Repair manual 7612541
RRE140H RRE140HC RRE140HCC RRE140HE RRE140HEC RRE140HECC RRE160H RRE160HC RRE160HCC
RRE160HE RRE160HEC RRE160HECC RRE160HR RRE180H RRE180HC RRE180HCC RRE180HE RRE180HEC
en
RRE180HECC RRE200H RRE200HC RRE200HCC RRE200HE RRE200HEC RRE200HECC RRE250H RRE250HC RRE250HCC RRE250HE RRE250HEC RRE250HECC
Translation of the original instruction List of models:
Model
T-Code
Valid from serial number
RRE140H
1018
6445237
RRE140HC
1018
6445237
RRE140HCC
1018
6445237
RRE140HE
1018
6445237
RRE140HEC
1018
6445237
RRE140HECC
1018
6445237
RRE160H
1018
6445237
RRE160HC
1018
6445237
RRE160HCC
1018
6445237
RRE160HE
1018
6445237
RRE160HEC
1018
6445237
RRE160HECC
1018
6445237
RRE160HR
1020
6445237
RRE180H
1019
6445237
RRE180HC
1019
6445237
RRE180HCC
1019
6445237
RRE180HE
1019
6445237
RRE180HEC
1019
6445237
RRE180HECC
1019
6445237
RRE200H
1019
6445237
RRE200HC
1019
6445237
RRE200HCC
1019
6445237
RRE200HE
1019
6445237
RRE200HEC
1019
6445237
RRE200HECC
1019
6445237
RRE250H
1019
6445237
RRE250HC
1019
6445237
RRE250HCC
1019
6445237
RRE250HE
1019
6445237
RRE250HEC
1019
6445237
RRE250HECC
1019
6445237
Table of contents
General introduction
1
General safety rules
2
Operating principle
3
Parameters
4
Installation
5
Maintenance
6
Troubleshooting
7
Chassis C0000
8
Motors C1000
9
Transmission/Drive gear C2000
10
Brake/wheel/track system C3000
11
Steering system C4000
12
Electrical system C5000
13
Hydraulics/Pneumatics C6000
14
Work function - lifting masts C7000
15
Auxiliary equipment, installation equipment C8000
16
Optional equipment/Extra equipment C9000
17
Instructions for disposal
18
Wiring diagram
19
Hydraulics schematics
20
Tools
21
Service data and grease specifications
22
Technical data
23
Index
24
Repair manual 7612541 en
General introduction
1
1.1
Warning levels and symbols .............................................................................................................................. 1 - 1
1.2
Pictograms ......................................................................................................................................................... 1 - 1
1.3
Abbreviations ..................................................................................................................................................... 1 - 2
Repair manual 7612541-040
1 General introduction Warning levels and symbols
1 General introduction 1 General introduction
1
1.1 Warning levels and symbols 1.1 Warning levels and symbols
The following warning levels and symbols are used in the repair manual: DANGER Indicates a dangerous situation that – if not avoided – will cause death or serious bodily injury. WARNING Indicates a dangerous situation that – if not avoided – could possibly cause death or serious bodily injury. CAUTION Indicates a dangerous situation that – if not avoided – will cause a slight or minor bodily injury.
NOTICE Used in connection with actions that can cause material damage but not bodily injury. Used to attract attention and to give information about various actions.
1.2 Pictograms 1.2 Pictograms
Symbol
Procedure
Symbol
Procedure
Visual inspection of condition, wear and loose connections.
Component replacement.
Cleaning
Measurement
Checks for leaks.
Check that screws, nuts, etc. are tightened to torque.
Listening for noise.
Lubrication, application.
Check of functions.
Calibration
Adjustment
Welding
Disassembly/removal
Assembly/installation
Open
Close
Refilling
Emptying
Update
Charging
Lift
Lower
An example of another type of pictogram is “Cut cable ties”:
1-1
Repair manual 7612541 en
1 General introduction Abbreviations
Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.
1.3 Abbreviations 1.3 Abbreviations
Abbrevi- Meaning ation
Explanation
ACC
Alternate Current Combi
Motor control, hydraulics and drive.
ACH
Alternate Current Hydraulic
Motor control, hydraulics.
ACT
Alternate Current Traction
Motor control, drive.
BCU
Onboard system
BDI
Battery Discharge Indicator
Unit indicating the state of battery charge.
CAN
Controller Area Network
A standardised interface that enable communication between different electrical units.
CID
Central Information Display
Display with menu-based information system that is used as the primary communication tool between operator and truck.
DX
Duplex
Mast with two sections.
