Service Manual

en

7FBRE12, 12C, 14, 14C, 16, 16C, 20, 20C, 25, 25C
Valid from serial number: 423260-

Order number: 201004-040

Issued: 2005-07-01 ITS

©TOYOTA Industrial Equipment Europe SARL Ancenis, France

 Issue date Resp. Changes
1999-11-01 ITS New issue
2000-04-15 ITS Update
2001-02-01 ITS Update
2001-03-12 ITS Update
2002-12-02 ITS Update
2003-02-06 ITS Update
2005-07-01 ITS Update: M2.1, M2.2, M4.1, M4.2, P2, P4, 0630, 3550.1, 3550.2,
5000.1, 5000.2, 5110, 5710.1 (Parameter 21), 5710.2 (Parameter
21), 6620, 7100.1, 7100.3, 8700, 9390, 9420

This manual covers following truck models:

T-code Model Serial number

403 7FBRE16, 1-3 423289-
404 7FBRE16C, 1-3 423289-
405 7FBRE20, 1-2 423289-
406 7FBRE20C, 1-2 423289-
407 7FBRE25, 1-2 423325-
408 7FBRE25C, 1-2 423325-
689 7FBRE12, 1-3 423260-
690 7FBRE12C, 1-3 423260-
691 7FBRE14, 1-3 423260-
692 7FBRE14C, 1-3 423260-

© TIEE SARL Servicemanual 7FBRE Godkänd av: K-G Andersson

 Table of contents
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

1- Table of contents
1- Table of contents ................................................................................. 1-1

2- General product information – M2.1 .................................................. 2-1

2.1 Presentation of TOYOTA’s reach trucks ........................................ 2-1
2.2 Application areas for TOYOTA’s reach trucks................................ 2-1
2.3 Prohibited applications for TOYOTA’s reach trucks ....................... 2-1
2.4 Truck data ...................................................................................... 2-2
2.5 Truck dimensions........................................................................... 2-3
2.6 Identification plate, truck ................................................................ 2-4
2.7 Capacity plate ................................................................................ 2-4
2.8 Modification plate ........................................................................... 2-5
2.9 Identification plate, mast ................................................................ 2-5
2.10 Main components........................................................................... 2-6
2.11 Warning and information plates and symbols ................................ 2-8

3- General product information – M2.2 .................................................. 3-1

3.1 Presentation of TOYOTA’s reach trucks ........................................ 3-1
3.2 Application areas for TOYOTA’s reach trucks................................ 3-1
3.3 Prohibited applications for TOYOTA’s reach trucks ....................... 3-1
3.4 Truck data ...................................................................................... 3-2
3.5 Truck dimensions........................................................................... 3-3
3.6 Identification plate, truck ................................................................ 3-4
3.7 Capacity plate ................................................................................ 3-4
3.8 Modification plate ........................................................................... 3-5
3.9 Identification plate, mast ................................................................ 3-5
3.10 Main components........................................................................... 3-6
3.11 Warning and information plates and symbols ................................ 3-8

4- Technical data – M4.1 ......................................................................... 4-1

5- Technical data – M4.2 ......................................................................... 5-1

6- Introduction, maintenance – P1 ......................................................... 6-1

6.1 Safety regulations with maintenance work ..................................... 6-1
6.2 Cleaning and washing.................................................................... 6-2
6.2.1 External cleaning ............................................................. 6-3
6.2.2 Cleaning the motor compartment .................................... 6-3
6.2.3 Electrical components ..................................................... 6-3
6.3 Safe lifting ...................................................................................... 6-4

7- Preventive Maintenance – P2.1 .......................................................... 7-1

7.1 Maintenance chart ......................................................................... 7-1

8- Preventive Maintenance – P2.2 .......................................................... 8-1

8.1 Maintenance chart ......................................................................... 8-1

© TIEE SARL Service Manual 7FBRE 1- 1

 Table of contents
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

9- Oil and grease specification – P3 ...................................................... 9-1

10- Tools –P4 ......................................................................................... 10-1

10.1 Super Seal ................................................................................... 10-1
10.1.1 AMP connector .............................................................. 10-2
10.1.2 AMP microtimer ............................................................. 10-3
10.1.3 Diverse tools .................................................................. 10-4

11- Cab heating/ventilation – 0630 ....................................................... 11-1

11.1 Air conditioning unit...................................................................... 11-1
11.1.1 Ventilation ...................................................................... 11-1
11.1.2 Main heater .................................................................... 11-1
11.1.3 Auxiliary heater .............................................................. 11-1
11.1.4 Temperature .................................................................. 11-1
11.1.5 Air direction .................................................................... 11-2
11.1.6 Fuses ............................................................................. 11-2
11.1.7 Air filter .......................................................................... 11-2
11.1.8 Emergency exit (12) ...................................................... 11-3
11.1.9 Lighting .......................................................................... 11-3

12- Driver Protection – 0840 ................................................................. 12-1

12.1 General ........................................................................................ 12-1
12.2 Tilt Stops ...................................................................................... 12-2
12.2.1 Inspection and Adjustment ............................................ 12-2
12.2.2 Removing the tilt stops .................................................. 12-3

13- Electric pump motor – 1710.1 ......................................................... 13-1

