external sensors is under 4.9 V.
1. Check that the cables are intact and correctly fitted.
2. Check external loads, e.g. faulty sensors, short circuits.
Disconnect them one by one.
2:432 External + 5 V error 5 V electrical supply for external sensor exceeds 5.1 V.
2:433 External + 15 V error 15 V electrical supply for external sensor is under 12 V.

1. Check that the cables are intact and correctly fitted.
2. Check external loads, e.g., faulty sensors, short circuits.
Disconnect them one by one.
2:434 External + 15 V error 15 V electrical supply for external sensor exceeds 16.5 V.
2:435 Internal + 7.5 V error 7.5 V electrical supply for internal circuits is under 7 V.
Check electrical supply to the MCU.
2:436 Internal + 7.5 V error 7.5 V electrical supply for internal circuits exceeds 8 V.
2:437 Frequency converter low Frequency converter voltage is under 12 V.
2:438 Frequency converter high Frequency converter voltage exceeds 62 V.
2:501 Check sum error The check sum is not correct.
2:502 General internal program Program error in the MCU program.

error in MCU
Report to BT.
2:504 Emergency mode error The MCU and CID display different status if the truck is in
emergency driving mode.
Restart the truck.
2:505 Program calculator The program calculator is not consistent.
2:507 Truck immobile Truck set in "unusable" mode.
2:510 CAN 1 error Error on initiation of CAN 1.

the other.

Troubleshooting
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Event Action
2:511 CAN 2 error
the other.
2:512 CAN 1 communication The MCU has problems with sending messages via CAN 1.
error
See 2:510.
2:513 CAN 2 communication The MCU has problems with sending messages via CAN 2.
error
See 2:511.
2:514 DHU login error No response to login received from DHU/TWIS.
Check that the login settings (parameters) are correct.
Check the DHU with regard to wiring harness and power
supply.
2:523 Battery current is high The current from the battery exceeds 800 A.
2:531 Internal + 5 V error Internal 5 V electrical supply is under 4.9 V

Replace the MCU.
2:532 Internal + 5 V error Internal voltage 5 V electrical supply exceeds 5.5 V
Replace the MCU.
2:533 Internal + 15 V error Internal voltage 15 V electrical supply is under 14.25 V
Replace the MCU.
2:534 Internal + 15 V error Internal voltage 15 V electrical supply exceeds 15.75 V
Replace the MCU.
2:537 Internal + V O error +V O electrical supply for digital output signals is under 9.7
V.
2:538 Internal + V O error +V O electrical supply for digital output signals is over 12 V.
2:540 Error on digital output sig- Output signal for main contactor has been short-circuited.
nal 3
1. Check the magnetic coils, the electrical supply, contacts
and wiring harness with regard to a short circuit.
2. Check that the main contactor works.
3. Replace the MCU.

Troubleshooting
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Event Action
2:555 Time out for start-up Not all modules started within 20 seconds.
Check that the truck wiring harness with contacts is intact
2:556 Time out for shutdown Not all modules been shut down within 20 seconds.
2:560 Error on digital output sig- Cable break output signal for main contactor.
nal 3
Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the output signal X131:7.
2:580 Main contactor error Main contactor welded.
Check the main contactor, X131:7 and the wiring harness.
Restart of the truck in the emergency mode position is nec-
essary to reset the error.
2:581 Main contactor error Main contactor activated but not read as closed.
Check the main contactor, X131:7 and the wiring harness.
2:582 Main contactor error The frequency converter with PTC is under 36 V.
Check the wiring harness from the MCU to the ACS.
Group 3 Travel system
3:080 Safety pedal moore than Safety pedal activated more than 20 minutes.
20 minutes
Check that the signal does not exceed 2.5 V when the
pedal is released and that the signal changes when the
pedal is engaged.
3:142 MCU output 5, signal error. The left-hand support arm brake is short-circuited.
Driving speed is reduced, Check the magnetic coil, electrical supply, contacts and wir-
13 and 7 km/hour in driving ing harness. Check the output signal X131:39.
and fork direction respec-
tively.
3:143 MCU output 6, signal error. The right-hand support arm brake is short-circuited.
See 3:142. Check the magnetic coil, electrical supply, contacts and wir-
3:162 MCU output 5, signal error. Cable break, left-hand support arm brake.
3:163 MCU output 6, signal error. Cable break, right-hand support arm brake.
3:180 Safety pedal Safety pedal signal is outside the permitted value; 1.5–
3.5 V
Check the output signal X131:31.