EPS
Electronic Power Steering
Complete steering servo with its own motor control.
ESO
Emergency Switch Off
Emergency stop switch.
FCM
Fuse Central Module
Fuse panel.
FCU
Fork Control Unit
Unit for fork functions.
GFU
General Function Unit
Unit for general functions.
HPS
Height Pre-Select
Height pre-selection
ICH
Integrated Control Handle
IPM
Intelligent Power Module
Power control unit
LID
Load Information Display
Display that provides the operator information such as lift height, load weight and height preselection.
MCU
Main Control Unit
Main control unit.
PDA
Personal Digital Assistant
A compact, portable handheld computer.
PPS
Personal Protection System
Personal protection system.
PTC
Positive Temperature Coefficient
Electrical property that causes resistance to increase with temperature.
SCU
Secondary Control Unit
Secondary control unit
SEU
Spider Expansion Unit
SF
Shuttle Forks
Telescoping fork unit.
TBD
To Be Defined
Means that the instruction/chapter will be supplemented at a later date.
TH
Turret Head
Turret head fork unit
I-Site
T.W.I.S. – Toyota Wireless Information System
TX
Triplex
Mast with three sections.
VNA
Very Narrow Aisle
Narrow aisles
VRE
Very narrow aisle Rider Electric
Repair manual 7612541 en
1-2
General safety rules
2
2.1
Authorised personnel ......................................................................................................................................... 2 - 1
2.2
Work safety ........................................................................................................................................................ 2 - 1
2.3
Electrical system ................................................................................................................................................ 2 - 2 2.3.1
Electrostatic risks................................................................................................................................. 2 - 2
2.3.2
Battery handling................................................................................................................................... 2 - 2
2.4
Safe lifting .......................................................................................................................................................... 2 - 3
2.5
Product modification .......................................................................................................................................... 2 - 4
2.6
Software............................................................................................................................................................. 2 - 4
2.7
Hydraulic system................................................................................................................................................ 2 - 4
Repair manual 7612541-040
2 General safety rules Authorised personnel
2 General safety rules 2 General safety rules
2.1 Authorised personnel 2.1 Authorised personnel
Only personnel trained in servicing and repair of this type of product are authorised to carry out service and repair activities.
2.2 Work safety 2.2 Work safety
For safe work, always remember:
▷
Always disconnect the battery when carrying out maintenance or repair work, unless otherwise stated in this repair manual.
▷
always disconnect the battery when performing welding work.
▷
Make sure that the place where service work is performed is a safe place. Follow the regulations.
▷
Keep the maintenance work site clean. Oil and water on the floor will make it slippery.
▷
Use the correct working posture. Service work often involves sitting on your knees or bending over forwards. Try sitting on a toolbox, for example, to relieve the strain on your knees and back.
▷
Loose items and jewellery can get caught in moving parts. So never wear loose articles or jewellery when performing maintenance or repairs.
▷
Exercise caution and always follow applicable local regulations when working at high heights.
▷
Use the correct tools for the work you are carrying out.
▷
Keep all tools well maintained.
▷
Make sure that all safety equipment including guards and covers are properly secured and that they work as intended before starting the repair work. If a guard or cover must be removed in order to perform the repair work, extra care must be taken, and when the repair work is finished the guard or cover must be refitted.
▷
Use paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your hands.
▷
The drive unit oil may be hot.
▷
Use only new and clean oil for the drive gear.
▷
Store and transport changed oil according to applicable local directions.
▷
Do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way. Follow local disposal regulations.
▷
Prior to welding or grinding on painted surfaces, be sure to remove the paint at least 100 mm around the welding/ grinding area by using sandblasting equipment or paint remover.
▷
To maintain a high level of product safety and to minimise downtime, all current maintenance instructions must be carried out.
▷
Always keep fire-fighting equipment close at hand, and do not use an open fire to check fluid levels or when searching for leaks
2-1
Repair manual 7612541 en
2
2 General safety rules Electrical system
2.3 Electrical system 2.3 Electrical system
When working on the electric system, keep the following in mind: WARNING Short-circuiting/Burn injuries Loose items and jewellery can get caught in moving parts. So never wear loose articles or jewellery when performing maintenance or repairs.
►
Remove any jewellery and loose items before starting work.
▷
Always use insulated tools when working on the electrical system.
▷
Always disconnect the battery before opening any covers to drive units or the electrical system.
▷
Always disconnect the battery prior to welding work using an electric welding unit. The welding current may damage the battery.
▷
Never remove the warranty seals on the electronic cards.