13.1 General ........................................................................................ 13-1
13.2 Dismantling the pump motor ........................................................ 13-1
13.3 Dismantling and assembling the pump motor .............................. 13-2
13.3.1 Dismantling .................................................................... 13-2
13.3.2 Assembling .................................................................... 13-3
13.4 Bearing replacement.................................................................... 13-4
13.4.1 Dismantling .................................................................... 13-4
13.4.2 Assembling .................................................................... 13-5
13.5 Installation instructions for external temperature sensor.............. 13-6

14- Electric Pump Motor – 1710.2 ......................................................... 14-1

14.1 General ........................................................................................ 14-1
14.2 Dismantling the Pump Motor........................................................ 14-1
14.2.1 Connection .................................................................... 14-1
14.3 Removing and Replacing the Pump Motor................................... 14-2
14.3.1 Dismantling .................................................................... 14-2
14.3.2 Assembling .................................................................... 14-3
14.4 Bearing replacement.................................................................... 14-3
14.4.1 Dismantling (D side) ...................................................... 14-4
14.4.2 Assembling .................................................................... 14-4
14.4.3 Dismantling (N side) ...................................................... 14-4
14.4.4 Assembling (N side) ...................................................... 14-5
14.4.5 Carbon brushes and brush holders ............................... 14-5

1- 2 Service Manual 7FBRE © TIEE SARL

 Table of contents
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

15- Electric Steering Motor – 1730 ....................................................... 15-1

15.1 General ........................................................................................ 15-1
15.2 Replacing the Steering Motor....................................................... 15-1
15.2.1 Dismantling .................................................................... 15-1
15.2.2 Assembling .................................................................... 15-1
15.3 Removing and replacing the carbon brushes............................... 15-2

16- Electric drive motor – 1760 ............................................................. 16-1

16.1 General ........................................................................................ 16-1
16.2 Dismantling the drive motor ......................................................... 16-1
16.3 Dismantling and assembling the drive motor ............................... 16-2
16.3.1 Dismantling the drive motor ........................................... 16-2
16.3.2 Assembling the drive motor ........................................... 16-3
16.4 Bearing replacement.................................................................... 16-4
16.4.1 Dismantling .................................................................... 16-4
16.4.2 Assembling .................................................................... 16-5
16.5 Installation instructions for external temperature sensor.............. 16-6

17- Mechanical drive gear unit – 2550 ................................................. 17-1

17.1 General ........................................................................................ 17-1
17.2 Components/data for the drive assembly/transmission................ 17-1
17.2.1 Component placement .................................................. 17-2
17.2.2 Technical data ............................................................... 17-3
17.2.3 Dismantling the transmission ......................................... 17-4
17.3 Replacing the drive motor/drive transmission .............................. 17-5
17.3.1 Dismantling the drive motor ........................................... 17-5
17.3.2 Dismantling the drive transmission ................................ 17-6
17.3.3 Assembling the transmission ......................................... 17-6
17.3.4 Installing the drive motor ............................................... 17-7
17.4 Checking/replacing the oil ............................................................ 17-8
17.4.1 Checking/refilling the oil ................................................. 17-8
17.4.2 Changing the Oil ............................................................ 17-8
17.5 Repairs ........................................................................................ 17-9
17.5.1 Replacing the drive shaft sealing ring ............................ 17-9
17.5.2 Leakage from the upper cover ..................................... 17-11
17.5.3 Leakage from the lower cover ..................................... 17-11
17.5.4 Replacing wheel bolts .................................................. 17-12

18- Travel brake system – 3100.1 ......................................................... 18-1

18.1 General ........................................................................................ 18-1
18.2 Operating description................................................................... 18-1
18.2.1 Releasing the accelerator .............................................. 18-2
18.2.2 Travel direction selector ................................................ 18-2
18.2.3 Pressing down the brake pedal ..................................... 18-2
18.2.4 Parking brake ................................................................ 18-2
18.2.5 Emergency braking ........................................................ 18-3
18.3 Electromechanical disc brake, drive motor................................... 18-4
18.3.1 Assembling .................................................................... 18-4
18.3.2 Dismantling .................................................................... 18-5
18.3.3 Inspection ...................................................................... 18-5
18.3.4 Assembling .................................................................... 18-5

© TIEE SARL Service Manual 7FBRE 1- 3

 Table of contents
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

18.4 Maintenance ................................................................................ 18-5

18.4.1 Adjusting the play .......................................................... 18-6
18.4.2 Wear .............................................................................. 18-6
18.4.3 Check the braking force ................................................. 18-7
18.5 Multiple disc brake, support arm .................................................. 18-8
18.5.1 Assembling .................................................................... 18-8
18.5.2 Dismantling .................................................................... 18-9
18.5.3 Inspection .................................................................... 18-10
18.5.4 Assembling .................................................................. 18-10
18.6 Maintenance .............................................................................. 18-10
18.6.1 Adjusting the play ........................................................ 18-11

19- Travel brake system – 3100.2 ......................................................... 19-1