Troubleshooting
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Event Action
3:300 Motor brake error The motor cannot brake adequately. The ACT cannot pro-
vide sufficient power to the motor with the result that this
cannot maintain the speed required. Can occur when driv-
ing on a downward incline.
The truck is braked with the
parking brake and, where
present, support arm
brakes.
Driving deactivated.
3:305 Temperature error Drive motor temperature is over 180°C.
The truck is braked to 0 km/ 1. Check the motor compartment fan.
h with the parking brake 2. Check the drive motor and temperature sensor.
and, where present, sup- 3. No fault; may be due to intensive operation.
port arm brakes.
3:314- CAN 2 communication The MCU or ACT have not received a response via CAN in
3:316 error. 70 ms.
See 3:305. Check that CAN 2 is intact in terms of wiring harness, final
resistance and contacts. Check that the green LED on the
ACT is on.
3:320- Incorrect DC voltage ACT DC voltage is outside the permitted voltage range.
3:322 See 3:305. Check the wiring harness, the fuses F1 and F71, and the
main contactor. Check that the green LED on the ACT is
on. Check the battery.
3:323 Overcurrent error Overcurrent ACT.

See 3:305. Check that the battery has the correct voltage and that
there are no short circuits.
3:325 Temperature error The temperature on the ACT cooling plate is over 125 °C.
See 3:305. Check the cooling plate and clean the cooling air duct.
Check the temperature sensor.
3:328 ACT short-circuited Short circuit in the ACT, motor cables or motor.
3:329 Internal parameter error in The displacement in the current measurement is too high.
the ACT
See 3:305. Restart the truck.
If the error remains, replace the ACT.
3:331 Internal + 5 V error. The internal 5 V supply in the ACT is outside the permitted
voltage range.
See 3:305. Check the electrical supply to the ACT.
3:333 Internal + 15 V error. The internal 15 V supply in the ACT is under the permitted
voltage range.
See 3:305. Check the electrical supply to the ACT.

Troubleshooting
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Event Action
3:380 Speed sensor error Cable break/short circuit in the speed sensor.
See 3:300. Check the sensor B11 and its wiring harness.
3:385 Accelerator 1 error The voltage from the pedal is outside the permitted range,
0.25–4.75 V.
Operation not possible. Check the wiring harness, pedals and X130:17.
The truck is braked by the
motor brake until it stops.
3:387 Brake pedal error (signal 1) The voltage from the pedal is outside the permitted range,
0.25–4.75 V.
See 3:385. Check the wiring harness, pedals and X130:4.
3:388 Brake pedal error (signal 2) The voltage from the pedal is outside the permitted range,
0.25–4.75 V.
See 3:385. Check the wiring harness, pedals and X130:18.
3:389 Brake pedal error Signals 1 and 2 from the brake pedal do not conform, differ-
ence of > 1.5 V.
See 3:385. Check the pedals and that there is no short circuit between
cables 85 and 86.
3:390 Error on the travel direc- The signal is outside the permitted range, 0.25–4.75 V.
tion selector
See 3:385. Check X505:4, the travel direction selector and wiring har-
ness.
3:500 Unexpected error Unknown drive error.
Check that the same versions of the software are being
used in the MCU and ACT. Update to the latest version.
Report to BT.
3:520 Start-up error
3:540 Error on digital output sig- Output signal for parking brake short-circuited.
nal 1
Check the magnetic coil with Q1 (48 V, ~32 ohms), the
electrical supply, contacts and wiring harness. Check the
output signal X131:20.
3:560 Error on digital output sig- Output signal for parking brake, interrupted power circuit
nal 1
Check the magnetic coil with Q1 (48 V, ~32 ohms), the
electrical supply, contacts and wiring harness. Check the
output signal X131:20.