2.3.1 Electrostatic risks 2.3.1 Electrostatic risks
Purpose These work instructions describe how to work in a safe manner with components that are sensitive to electrostatic chocks. Scope These work instructions apply to all that work with component or units that are sensitive to electrostatic chocks. Procedure Electrostatic discharges from people may destroy sensitive equipment. For this reason, one must follow the instructions for packaging and earthing. Always pay attention to these precautionary instructions. Electronic card are supplied in electrostatically protected packages or envelopes. These packages carry the following symbol:
▷
Leave electrostatically sensitive equipment in their respective packaging until you can place them on an electrostatically protected work area.
▷
Electrostatically sensitive equipment should only be handled when they are properly earthed.
▷
Use electrostatically protected footwear!
▷
Store electrostatically sensitive equipment in their protective packaging or on electrostatically protected surfaces.
▷
Use an antistatic surface: Anti-static carpet 148115, page 21 - 4.
2.3.2 Battery handling 2.3.2 Battery handling
When working on the battery, keep the following in mind:
▷
Working with and charging batteries should always be performed in accordance with the safety instructions provided by the battery manufacturer.
▷
Always use safety equipment to protect the eyes, face and skin while checking or handling batteries.
Repair manual 7612541 en
2-2
2 General safety rules Safe lifting
▷
Do not place any electrically conductive items on the battery terminals or their connections.
▷
Ensure there is a shower and an eye bath nearby in case an accident happens.
▷
Batteries generate explosive gases. Never use an open flame or other sources of ignition in close vicinity to a battery.
▷
Do not place tools or other metal objects on the battery. This can cause a short-circuit and even an explosion.
▷
The battery must be used according to the battery manufacturer's instructions regarding ambient and working temperatures. Otherwise there is a large risk that the battery is damaged and that it will soon have to be replaced.
▷
Spilled electrolyte must be neutralised at once using a lot of water.
NOTICE Changing to the correct battery type Only change to a battery that meets the data given on the product identification plate. The weight of the battery affects the stability and braking capacity of the truck. Information on the minimum permitted battery weight is on the product identification plate. WARNING Risk of centre of gravity shifting A battery weight that is too low gives impaired stability and braking capacity.
►
The battery weight must be in accordance with the data on the truck’s identification plate.
WARNING Battery acid may cause burns Battery acid may cause burns.
► ►
If battery acid gets onto your skin or clothes, flush immediately with cold water. If you get battery acid in the face or in the eyes, immediately flush the area with cold water and seek medical assistance.
2.4 Safe lifting 2.4 Safe lifting
When lifting the product, remember that:
▷
All lifting must be carried out on a level, non-slip and stable surface. Asphalt surfaces should be avoided if possible.
▷
To prevent the product moving while it is being lifted, it must not be lifted 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 wheels must be blocked to stop the product from moving.
▷
Select the lifting point so that the lift is as light as possible, for example one corner at a time. If there are lifting points indicated on the lower part of the chassis, these must be used to ensure balanced lifting.
▷
Make sure the surface where the jack is placed is clean and free of oil and grease.
▷
Make sure your hands and the jack lever are free of grease and oil.
▷
Only use the lever supplied with the jack. If the lever is too short, more exertion than is necessary will be required. If the lever is too long, there is a risk that the jack will be overloaded.
▷
Never work under a product that is not supported by trestles and secured by a lifting device.
▷
Never work under a raised product without it being properly supported on trestles.
▷
Never support the jack on trestles to achieve a higher lift.
Put trestles:
2-3
Repair manual 7612541 en
2
2 General safety rules Product modification
▷
as close to the lifted part of the chassis as possible in order to reduce the falling height if the product should collapse.
▷
so that no wheels may turn causing the product to move.
2.5 Product modification 2.5 Product modification
Any modification of the product must be approved beforehand. No modification of product may be performed that may influence the capacity, stability and safety of the product without prior written approval from the manufacturer, its representative or successor. In the case of the manufacturer no longer being in business and there being no successor, the user of the product may arrange for modifications on the precondition that the user:
▷
makes sure that an engineer with expert knowledge of the product type and its safety designs, tests and implements the modification,
▷
files all documentation of the design, tests and implementation of the modification,
▷
approves and makes the applicable changes to the capacity plate, adhesive labels, markings and operator’s manual,
▷
affixes a permanent and well visible sign to the product stating how the product has been modified, together with the date of the modification and the name and address of the company that carried out the modification work.
2.6 Software 2.6 Software
Erroneous handling of the product systems and/or the external systems of the product may affect the safety of the product and the environment. 1.