19.1 General ........................................................................................ 19-1
19.2 Operating description................................................................... 19-1
19.2.1 Releasing the accelerator .............................................. 19-1
19.2.2 Travel direction selector ................................................ 19-2
19.2.3 Pressing down the brake pedal ..................................... 19-2
19.2.4 Parking brake ................................................................ 19-3
19.2.5 Emergency brake .......................................................... 19-3
19.3 Electromechanical disc brake, drive motor .................................. 19-3
19.3.1 Assembling .................................................................... 19-3
19.3.2 Dismantling .................................................................... 19-4
19.3.3 Inspection ...................................................................... 19-4
19.3.4 Assembling .................................................................... 19-5
19.4 Maintenance ................................................................................ 19-5
19.4.1 Adjusting the play .......................................................... 19-5
19.4.2 Wear .............................................................................. 19-6
19.4.3 Check the braking force ................................................. 19-6

20- Drive wheel – 3530 .......................................................................... 20-1

20.1 General ........................................................................................ 20-1
20.2 Dismantling the drive wheel ......................................................... 20-1
20.3 Assembling the drive wheel ......................................................... 20-1

21- Fork/support arm wheel – 3550.1 ................................................... 21-1

21.1 General ........................................................................................ 21-1
21.2 Dismantling the wheel .................................................................. 21-2
21.3 Assembling the wheel .................................................................. 21-3
21.4 Dismantling/assembling the wheel bearings ................................ 21-5
21.4.1 265 mm wheel and 300 mm wheels without brakes. ..... 21-5
21.4.2 300 mm wheel with brake and 350 mm wheel .............. 21-6

22- Fork/support arm wheel – 3550.2 ................................................... 22-1

22.1 General ........................................................................................ 22-1
22.2 Dismantling the wheel .................................................................. 22-1
22.3 Assembling the drive wheel ......................................................... 22-2
22.4 Dismantling the wheel bearing ..................................................... 22-2
22.5 Assembling the wheel bearing ..................................................... 22-2

1- 4 Service Manual 7FBRE © TIEE SARL

 Table of contents
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

23- Mechanical steering system – 4100 ............................................... 23-1

23.1 General ........................................................................................ 23-1
23.2 Replacing the steering generator ................................................. 23-1
23.2.1 Dismantling .................................................................... 23-1
23.2.2 Assembling .................................................................... 23-1

24- Steering angle sensor – 4350 ......................................................... 24-1

24.1 General ........................................................................................ 24-1
24.2 Procedure .................................................................................... 24-1
24.2.1 Adjustment of directional sensor ................................... 24-2
24.2.2 Adjustment of the steering angle sensor ....................... 24-3

25- Electrical system – 5000.1 .............................................................. 25-1

25.1 General ........................................................................................ 25-1
25.1.1 Electrical panel .............................................................. 25-1
25.2 List of symbols ............................................................................. 25-2
25.3 Electrical diagram ........................................................................ 25-5
25.3.1 List of components ...................................................... 25-16
25.3.2 Diagram 1 .................................................................... 25-20
25.3.3 Diagram 2 .................................................................... 25-20
25.3.4 Diagram 3 .................................................................... 25-21
25.3.5 Diagram 4 .................................................................... 25-21
25.3.6 Diagram 5 .................................................................... 25-22
25.3.7 Diagram 6 .................................................................... 25-23
25.3.8 Diagram 7 .................................................................... 25-23
25.3.9 Diagram 8 .................................................................... 25-24
25.4 Description of function................................................................ 25-25
25.4.1 Ignition key in the 0 position ........................................ 25-25
25.4.2 Ignition key in 1 position .............................................. 25-26
25.4.3 Selection of travel direction ......................................... 25-27
25.4.4 Driving ......................................................................... 25-28
25.4.5 Steering ....................................................................... 25-28
25.4.6 Steering wheel indicator .............................................. 25-29
25.4.7 Braking ........................................................................ 25-29
25.4.8 Fork lift ......................................................................... 25-30
25.4.9 Maximum height .......................................................... 25-30
25.4.10 Maximum height .......................................................... 25-31
25.4.11 Fork lowering ............................................................... 25-31
25.4.12 Mast out/in ................................................................... 25-31
25.4.13 Fork tilt up/down .......................................................... 25-32
25.4.14 Hydraulic function 4 ..................................................... 25-32
25.4.15 Hydraulic function 5 ..................................................... 25-32
25.4.16 Height indication .......................................................... 25-32
25.4.17 Height selection ........................................................... 25-33
25.4.18 Operator - ID ................................................................ 25-33

26- 14Electrical System – 5000.2 .......................................................... 26-1

26.1 General ........................................................................................ 26-1
26.1.1 Electrical Panel .............................................................. 26-1
26.2 Symbol list.................................................................................... 26-2
26.3 Electrical diagram ........................................................................ 26-4
26.3.1 Component List ........................................................... 26-14
26.3.2 Figure 1 ....................................................................... 26-18
26.3.3 Figure 2 ....................................................................... 26-18
26.3.4 Figure 3 ....................................................................... 26-19
© TIEE SARL Service Manual 7FBRE 1- 5
 Table of contents
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