Troubleshooting
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Event Action
Group 4 Hydraulic system
4:180 Height sensor error No pulses from the main lift height sensor on lift/lowering.
Disabled lift function 1. Check the main lift height sensor, the electrical supply
and wiring harness.
2. Recalibrate valve Q4 and Q5.
3. The fork load may be too heavy on lifting.
4:181 Height sensor value invalid The current height value for main lift does not correspond to
the signal from the height reference sensor on lowering.
Disabled lift function Check the lift reference sensor, the main lift height sensor,
the electrical supply and wiring harness.
4:182 Height sensor error No pulses from the free lift height sensor on lift/lowering.
Disabled lift function Check the height sensor, the electrical supply and wiring
harness.
The fork load may be too heavy on lifting.
4:183 Height sensor value invalid The current height value for free lift does not match the sig-
nal from the height reference sensor on lowering.
4:184 Abnormal lift/lowering The fork speed is too high.

speed
Lift and lowering disabled This error should not occur during normal operation. Check
both height sensors if lift/lowering speed is working nor-
mally.
4:185 Height sensor error The height reference signal for free lift is absent when its
presence would be expected. The free lift height sensor
value indicates that the height reference sensor should
have changed.
Lift/lowering speed reduced Check the reference sensor and fork height as displayed
against the actual fork height.
4:186 Height sensor error The height reference signal for main lift is absent when its
presence would be expected. The free main lift height sen-
sor value indicates that the height reference sensor should
have changed.
Lift/lowering speed reduced Check the reference sensor and fork height as displayed
against the actual fork height.
4:187 Abnormal lift height The calculated lift height is lower than –150 mm, or 50 mm
higher than the maximum fork height according to parame-
ter 1010.
Lift/lowering speed reduced Activate the reference sensors by lifting and lowering the
forks. If the error remains, check all height-related parame-
ters.

Troubleshooting
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Event Action
4:188 Error on the cabin tilt sen- The cabin tilt sensors are emitting different values (Ergo
sor truck).
Tilting up of the cabin pre- Check the electrical supply, harness and sensors for cabin
vented. tilting.
4:189 Pressure sensor error The pressure signal is outside the permitted range, 0.3–4.7
V.
4:189 Pressure sensor error The pressure signal is outside the permitted range, 0.3–4.7
V.
The program assumes the Check pressure sensor B4, the electrical supply, X130:3
maximum load on the forks and wiring harness.
(250 bar)
4:192 Mast separation sensor The mast separation sensors A and B have a signal combi-
error nation that is not permitted.
Lift/lowering speed reduced Check the mast separation sensor signals, X130:39 and
X130:27. They must change at the same time as the mast
is separated and have opposite values.
4:193 Reach movement sensor No pulses from the reach movement length sensor during
error reach movement.
Reduced reach movement 1. Check the length sensors' signal X130:38 and X130:11. If
speed the reach carriage has reached its end position, check
parameter 1265, reach movement length.
2. Recalibrate valve Q6 and Q7.
3. If the reach carriage moves too ponderously, check the
adjustment of the rollers.
4:200 Unexpected error Unknown drive error.
Deactivated hydraulics Check that the same versions of the software are being
used in the MCU and ACH. Update to the latest version.
Report to BT.
4:205 Temperature error Pump motor temperature is over 180 °C.
Deactivated hydraulics 1. Check the motor compartment fan.
2. Check the pump motor and temperature sensor.
3. No fault; may be due to intensive operation.
4:214– CAN 2 communication The MCU or ACH have not received a response via CAN in
4:216 error 70 ms.
See 4:205. Check that CAN 2 is intact in terms of wiring harness, final
resistance and contacts. Check that the green LED on the
ACH is on and remains on.
4:220– Incorrect DC voltage ACH DC voltage is outside the permitted voltage range.
4:222 See 4:205. Check the wiring harness, the fuses F3 and F71, and the
main contactor. Check that the green LED on the ACH is
on.