Always make sure that the correct software is downloaded to the product.
2.
In case of parameter adjustments, the recommended values must be respected.
3.
Only adjust one parameter at the time when performing changes to the truck. Check the function after each adjustment.
4.
Change the parameters in small increments.
2.7 Hydraulic system 2.7 Hydraulic system
When working on the hydraulic system, keep the following in mind:
▷
Lower the forks completely and keep pressing the button for another 5 - 10 seconds to relieve system pressure.
▷
The hydraulic oil may be hot.
▷
Only fill the hydraulic system with new and clean oil.
Repair manual 7612541 en
2-4
3
Repair manual 7612541-040
Operating principle
3 Operating principle Description
3 Operating principle 3 Operating principle
3.1 Description 3.1 Description
The Operating principle section provides a general description on how the AutoShuttle functions work and how they are interdependent. Because the control structure of the product is so complex, it is not possible to describe all combinations. Similarly, it is not possible to describe all influencing factors. Only a selection of such factors are indicated. A good aid is found in the descriptive sections of the repair manual and in the parameter descriptions in particular.
3-1
Repair manual 7612541 en
3
4 Parameters Parameter list
4 Parameters 4 Parameters
4.1 Parameter list 4.1 Parameter list
Software: 7584588
4
4.1.1 Operator parameters 4.1.1.1 Log-in profiles The operator parameters can be adjusted individually to the available log-in profiles. The parameter’s connection to the operator is done by a combination of operator and parameter numbers where the single digit always corresponds to the parameter. Operator profile
Parameter range
1
1-10
2
11-20
3
21-30
4
31-40
5
41-50
6
51-60
7
61-70
8
71-80
9
81-90
10
91-100
Tab. 1: Connection to logged-in operator
4.1.1.2 Control units The steering angle sensitivity can be individually adjusted between 1 and 10 for driving at low and high speeds. 1 gives the lowest speed of steering movement in relation to the steering wheel movement, and 10 offers the highest speed. If the steering feels too sluggish or unresponsive in any of the low or high speed ranges, the corresponding value is changed upwards or downwards through the setup screen for driver parameter 1.
No.
Designation
Min
Std.
Max
Step
1
Steering sensitivity (high speed)
6
15
20
1
Unit
The number of turns of the steering wheel that represents one turn of the drive wheel. In increments of 1
No.
Designation
Min
Std.
Max
Step
1
Steering sensitivity (low speed)
5
8
20
1
Unit
The number of turns of the steering wheel that represents one turn of the drive wheel. In increments of 1
No.
Designation
Min
Std.
Max
Step
1
The steering's progressivity
1541
3848
5140
1
Unit
The parameter shown via TruckCom is a combination of the sensitivity values low speed and for high speed. Total value for low and high speed. The parameter value can be calculated as (high * 256 + low), where low = steering ratio at low speed and high = steering ratio at high speed. For example low = 8 and high = 15 gives a parameter value of (15 * 256 + 8) = 3848.
4.1.1.3 Maximum travel speed These two parameters are used to limit the maximum travel speed for the logged-in operator profile.
4-1
Repair manual 7612541 en
4 Parameters Parameter list
For parameters 2 and 3, 100% corresponds to travel speed. The maximum speed varies depending on the truck type.
Example: If operator profile ‘1’ has parameter ‘2’ set to 80 %, operator profile‘2’ has their corresponding parameter ‘12’ set to 70 %, the maximum travel speed is limited to: •
8.8 km/h for operator profile '1'
•
7.7 km/h for operator profile '2'
The maximum travel speed can also be limited by the service parameters and it is always the lowest speed for a parameter that is the limiting one.
No.
Designation
Min
Std.
Max
Step
Unit
2
Maximum speed, drive wheel direction
1
10
10
1
10%
The parameter is used to limit the maximum travel speed for the operator profile that is logged on.
No.
Designation
Min
Std.
Max
Step
Unit
3
Maximum speed, fork direction
1
10
10
1
10%
The parameter is used to limit the maximum travel speed for the operator profile that is logged on.
4.1.1.4 Acceleration/Deceleration These two parameters can be used to get a smoother acceleration/deceleration where the application or operator profile so requires.
No.
Designation
Min
Std.
Max
Step
Unit
4
Acceleration
3
8
10
1
10%
The parameter can be used to get a smoother acceleration where the application or operator profile so requires.
No.
Designation
Min
Std.