26.3.5 Figure 4 ....................................................................... 26-19

26.3.6 Figure 5 ....................................................................... 26-20
26.3.7 Figure 6 ....................................................................... 26-21
26.3.8 Figure 7 ....................................................................... 26-21
26.3.9 Figure 8 ....................................................................... 26-22
26.4 Functional Description ............................................................... 26-22
26.4.1 Key in Position 0 .......................................................... 26-23
26.4.2 Key in Position I ........................................................... 26-23
26.4.3 Choice of travel direction ............................................. 26-24
26.4.4 Driving ......................................................................... 26-25
26.4.5 Steering ....................................................................... 26-25
26.4.6 Steering wheel indicator .............................................. 26-26
26.4.7 Braking ........................................................................ 26-26
26.4.8 Fork lifting .................................................................... 26-27
26.4.9 Maximum Height .......................................................... 26-27
26.4.10 Fork lowering ............................................................... 26-27
26.4.11 Mast out/in ................................................................... 26-28
26.4.12 Fork tilt up/down .......................................................... 26-28
26.4.13 Hydraulic function 4 ..................................................... 26-28
26.4.14 Driver identification ...................................................... 26-29

27- Battery – 5110 .................................................................................. 27-1

27.1 Battery dimensions ...................................................................... 27-1
27.2 Setting the battery parameters on 7FBRE trucks fitted with
Hawker Evolution gel batteries..................................................... 27-2
27.2.1 General .......................................................................... 27-2
27.2.2 Battery recommendation ............................................... 27-2
27.2.3 Battery installation ......................................................... 27-2
27.2.4 Recommended parameter setting for ventilation
regulated batteries ......................................................... 27-3
27.2.5 Instructions for verifying the parameter setting .............. 27-3

28- Transistor panel – 5460 .................................................................. 28-1

28.1 Frequency converter .................................................................... 28-1
28.1.1 General description ....................................................... 28-1
28.1.2 Terminal connections and pole bolts ............................. 28-2
28.1.3 Technical Data ............................................................... 28-3
28.1.4 Installation of New Frequency Converter on Truck ....... 28-3
28.1.5 Programming ................................................................. 28-3

29- Power electronics panel – 5660 ..................................................... 29-1

29.1 General description...................................................................... 29-1
29.1.1 Terminal connections and pole bolts ............................. 29-2
29.1.2 Technical Data ............................................................... 29-3
29.1.3 Installing a new transistor panel .................................... 29-3
29.2 Parameter .................................................................................... 29-3
29.3 Diagnostics and trouble shooting ................................................. 29-4
29.3.1 Displaying error codes, logging errors ........................... 29-4
29.3.2 Error codes, trouble shooting ........................................ 29-5
29.3.3 Resetting an error .......................................................... 29-5
29.4 Maintenance ................................................................................ 29-6
29.4.1 Safety ............................................................................ 29-6
29.4.2 Cleaning ........................................................................ 29-6

1- 6 Service Manual 7FBRE © TIEE SARL

 Table of contents
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

29.5 Hand terminal 1307...................................................................... 29-7

29.6 Using the hand terminal ............................................................... 29-9
29.6.1 Check and adjust parameters ...................................... 29-10
29.6.2 Special program mode ................................................ 29-11
29.6.3 Using TEST mode ....................................................... 29-11
29.6.4 Using DIAGNOSTICS MODE ...................................... 29-11
29.6.5 SPECIAL DIAGNOSTICS MODE ................................ 29-12

30- Electronic card – 5710.1 ................................................................. 30-1

30.1 General description...................................................................... 30-1
30.2 Terminal connections and voltages on A5 ................................... 30-2
30.2.1 10X ................................................................................ 30-2
30.2.2 20X ................................................................................ 30-3
30.2.3 30X ................................................................................ 30-3
30.2.4 40X ................................................................................ 30-4
30.2.5 50X ................................................................................ 30-4
30.2.6 60X ................................................................................ 30-5
30.2.7 70X ................................................................................ 30-5
30.2.8 80X ................................................................................ 30-6
30.2.9 90X ................................................................................ 30-6
30.3 Adjusting the lowering speed ....................................................... 30-7
30.4 Show ............................................................................................ 30-7
30.5 Programming ............................................................................... 30-8
30.5.1 Clock .............................................................................. 30-8
30.5.2 Driver parameters (1–7) ................................................ 30-9
30.6 Warning Codes ............................................................................ 30-9
30.7 Error Codes................................................................................ 30-10
30.7.1 Error mode ................................................................... 30-10
30.7.2 Safety logic .................................................................. 30-10
30.7.3 Warning Codes without registration ............................. 30-11
30.8 Warning codes with registration ................................................. 30-32
30.9 Error Codes................................................................................ 30-49
30.9.1 Error codes with registration ........................................ 30-50
30.10 Operating Time .......................................................................... 30-81
30.11 Parameter Settings .................................................................... 30-81
30.11.1 Parameter 1 ................................................................. 30-84
30.11.2 Parameter 2 ................................................................. 30-84
30.11.3 Parameter 3 ................................................................. 30-84
30.11.4 Parameter 4 ................................................................. 30-84
30.11.5 Parameter 5 ................................................................. 30-85
30.11.6 Parameter 10 ............................................................... 30-85
30.11.7 Parameter 11 ............................................................... 30-85
30.11.8 Parameter 12 ............................................................... 30-85
30.11.9 Parameters 13 to 14 .................................................... 30-85
30.11.10 Parameters 15 and 16 ............................................... 30-85
30.11.11 Parameters 17 and 18 ............................................... 30-86
30.11.12 Parameter 19 ............................................................. 30-86
30.11.13 Parameter 20 ............................................................. 30-86
30.11.14 Parameter 21 ............................................................. 30-87
30.11.15 Parameter 22 ............................................................. 30-88
30.11.16 Parameter 23 ............................................................. 30-88
30.11.17 Parameter 24 ............................................................. 30-88
30.11.18 Parameter 25 ............................................................. 30-88
30.11.19 Parameter 27 ............................................................. 30-88