Troubleshooting
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Event Action
4:223 Overcurrent error Overcurrent ACH.
See 4:205. Check that the battery has the correct voltage and that
there are no short circuits present.
4:225 Temperature error The temperature on the ACH cooling plate is over 125 °C.
See 4:205. Check the cooling plate and clean the cooling air duct.
Check the temperature sensor.
4:228 ACH short-circuited Short circuit in the ACH, motor cables or motor.
See 4:205. Check the cables between the ACH and motor.
4:229 Internal parameter error in The displacement in the current measurement is too high.
the ACH
See 4:205. Restart the truck.
If the error remains, change the ACH.
4:231 Internal + 5 V error The internal 5 V supply in the ACH is outside the permitted
voltage range.
See 4:205. Check the electrical supply to the ACH.
4:233 Internal + 15 V error The internal 15 V supply in the ACH is under the permitted
voltage range.
See 4:205. Check the electrical supply to the ACH.
4:240 Error on the free lift valve. Short circuit in output signal for the free lift valve.
Lift deactivated Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the output signal (K1:10) on the ACH.
4:241 Error on the free lowering Short circuit in output signal for the free lowering valve.
valve
Lowering of forks during Check the magnetic coil, electrical supply, contacts and wir-
free lift prevented ing harness. Check the output signal (K1:2) on the ACH.
4:242 Valve error when Ergo Short circuit in output signal for upward tilt of operator
cabin tilted up. cabin.
Tilting up of cabin is pre- Check the magnetic coil, electrical supply, contacts and wir-
vented. ing harness. Check the output signal (K1:12) on the ACT.
4:243 Error on digital output sig- Short circuit in output signal for AUX 2.
nal 4.
Aux (extra function) deacti- Check the magnetic coil, electrical supply, contacts and wir-
vated. ing harness. Check the output signal (X131:21).
nal 12.

Troubleshooting
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Event Action
nal 13.
nal 14.
Tilt or sideshift affected Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the output signal (X131:38).
4:247 Error on cabin tilt-down. Short circuit in output signal for downward tilt of operator
cabin.
Cabin tilt prevented. Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the signal (K1:2) on the ACH.
4:248 Error on digital output sig- Short circuit in output signal for AUX direction A.
nal 11.
AUX deactivated. Check the magnetic coil, electrical supply, contacts and wir-
4:249 Error on digital output sig- Short circuit in output signal for AUX direction B.
nal 15.
4:250 Error on MCU output signal Short circuit in output signal for main lift valve.
1.
All hydraulic functions Check the magnetic coil, electrical supply, contacts and wir-
deactivated. ing harness. Check the output signal (X131:26).
4:251 Error on MCU output signal Short circuit in output signal for main lowering valve.
2.
All hydraulic functions Check the magnetic coil, electrical supply, contacts and wir-
deactivated. ing harness. Check the output signal (X131:40).
4:252 Error on MCU output signal Short circuit in output signal for mast reach valve.
3.
Reach movement deacti- Check the magnetic coil, electrical supply, contacts and wir-
vated ing harness. Check the output signal (X131:41).
4:253 Error on MCU output signal Short circuit in output signal formast retraction valve.
4.
4:260 Error on the free lift valve Interrupted circuit in the free lift valve output signal
Lift deactivated. Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the output signal (K1:10).

Troubleshooting
815, 816 6051502 2008-08-21 261828-040

Event Action
4:262 Error when Ergo cabin Interrupted circuit in operator cabin output signal for upward
tilted up. tilt.
Cabin tilt deactivated. Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the output signal (K1:10) on the ACT.
4:263 Error on digital output sig- Interrupted circuit in output signal for AUX 2.
nal 4.
nal 12.
nal 13.
AUX deactivated Check the magnetic coil, electrical supply, contacts and wir-
nal 14.
AUX deactivated Check the magnetic coil, electrical supply, contacts and wir-
4:267 Error when Ergo cabin Interrupted circuit in output signal for downward tilt of Ergo
tilted down. cabin.
Cabin tilt deactivated. Check the magnetic coil, electrical supply, contacts and wir-
ing harness. Check the signal (K1:2) on the ACH.
4:268 Error on digital output sig- Interrupted circuit in output signal for AUX direction A.
nal 11.
4:269 Error on digital output sig- Interrupted circuit in output signal for AUX direction B.
nal 15.
4:270 Error on MCU output signal Interrupted circuit in output signal for main lift valve.
1.
Lift deactivated. Check the magnetic coil, electrical supply, contacts and wir-
4:272 Error on MCU output signal Interrupted circuit in output signal for mast reach valve.
3.