Max
Step
Unit
5
Automatic braking at reduction of speed control
0
8
10
1
10%
The parameter can be used to get a smoother deceleration where the application or operator profile so requires.
4.1.1.5 Cab tilt This parameter is for setting the fork height above the floor level when the operator wants the cab (E-model) to start tilting upwards. To activate the function, see parameter 1104 and for downward tilting see parameter 355. To turn off the cab tilt display on the CID, see parameter 514
No.
Designation
Min
Std.
Max
Step
Unit
6
Fork height when the Ergo cab begins to tilt upwards
500
2000
13000
100
mm
Applies to the Ergo variant only, parameter 1104 set to 1.
4.1.2 Service parameters 4.1.2.1 General Before any service parameter can be changed, the CAN service key must be connected to the contact [X41]. Changing specific truck parameters changes the truck's driving properties. Do not change any parameter values without the necessary know-how.
Repair manual 7612541 en
4-2
4 Parameters Parameter list
No.
Designation
Min
Std.
Max
Step
Unit
101
Service intervals
0
0
5000
1
h
Use this parameter to determine the service interval of the truck. The buzzer sounds and a spanner is shown on the CID when the service counter is at zero. The counter shows the time that has passed since the last service intervention. If an earlier service intervention is required, simply activate this parameter without adjusting the time. If the value is set to '0', then no service interval is set and the CID's hour meter screen does not show the 'S' field – Remaining time to service.
No.
Designation
Min
Std.
Max
Step
Unit
104
Time to automatic logout
0
20
120
1
min.
The parameter gives the time, in minutes, before automatic logout if the truck is inactive. If the value is set as ‘0’, logout takes place after 4 hours.
No.
Designation
Min
Std.
Max
Step
116
Drive function with open door (cold-store cab)
0
1
1
1
Unit
Specifies the driving function when the door on the cold storage truck is open.
Value
Drive function
0
Driving not possible
1
Driving limited to creep speed (2.5 km/h as default)
Parameter 1105 activates the function. Parameter 202 manages the set speed for creep speed.
4.1.2.1.1 Travel alarms 1 and 2 There are two dedicated outputs for travel alarm on the MCU. One has by default been assigned to the buzzer and one to the warning lamp. Both can be configured regarding frequency and activation pattern. The "travel alarm 1" function is activated by parameter 1108 and the "travel alarm 2" function is activated by parameter 1112.
No.
Designation
Min
Std.
Max
Step
105
Travel alarm frequency
0
0
2
1
Unit
Parameter 105 controls the travel alarm frequency on output X131:23. The activation pattern for output X131:23 is set via parameter 114. The travel alarm function is activated by factory parameter 1108.
Value
Type
0
Constant
1
Flashing 1 Hz
2
Flashing 2 Hz
No.
Designation
Min
Std.
Max
Step
106
Warning lamp frequency
0
0
2
1
Unit
Parameter 106 controls the warning lamp frequency [P5] on output X131:34. The activation pattern for output X131:34 is set via parameter 115. The warning lamp function is activated by factory parameter 1112.
Value
Type
0
Constant
1
Flashing 1 Hz
4-3
Repair manual 7612541 en
4
4 Parameters Parameter list
Value
Type
2
Flashing 2 Hz
No.
Designation
Min
Std.
Max
Step
114
Travel alarm activation pattern [P4]
0
0
255
1
Unit
The parameter specifies the activation pattern for the travel alarm, output X131:23 The activation pattern is activated as indicated in the table below.
Function that activates the travel alarm
Value
Driving in the drive wheel direction
1
Driving in fork direction
2
Fork lifting
4
Fork lowering
8
Cab tilt
16
Reach
32
Aux (Hydraulics)
64
Truck started up
128
The frequency for output X131:23 is set via parameter 105. The travel alarm function is activated by factory parameter 1108.
No.
Designation
Min
Std.
Max
Step
115
Activation pattern for warning lamp [P5]
0
0
255
1
Unit
The parameter specifies the activation pattern for the warning lamp [P5], output X131:34. The activation pattern is activated as indicated in the table below.
Function that activates the travel alarm
Value
Driving in the drive wheel direction
1
Driving in fork direction
2
Fork lifting
4
Fork lowering
8
Cab tilt
16
Reach
32
Aux (Hydraulics)
64
Truck started up
128
The frequency for output X131:34 is set via parameter 106. The travel alarm function is activated by factory parameter 1112.
No.
Designation
Min
Std.
Max
Step
Unit
117
Collision sensor's alarm
0
0
1
1
-
The parameter specifies how the alarm is given when the collision sensor is activated.