© TIEE SARL Service Manual 7FBRE 1- 7

 Table of contents
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

30.11.20 Parameter 28 ............................................................. 30-88

30.11.21 Parameter 29 ............................................................. 30-88
30.11.22 Parameter 37 ............................................................. 30-89
30.11.23 Parameter 38 ............................................................. 30-89
30.11.24 Parameter 39 ............................................................. 30-90
30.11.25 Parameters 40 to 42 .................................................. 30-90
30.11.26 Other parameters ....................................................... 30-90
30.11.27 Installing a new card in the truck ............................... 30-91

31- Electronic card – 5710.2 ................................................................. 31-1

31.1 General description...................................................................... 31-1
31.2 Terminal connections and voltages on A5 ................................... 31-2
31.2.1 10X ................................................................................ 31-2
31.2.2 20X ................................................................................ 31-3
31.2.3 30X ................................................................................ 31-3
31.2.4 40X ................................................................................ 31-4
31.2.5 50X ................................................................................ 31-4
31.2.6 60X ................................................................................ 31-5
31.2.7 70X ................................................................................ 31-5
31.2.8 80X ................................................................................ 31-6
31.2.9 90X ................................................................................ 31-6
31.3 Adjusting the lowering speed ....................................................... 31-7
31.4 Show............................................................................................ 31-7
31.5 Programming ............................................................................... 31-8
31.5.1 Clock .............................................................................. 31-8
31.5.2 Driver parameters (1–7) ................................................ 31-8
31.6 Warning Codes ............................................................................ 31-9
31.7 Error Codes................................................................................ 31-10
31.7.1 Error mode ................................................................... 31-10
31.7.2 Safety logic .................................................................. 31-10
31.7.3 Warning Codes without registration ............................. 31-11
31.8 Warning codes with registration ................................................. 31-17
31.9 Error Codes................................................................................ 31-21
31.9.1 Error codes with registration ........................................ 31-22
31.10 Running Time............................................................................. 31-32
31.11 Parameter Settings .................................................................... 31-32
31.11.1 Parameter 1 ................................................................. 31-34
31.11.2 Parameter 2 ................................................................. 31-34
31.11.3 Parameter 3 ................................................................. 31-34
31.11.4 Parameter 4 ................................................................. 31-34
31.11.5 Parameter 5 ................................................................. 31-35
31.11.6 Parameter 10 ............................................................... 31-35
31.11.7 Parameter 11 ............................................................... 31-35
31.11.8 Parameter 12 ............................................................... 31-35
31.11.9 Parameters 13 ............................................................. 31-35
31.11.10 Parameters 15 ........................................................... 31-35
31.11.11 Parameter 20 ............................................................. 31-35
31.11.12 Parameter 21 ............................................................. 31-36
31.11.13 Parameter 23 ............................................................. 31-37
31.11.14 Parameter 24 ............................................................. 31-37
31.11.15 Parameter 25 ............................................................. 31-37
31.11.16 Parameter 26 ............................................................. 31-37
31.11.17 Parameter 27 ............................................................. 31-37
31.11.18 Parameter 28 ............................................................. 31-37
31.11.19 Parameter 38 ............................................................. 31-37
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Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

31.11.20 Parameter 39 ............................................................. 31-38

31.11.21 Parameters 40 to 42 .................................................. 31-38
31.11.22 Other parameters ....................................................... 31-38
31.11.23 Installing a new card in the truck ................................ 31-39

32- Hydraulic system – 6000.1 .............................................................. 32-1

32.1 General ........................................................................................ 32-1
32.2 Symbols ....................................................................................... 32-1
32.2.1 Hydraulic chart 1 (2) ...................................................... 32-3
32.2.2 Hydraulic chart 2 (2) ...................................................... 32-4
32.3 List of symbols ............................................................................. 32-5
32.3.1 Component placement 1 (2) .......................................... 32-7
32.3.2 Component placement 2 (2) .......................................... 32-8
32.4 Adjusting fork lowering ................................................................. 32-9
32.5 Setting the maximum lifting capacity .......................................... 32-10

33- Hydraulic system – 6000.2 .............................................................. 33-1

33.1 General ........................................................................................ 33-1
33.2 Symbols ....................................................................................... 33-1
33.2.1 Hydraulic chart 1 (3) ...................................................... 33-3
33.2.2 Hydraulic chart 2 (3) ...................................................... 33-4
33.2.3 Hydraulic chart 3 (3) ...................................................... 33-5
33.3 List of symbols ............................................................................. 33-6
33.3.1 Component placement 1 (2) .......................................... 33-7
33.3.2 Component placement 2 (2) .......................................... 33-8
33.4 Adjusting fork lowering ................................................................. 33-9
33.5 Setting the max lifting capacity................................................... 33-10