Troubleshooting
261828-040 2008-08-21 6051502 815, 816

Event Action
4:273 Error on MCU output signal Interrupted circuit in output signal for mast retraction valve.
4.
4:280 Analogue signal 1 error. Lift/lowering lever voltage outside the permitted range 0.3–
4.7 V.
Lift/lowering deactivated. Check the wiring harness in the control panel. Replace the
lever.
Check input signal X505:2.
4:281 Analogue signal 2 error. Reach mast lever voltage outside the permitted range 0.3–
4.7 V.
Reach mast deactivated. Check the wiring harness in the control panel. Replace the
lever.
4:282 Analogue signal 3 error. Aux 1 lever voltage outside the permitted range 0.3–4.7 V.
Aux 1 lever deactivated. Check the wiring harness in the control panel. Replace the
lever.
lever.
lever.
4:285 Speed sensor error Interrupted circuit/short circuit in the speed sensor.
All hydraulic functions Check the wiring harness to sensor B11.
deactivated. Check sensor B11.
4:286 Fork tilt sensor error The sensor signal is outside the permitted range, 0.3–4.7 V.
All hydraulic functions Check the sensor and wiring harness to the sensor.
deactivated.
4:287 Sideshift sensor error Both sensor signals are absent.
All hydraulic functions Check the sensors and wiring harness to the sensors.
deactivated.
4:520 Start-up error
4:561 Error on the free lowering Interrupted circuit in output signal for the free lowering
valve. valve.
ing harness. Check the output signal (K1:2).

Troubleshooting
815, 816 6051502 2008-08-21 261828-040

Event Action
4:571 Error on MCU output signal Interrupted circuit in output signal for the main lowering
2. valve.
Group 5 Steering system warnings and errors
5:010- CAN communication warn- The EPS CAN module has received/transmitted too many
5:011 ing error messages.
Check that CAN 2 is intact in terms of wiring harness,
socket resistors and contacts.
5:035 Temperature warning The EPS temperature exceeds 68 °C.
Check the motor compartment fan.
5:135 I2T warning EPS temperature has reached 80 % of the permitted value.
Driving speed is reduced to The code is followed by 5:325 if the problem persists.
8 km/h.
5:182- Reference sensor error Reference sensor signal is incorrect.
5:184 See 5:135. Check the wiring harness X130:25.
5:300 Error on steering The steering does not react as it should when steering.
5:304 Driving deactivated.
The truck is braked with the
motor brake until it stops.
5:301 Power stage error EPS has lost the power stage without transmitting an error
message.
See 5:300.
5:302 Data download error The MCU has not been able to download parameters to the
EPS.
See 5:300. Download a new program to both the MCU and the EPS.
5:303 Start-up error No response from the EPS on start-up.
See 5:300. Check the EPS wiring harness and fuse F64.
5:320 Incorrect DC voltage EPS direct current is under 24 V.
See 5:300. Check the wiring harness, the fuse F72, and the main con-
tactor.
5:325 I2T error The EPS is limiting the current to the nominal value (10 A).
See 5:300. Check that the drive wheel has not got jammed in the floor.
This problem can occur if the operator continues to steer
when the truck has stopped or is stationary.
5:326 Temperature error The temperature on the EPS power stage is outside the
permitted range, –40 to +85 °C.
See 5:300.

Troubleshooting
261828-040 2008-08-21 6051502 815, 816

Event Action
5:335- Internal error EPS internal error
5:336
5:380 Steer sensor, error Power supply error, steer sensor 1 in the steering wheel.
See 5:300. Check the steer sensor and wiring harness.
5:381 Steer sensor, error Power supply error, steer sensor 2 in the steering wheel.
5:382 Steer sensor, error Abnormal speed from the steer sensor in the steering
wheel.
See 5:300. Check the pulse generator and wiring harness.
5:383 Steer sensor, error Steer sensor 1 and 2 in the steering wheel transmit different
signals
5:414- CAN 2 communication The MCU or EPS has not received a response via CAN in
5:416 error 70 ms.
The truck is braked with the Check that CAN 2 is intact in terms of wiring harness, final
motor brake until it stops. resistance and contacts.
5:421 Incorrect DC voltage The EPS DC voltage exceeds 78 V.
See 5:414. Check the wiring harness and fuse F64.
5:422 Short circuit
See 5:414.
5:435- Internal error EPS internal error
5:438
5:500 Unexpected error Unknown steering error.