Value
Type
0
Repeated tone pulses
1
One tone pulse
For setting the collision sensor’s sensitivity, see parameters 110 and 111.
Repair manual 7612541 en
4-4
4 Parameters Parameter list
No.
Designation
Min
Std.
Max
Step
118
Warning buzzer during lifting platform use (MEWP, special option)
0
0
1
1
Unit
Parameter settings:
Value
Function
0
Non-active
1
Active
4
The function is activated using parameter 1121 (Special option).
4.1.2.1.2 Battery No.
Designation
Min
Std.
Max
Step
107
Battery size
1
9
20
1
Unit
Parameter 107 specifies the capacity of the battery on the truck. The parameter can also be used to compensate for different ways of driving by: • increasing the value to discharge the battery even more • reducing the value if the battery is discharged too much. For recommended parameter settings, see the table below.
Value: RRE140-160
Battery
10
930 Ah
11
775 Ah
13
620 Ah
16
465 Ah
Tab. 2: RRE 140-160
Value: RRE180-250
Battery
9
930 Ah
11
775 Ah
14
620 Ah
Tab. 3: RRE 180-250 It is necessary to specify the type of battery the truck is equipped with. In order to set the meter for the battery’s level of discharge, the following should be taken into account: • Acid density when the battery is fully charged, to check the quality of battery. This value should be in the range 1.27-1.29. Please note that the acid density may vary between different battery brands. • When the lifting capability is reduced (the battery discharged to 80%) the value should be close to 1.14 but not lower. Freely ventilated batteries See the table for recommended parameter settings for free ventilated batteries. DANGER! Battery service life will be reduced if the value of parameter 107 is set too high. The standard setting of parameter 107 is set for normal truck handling. Other applications may require a different setting of parameter 107. Check that the parameter setting is the correct one using the instructions below. Verifying the parameter setting for freely ventilated batteries: 1. Charge the battery. 2. Operate the truck in its normal application until the battery indicator indicates a discharged battery (0% in the display). 3. Disconnect the battery from the truck and allow it to rest for at least two hours. Note: Do not allow any charging or discharging during this time. 4. Measure the acid weight of the battery at room temperature. If the acid weight is less than 1.15 g/cm3, the parameter value must be reduced. If the value significantly exceeds 1.15 g/cm3, the risk of damage to the battery is reduced. At the same time, however, the operating time of the truck decreases. If extended operating time is desired, then increase the parameter value, but maximum by one unit. Note: Each change should be followed up by a new verification of the parameter setting. Parameter settings for valve-regulated batteries (VRLA)
4-5
Repair manual 7612541 en
4 Parameters Parameter list
When setting parameter 107 in a truck with Reflex truck with Hawker Evolution batteries, BT recommends reducing the recommended value for wet batteries by six (6) units. DANGER! Battery service life will be reduced if the value of parameter 107 is set too high. The standard setting of parameter 107 is set for normal truck handling. Other applications may require a different setting of parameter 107. Check that the parameter setting is the correct one using the instructions below. When checking the charging state on a discharged 48 V battery, its no-load voltage should be measured after a rest period. The zero indication should appear at an open circuit voltage that must not fall below 2.02 V/cell or 48.48 V. See the instructions below. Instructions for verifying parameter setting 1. Charge the battery. 2. Use the truck in its normal application until the battery indicator shows a discharged battery (0% on the display). 3. Disconnect the battery from the truck and allow it to rest for at least two hours. Note: Do not allow any charging or discharging during this time. 4. Measure the voltage on the battery at +20°C. If the voltage is less than Uend, (see the table below), the parameter value must be reduced. If the value exceeds Uend considerably, the risk of causing damage to the battery is reduced. At the same time, the operating time of the truck is reduced. If a longer operating time is required, the parameter value can be slightly increased. 5. Each change should be followed up by a new verification of the parameter setting. Battery type Battery voltage at rest, Uend Hawker Evolution 48.48 V
No.
Designation
Min
Std.
Max
Step
Unit
108
Battery level when acceleration and lift speed are limited
0
5
20
5
%
Parameter 108 is used to state the level of the battery's remaining capacity according to the CID battery charge symbol when the acceleration and lift speed are limited to 70% of their maximum. A further, not parameter-controlled, limitation occurs when the CID battery charge symbol shows 0 %. In this case, the following are limited: • Acceleration – 30% of maximum performance • Lifting – 50% of maximum performance
4.1.2.1.3 Shock sensor Be sure to set the parameters for collision sensitivity upon installation of the truck. If shock sensor sensor is installed on the CAN bus, this registers when the truck bumps against something. If a collision exceeds a certain force, set by parameters 110 and 111, it is interpreted as a collision, and the truck speed is reduced to creep speed, a signal is heard and error code 2:106 is displayed. For setting how the alarm is to be given when the shock sensor is activated, see parameter 117. Information about the collision is stored in the truck's internal memory. The last ten registered collisions can be displayed together with operator identity via the PIN code. Additional information is available via TruckCom where collision levels and time indications can also be read.