34- Hydraulic pump – 6140.1 ................................................................ 34-1

34.1 General ........................................................................................ 34-1
34.2 Replacing the hydraulic pump...................................................... 34-1
34.2.1 Dismantling .................................................................... 34-1
34.2.2 Assembling .................................................................... 34-2

35- Hydraulic pump – 6140.2 ................................................................ 35-1

35.1 General ........................................................................................ 35-1
35.2 Replacing the hydraulic pump...................................................... 35-1
35.2.1 Dismantling .................................................................... 35-1
35.2.2 Assembling .................................................................... 35-2

36- Mast mounted hose reel – 6370 ..................................................... 36-1

36.1 General ........................................................................................ 36-1
36.2 Assembling .................................................................................. 36-1
36.3 Check after assembly................................................................... 36-2

37- Hydraulic cylinder – 6600 ............................................................... 37-1

37.1 General ........................................................................................ 37-1
37.2 Duplex mast ................................................................................. 37-1
37.2.1 Dismantling the lift cylinders from the mast ................... 37-1
37.2.2 Dismantling the cylinder ................................................ 37-2
37.2.3 Dismantling the rod seal, guide ring, guide ring holder
and locking ring in lift cylinder ........................................ 37-2

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T-code Valid from serial number Date Order number
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37.2.4 Assembling the locking ring, rod seal, guide ring and
guide ring holder in the lift cylinder ................................ 37-3
37.2.5 Dismantling and assembling the lower brake valve ....... 37-3
37.2.6 Assembling the cylinder ................................................. 37-3
37.2.7 Assembling the cylinder in the mast .............................. 37-4
37.3 Triplex mast ................................................................................. 37-5
37.3.1 Dismantling the free lift cylinder from the mast .............. 37-5
37.3.2 Dismantling the mast lift cylinders from the mast .......... 37-5
37.4 Cylinder seals .............................................................................. 37-5
37.5 Replacing wear parts in the cylinder ............................................ 37-6
37.5.1 Securing ........................................................................ 37-6
37.5.2 Dismantling the cylinder ................................................ 37-6
37.5.3 Replacing the lower support ring ................................... 37-6
37.5.4 Replacing the O-ring on the top sleeve ......................... 37-7
37.5.5 Replacing the internal wear parts in the top sleeve ....... 37-7
37.5.6 Assembling the cylinder ................................................. 37-8
37.5.7 Assembling the free lift cylinder in the mast .................. 37-8
37.5.8 Assembling the mast lift cylinder ................................... 37-9

38- Main lift cylinder – 6610 .................................................................. 38-1

38.1 General ........................................................................................ 38-1
38.2 Tools ............................................................................................ 38-1
38.3 Dismantling the lift cylinders from the mast .................................. 38-2
38.4 Dismantling the cylinder ............................................................... 38-2
38.4.1 Dismantling the rod seal, guide ring, guide ring holder
and locking ring in lift cylinder ........................................ 38-3
38.4.2 Fit the locking ring, rod seal, guide ring and guide ring
holder in the lift cylinder ................................................. 38-3
38.4.3 Dismantling and assembling the hose rupture valve ..... 38-3
38.5 Assembling the cylinder ............................................................... 38-4
38.5.1 Assembling the cylinder in the mast .............................. 38-4

39- Free lift cylinder – 6620 ................................................................... 39-1

39.1 General ........................................................................................ 39-1
39.2 Tools ............................................................................................ 39-1
39.3 Dismantling .................................................................................. 39-2
39.3.1 Dismantling the cylinder ................................................ 39-3
39.4 Dismantle the rod seal and the support ring................................. 39-3
39.4.1 Assembling the rod seal and the support ring. .............. 39-3
39.5 Dismantling the ram ..................................................................... 39-4
39.5.1 Assembling the ram in the free lift cylinder .................... 39-4
39.6 Dismantling and assembling the hose rupture valve .................... 39-4
39.7 Assembling the cylinder ............................................................... 39-5
39.8 Assembling .................................................................................. 39-5

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40- Reach cylinder – 6650.1 .................................................................. 40-1

40.1 General ........................................................................................ 40-1
40.2 Assembling and dismantling the reach cylinder ........................... 40-1
40.2.1 Dismantling .................................................................... 40-1
40.2.2 Dismantling the cylinder ................................................ 40-2
40.2.3 Dismantle the rod seal and the support ring. ................. 40-2
40.2.4 Assembling the rod seal and the support ring. .............. 40-2
40.2.5 Dismantling the ram ....................................................... 40-2
40.2.6 Assembling the ram ....................................................... 40-3
40.2.7 Assembling the cylinder ................................................. 40-3
40.3 Assembling .................................................................................. 40-3

41- Reach cylinder – 6650.2 .................................................................. 41-1

41.1 General ........................................................................................ 41-1
41.2 Assembling and dismantling the reach cylinder ........................... 41-1
41.2.1 Dismantling the cylinder ................................................ 41-2
41.2.2 Dismantling the rod ........................................................ 41-3
41.2.3 Dismantle the to sleeve seals ........................................ 41-3
41.2.4 Assembling the top sleeve ............................................. 41-3
41.2.5 Fit the ram seal .............................................................. 41-3
41.2.6 Dismantling the rod ........................................................ 41-3
41.2.7 Assembling the cylinder ................................................. 41-4
41.3 Assembling .................................................................................. 41-4