Check that the same versions of the software are being
used in the MCU and EPS. Update to the latest version.
Report to BT.
5:509 Unwanted steering move- The steered wheel turns in spite of no steering command
ment being transmitted.
Group 6 Does not apply to reach mast trucks.

Group 7 GFU warnings and errors
7:411- CAN communication error The MCU or GFU have not received a response via CAN in
7:412 70 ms.
The truck is braked with the Check that CAN 1 is intact in terms of wiring harness, final
motor brake until it stops. resistance and contacts.

Troubleshooting
ACT/ACH transistor regulators
815, 816 6051502 2008-08-21 261828-040
7.3 ACT/ACH transistor regulators
7.3.1 Cable connections and pole bolts

Connections, travel control (ACT)
Connection Cable Designation Active In/Out
1 14 Motor temperature In
2 35 Cabin 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 Cabin 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
14 13 Pulse transducer, 12 V, 1 kOhm In
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

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Order number: 261828-040

Issue date Publication Changes

This manual covers following truck models:

T-code Model Serial number

© BT Repair Manual RRE140/160/180/200/250

2 – General introduction ......................................................................... 2-1

3 – General safety rules .......................................................................... 3-1

4 – Functions and parameters ................................................................ 4-1

© BT Repair Manual RRE140/160/180/200/250 1– 1

Right-hand control panel, single control ........................ 4-14

1– 2 Repair Manual RRE140/160/180/200/250 © BT

4.9.7 Height preselector and TruckCom ................................. 4-57

5 – Installation ......................................................................................... 5-1

© BT Repair Manual RRE140/160/180/200/250 1– 3

5.2.3 Parameters for optional equipment ................................. 5-4

6 – Maintenance ....................................................................................... 6-1

7 – Troubleshooting ................................................................................ 7-1

1– 4 Repair Manual RRE140/160/180/200/250 © BT

7.3.2 Connections on the MCU .............................................. 7-36

8 – Frame/Chassis 0000 .......................................................................... 8-1

9 – Motors 1000 ........................................................................................ 9-1

10 – Drive gear 2000 .............................................................................. 10-1

© BT Repair Manual RRE140/160/180/200/250 1– 5

Exposing the drive gear ................................................. 10-2

11 – Brake and wheel 3000 ................................................................... 11-1

12 – Steering system 4000 .................................................................... 12-1

1– 6 Repair Manual RRE140/160/180/200/250 © BT

12.3 Steering bearings (4380).............................................................. 12-7

13 – Electrical system 5000 .................................................................. 13-1

14 – Hydraulic system 6000 .................................................................. 14-1

© BT Repair Manual RRE140/160/180/200/250 1– 7

14.2.1 Emergency lowering of forks ......................................... 14-7

15 – Mast/Lift system 7000 ................................................................... 15-1

1– 8 Repair Manual RRE140/160/180/200/250 © BT

Stiff links ...................................................................... 15-17

© BT Repair Manual RRE140/160/180/200/250 1– 9

16 – External Equipment 8000 .............................................................. 16-1

17 – Options 9000 .................................................................................. 17-1

18 – Appendix “Destruction instructions” .......................................... 18-1

19 – Wiring diagrams ............................................................................ 19-1

20 – Hydraulics schematics ................................................................. 20-1

21 – Tool ................................................................................................. 21-1

22 – Appendix “Service data and grease specifications” .................. 22-1

23 – Technical data ............................................................................... 23-1

1 – 10 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

The pictogram might have additional information below, saying how

2– 2 Repair Manual RRE140/160/180/200/250 © BT

3 – General safety rules

3.1 Safety while working

© BT Repair Manual RRE140/160/180/200/250 3– 1

3.2 Electrical system

3– 2 Repair Manual RRE140/160/180/200/250 © BT

3.3 Safe lifting

© BT Repair Manual RRE140/160/180/200/250 3– 3

3– 4 Repair Manual RRE140/160/180/200/250 © BT