No.
Designation
Min
Std.
Max
Step
109
Resetting procedure for logged data
0
0
4
1
Unit
The parameter indicates whether saved data from the collision sensor should be deleted upon login or not, and whether to reset the BDI counter.
Value
Function
0
Delete nothing
1
Delete histogram log
2
Clear collision log
3
Not used
4
Reset BDI
No.
Designation
Min
Std.
Max
Step
Unit
110
Shock sensor sensitivity along the X-axis (forward/reverse)
0
0
100
1
-
The parameter specifies at which level along the X-axis (fork/drive wheel direction) truck functions should be blocked when there is a collision.
No.
Designation
Min
Std.
Max
Step
Unit
111
Shock sensor sensitivity along the Y-axis (right/left)
0
0
100
1
-
Repair manual 7612541 en
4-6
4 Parameters Parameter list
The parameter specifies at which level along the Y-axis (sideways truck functions should be blocked when there is a collision.
No.
Designation
Min
Std.
Max
Step
Unit
112
Resetting procedure after collision
0
0
1
1
-
The parameter specifies the condition for how the truck is to be taken into operation again after the impact sensors have been triggered:
Value
Function
0
Login with a special PIN code is required
1
The truck must be restarted
The PIN code required to reset the shock sensor is entered in the login profile Block:10, Profile:1
4.1.2.1.4 Generic outputs No.
Designation
Min
Std.
Max
Step
120
Frequency for extra output 1 (Default = not used)
0
0
2
1
Unit
Parameter 120 controls the frequency on output X133:8. The activation pattern for output X133:8 is set via parameter 122. The function for the output is activated via factory parameter ????.
Value
Type
0
Constant
1
Flashing 1 Hz
2
Flashing 2 Hz
No.
Designation
Min
Std.
Max
Step
121
Frequency for extra output 2 (Default = not used)
0
0
2
1
Unit
Parameter 121 controls the frequency on output X133:23. The activation pattern for output X133:23 is set via parameter 123. The function for the output is activated via factory parameter ????.
Value
Type
0
Constant
1
Flashing 1 Hz
2
Flashing 2 Hz
No.
Designation
Min
Std.
Max
Step
122
Activation pattern for extra output 1 (Default = not used)
0
0
255
1
Unit
The parameter specifies the activation pattern for extra output X133:8.
4-7
Repair manual 7612541 en
4
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4 Parameters Parameter list
The activation pattern is activated as indicated in the table below.
Function that activates the travel alarm
Value
Driving in the drive wheel direction
1
Driving in fork direction
2
Fork lifting
4
Fork lowering
8
Cab tilt
16
Reach
32
Aux (Hydraulics)
64
Truck started up
128
The frequency for output X133:8 is set via parameter 120. The function is activated with factory parameter ????.
No.
Designation
Min
Std.
Max
Step
123
Activation pattern for extra output 2 (Default = not used)
0
0
255
1
Unit
The parameter specifies the activation pattern for extra output X133:23. The activation pattern is activated as indicated in the table below.
Function that activates the travel alarm
Value
Driving in the drive wheel direction
1
Driving in fork direction
2
Fork lifting
4
Fork lowering
8
Cab tilt
16
Reach
32
Aux (Hydraulics)
64
Truck started up
128
The frequency for output X133:23 is set via parameter 121. The function is activated with factory parameter ????.
4.1.2.2 Driving 4.1.2.2.1 General No.
Designation
Min
Std.
Max
Step
Unit
201
Braking force when reversing the travel direction
0
90
100
10
%
The parameter can be used to produce a smoother deceleration when the application requires this for all operator profiles.
No.
Designation
Min
205
Speed reduction via external function-related sensors (Default = 0 not used)
Std.
Max
Step
Unit
100
100
10
%
Two inputs on the SCU, X133:31 and X133:4, are used to reduce the travel speed. If one or both of the inputs is actuated by a high signal from external sensors, speed is reduced according to this parameters.
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4 Parameters Parameter list
No.
Designation
Min
Std.