42- Tilt cylinder – 6660.1 ....................................................................... 42-1

42.1 General ........................................................................................ 42-1
42.2 Mast with valve on the fork carriage ............................................. 42-2
42.2.1 Dismantling the fork carriage ......................................... 42-2
42.2.2 Dismantling the cylinder ................................................ 42-3
42.2.3 Dismantling the rod seal ................................................ 42-3
42.2.4 Dismantling the ram ....................................................... 42-3
42.2.5 Assembling the ram ....................................................... 42-3
42.2.6 Assembling the rod seal ................................................ 42-4
42.2.7 Assembling the cylinder ................................................. 42-4
42.2.8 Assembling the fork carriage ......................................... 42-4
42.3 Mast without valve on the fork carriage ........................................ 42-5
42.3.1 Dismantling the fork carriage ......................................... 42-5
42.3.2 Dismantling the cylinder ................................................ 42-6
42.3.3 Dismantling the rod seal ................................................ 42-6
42.3.4 Dismantling the ram ....................................................... 42-6
42.3.5 Assembling the ram ....................................................... 42-6
42.3.6 Assembling the rod seal ................................................ 42-7
42.3.7 Assembling the cylinder ................................................. 42-7
42.3.8 Assembling the fork carriage ......................................... 42-7

43- Tilt cylinder – 6660.2 ....................................................................... 43-1

43.1 General ........................................................................................ 43-1
43.2 Assembling and dismantling the tilt cylinder................................. 43-1
43.2.1 Dismantling the cylinder ................................................ 43-2
43.2.2 Dismantling the rod ........................................................ 43-3
43.2.3 Dismantling the ram seals ............................................. 43-3
43.2.4 Dismantle the top sleeve seals ...................................... 43-3
43.2.5 Assembling the top sleeve ............................................. 43-3

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T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

43.2.6 Assembling the ram seal ............................................... 43-3

43.2.7 Dismantling the rod ........................................................ 43-3
43.2.8 Assembling the cylinder ................................................. 43-4
43.3 Assembling .................................................................................. 43-4

44- Main mast – 7100.1 .......................................................................... 44-1

44.1 General ........................................................................................ 44-1
44.2 List of tools................................................................................... 44-1
44.3 Transporting the truck .................................................................. 44-2
44.4 Assembling the mast.................................................................... 44-3
44.5 Dismantling the mast ................................................................... 44-8
44.6 Adjust the play ............................................................................. 44-9
44.6.1 Adjusting the mast play ............................................... 44-12
44.6.2 Radial play ................................................................... 44-13
44.7 Assembling ................................................................................ 44-13

45- Main mast – 7100.2 .......................................................................... 45-1

45.1 General ........................................................................................ 45-1
45.2 List of tools................................................................................... 45-1
45.3 Transporting the truck .................................................................. 45-2
45.4 Assembling the mast.................................................................... 45-3
45.5 Dismantling the mast ................................................................... 45-7
45.5.1 Chains, cylinders and hoses .......................................... 45-8
45.5.2 Dismantling the runner .................................................. 45-9
45.5.3 Inner guide ................................................................... 45-10
45.6 Assembling Duplex mast ........................................................... 45-13
45.6.1 Assembly-shimming the side play ............................... 45-13
45.6.2 Inner guide ................................................................... 45-14
45.6.3 Chains, cylinders and hoses ........................................ 45-14
45.6.4 Fork carriage ............................................................... 45-15
45.6.5 Docking the mast in the truck ...................................... 45-15
45.7 Assembling the Triplex mast ...................................................... 45-15
45.7.1 Assembly-shimming the side play ............................... 45-15
45.7.2 Inner guide ................................................................... 45-16
45.7.3 Chains, cylinders and hoses ........................................ 45-16
45.7.4 Fork carriage ............................................................... 45-17

46- Main mast – 7100.3 .......................................................................... 46-1

46.1 General ........................................................................................ 46-1
46.2 List of tools................................................................................... 46-1
46.3 Transporting the truck .................................................................. 46-2
46.4 Assembling the mast.................................................................... 46-3
46.5 Dismantling the mast ................................................................... 46-7
46.6 Adjust the play ............................................................................. 46-8
46.6.1 Adjusting the mast play. .............................................. 46-11
46.6.2 Radial play ................................................................... 46-12
46.7 Assembling ................................................................................ 46-12

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47- Main lift chain system – 7120 ......................................................... 47-1

47.1 General ........................................................................................ 47-1
47.2 Checking the chain setting ........................................................... 47-1
47.3 Chain inspection .......................................................................... 47-1
47.3.1 Noise ............................................................................. 47-1
47.3.2 Surface rust ................................................................... 47-1
47.3.3 Rusty links ..................................................................... 47-1
47.3.4 Stiff links ........................................................................ 47-2
47.3.5 Bolt rotation ................................................................... 47-2
47.3.6 Loose bolts .................................................................... 47-2
47.3.7 Outline wear .................................................................. 47-3
47.3.8 Stretching ...................................................................... 47-4
47.3.9 Damage ......................................................................... 47-4
47.3.10 Damaged discs .............................................................. 47-5
47.3.11 Damaged bolts .............................................................. 47-5
47.3.12 Dirty chain ...................................................................... 47-5
47.4 Cleaning....................................................................................... 47-5
47.5 Lubrication ................................................................................... 47-6