Max
Step
Unit
208
Creep speed function in travel direction control
0
1
1
1
-
The parameter manages the creep speed function in the travel direction control. The function can be configured via parameter 242.
Value
Function
0
Inactivated
1
Activated
4
No.
Designation
Min
Std.
Max
Step
Unit
213
Setting the truck’s maximum travel speed
0
140
140
5
0.1 km/ h
The parameter can be used to permanently reduce the truck’s maximum travel speed. This setting will apply to all operator profiles.
No.
Designation
Min
Std.
Max
Step
Unit
214
Adjusting the travel speed in the main lift range
15
40
80
5
0.1 km/ h
The parameter is used to adjusted the reduced travel speed, Min 1.5 km/h Max 8 km/h, when the forks are in the main lift area. This parameter is only valid when the truck is equipped with height indication. If the truck does not have height indication, the speed is always reduced to 4 km/h when the forks are in the main lift area. This parameter is only relevant if parameter 1118 is set to 0.
No.
Designation
Min
Std.
Max
Step
242
Configuration of function in travel direction selector
0
0
2
1
Unit
This parameter is used to set which double-click function is available via the travel direction selector.
Parameter value
Function
0
Inactivated
1
Click to creep mode
2
Click to steer straight
4.1.2.2.1.1 Adjusting error-dependant maximum travel speeds These parameters are used to reduce the speeds which are normally set as maximum travel speeds in connection with warnings or faults.
No.
Designation
Min
Std.
Max
Step
Unit
202
Adjusting the creep speed max. 2.5 km/h
30
100
100
10
%
The parameter can be used to adjust the creep speed. Can only be lowered.
No.
Designation
Min
Std.
Max
Step
Unit
203
Adjusting the half-speed max. 4 km/h
30
100
100
10
%
The parameter is used to specify the maximum speed for half-speed, max. 4 km/h. Can only be lowered.
No.
Designation
Min
Std.
Max
Step
Unit
204
Adjusting the safety speed, max. 1.3 km/h
30
100
100
10
%
The parameter is used to specify the maximum speed for safety speed, max. 1.3 km/h. Can only be lowered.
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Repair manual 7612541 en
4 Parameters Parameter list
4.1.2.2.1.2 Reduced maximum travel speed over a certain lifting height and reach length With the parameter pair 209/210, it is possible to activate and adjust a speed limitation when the forks are raised above a certain height. With the parameter pair 211/212, it is possible to activate and adjust a speed limitation when the reach carriage is extended beyond a certain length.
No.
Designation
Min
Std.
Max
Step
Unit
209
Lift height where the travel speed is limited
0
0
15000
100
mm
The parameter specifies the lift height at which speed reduction is activated. Speed reduction is controlled by parameter 210.
No.
Designation
Min
Std.
Max
Step
Unit
210
Setting travel speed reduction above a certain lift height
0
140
140
5
0.1 km/ h
The parameter indicates the travel speed to be applied when the forks are over a specified height. The lift height at which speed reduction is activated is controlled by parameter 209.
No.
Designation
Min
Std.
Max
Step
Unit
211
Reach carriage position when travel speed is limited
0
0
840
10
mm
The parameter indicates at which length of the reach movement speed reduction is activated. Speed reduction is controlled by parameter 212.
No.
Designation
Min
Std.
Max
Step
Unit
212
Setting travel speed reduction above a certain reach length
0
140
140
5
0.1 km/ h
The parameter indicates the travel speed to be applied when the reach carriage is extended beyond a specified length. The reach movement length at which speed reduction is activated is controlled by parameter 211.
4.1.2.2.1.3 Fork laser Factory parameter 1132 is set to activate the fork laser. The fork laser is activated over the lift height (parameter 217) and when the forks are horizontal (parameter 218).
No.
Designation
Min
Std.
Max
Step
Unit
217
Lift height at which the fork laser is activated
0
2300
15000
100
mm
The parameter indicates the lift height at which the fork laser should come on. The function is activated with factory parameter 1132, page 4 - 000.
No.
Designation
Min
Std.
Max
Step
Unit
218
Adjustment of permitted degree of deviation from 0° (tilt) at which the laser is activated
0
10
100
1
0.1°
This parameter handles the specified degree of deviation from 0° tilt at which the fork laser will be activated. The default value is 10, which means that the fork laser is activated at 1° down and 1° up.
4.1.2.2.1.4 Blue/red warning lamp Factory parameter 1131 is set to activate the warning lamp. Control of the warning lamp in the drive wheel direction (parameters 219-222) and the warning lamp in the fork direction (parameters 224-227).
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