48- Battery charger – 8340 .................................................................... 48-1

48.1 General ........................................................................................ 48-1
48.2 Installation.................................................................................... 48-1
48.3 Functional description .................................................................. 48-2
48.3.1 Display functions ........................................................... 48-2
48.3.2 Charging process .......................................................... 48-2
48.3.3 Shutdown conditions ..................................................... 48-3
48.3.4 Delayed power on and charging .................................... 48-3
48.3.5 Extra charging ............................................................... 48-3
48.3.6 Equalised charging ........................................................ 48-3
48.3.7 Current and voltage characteristics ............................... 48-3
48.3.8 Safety shutdowns .......................................................... 48-4
48.3.9 Display and keyboard .................................................... 48-4
48.3.10 Acid circulation ............................................................ 48-11
48.4 Service and maintenance........................................................... 48-12
48.4.1 Basic programming, code 30 ....................................... 48-12
48.4.2 Resetting the statistics, code 31 .................................. 48-12
48.4.3 Calibrating the measurement value ............................. 48-13
48.4.4 Calibrating and programming API ............................... 48-14
48.4.5 Adjusting the charging characteristics ......................... 48-15
48.4.6 Trouble shooting .......................................................... 48-15
48.4.7 Trouble shooting acid circulation ................................. 48-17
48.4.8 Service measures ........................................................ 48-17
48.4.9 Preventive maintenance .............................................. 48-19

49- Control/computer equipment – 8700 ............................................. 49-1

49.1 General ........................................................................................ 49-1
49.2 Connection................................................................................... 49-1
49.3 Layout .......................................................................................... 49-2
49.3.1 Main window .................................................................. 49-2
49.3.2 Nodes ............................................................................ 49-2
49.3.3 Icons .............................................................................. 49-3
49.3.4 Tool buttons and menu list ............................................ 49-4
49.3.5 Information window ........................................................ 49-4
49.3.6 Status row ...................................................................... 49-4

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T-code Valid from serial number Date Order number
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49.4 Function for connection............................................................... 49-5

49.5 Function for disconnecting ........................................................... 49-5
49.6 Function for program downloading............................................... 49-5
49.6.1 Normal loading .............................................................. 49-6
49.6.2 Loading in old versions of the electronic card ............... 49-6
49.6.3 Emergency loading ........................................................ 49-6
49.7 Function for truck report ............................................................... 49-7
49.8 Function for parameters............................................................... 49-8
49.9 Function for diagnostics ............................................................. 49-10
49.9.1 Signal colours .............................................................. 49-10
49.9.2 Tab for “Analogue” ....................................................... 49-11
49.9.3 Tab for “Temperature” ................................................. 49-12
49.9.4 Tab for “Digital” ............................................................ 49-13
49.10 Other menu functions................................................................. 49-14
49.10.1 Save to file ................................................................... 49-14
49.10.2 Loading from a file ....................................................... 49-14
49.10.3 Resetting the CAN adapter .......................................... 49-14
49.10.4 Deleting the fault code log ........................................... 49-14
49.10.5 Resetting the hour meter ............................................. 49-14
49.10.6 Reading the fault code log ........................................... 49-14
49.10.7 Adjusting the date/time ................................................ 49-14
49.10.8 Adjusting the hour meter on older cards ...................... 49-15
49.10.9 Help ............................................................................. 49-15
49.10.10 Conclude .................................................................... 49-15
49.11 Specifications............................................................................. 49-15
49.12 Installation.................................................................................. 49-16
49.12.1 Installation on a PC with Windows XP/2000/NT .......... 49-16
49.12.2 Installation on a PC with Windows 95/98 .................... 49-16
49.12.3 In the event of any problems with communication
with CAN ...................................................................... 49-17
49.12.4 Uninstallation ............................................................... 49-17

50- Extra hazard warning lights/alarm – 9370 ..................................... 50-1

50.1 General ........................................................................................ 50-1
50.2 Assembling .................................................................................. 50-1
50.3 Setting.......................................................................................... 50-2

51- Positioning equipment – 9390 ........................................................ 51-1

51.1 General ........................................................................................ 51-1
51.2 Height indication .......................................................................... 51-1
51.3 Function ....................................................................................... 51-2
51.4 Display ......................................................................................... 51-3
51.5 Height pre-set .............................................................................. 51-4
51.6 Function ....................................................................................... 51-5
51.7 Display ......................................................................................... 51-6
51.7.1 Description of the display symbols ................................ 51-7
51.8 Assembly of height pre-set........................................................... 51-8
51.9 Programming ............................................................................... 51-8
51.9.1 Programming a level ...................................................... 51-8
51.9.2 Deleting programmed levels .......................................... 51-9

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51.10 Automatic driving ....................................................................... 51-10

51.10.1 Collect load .................................................................. 51-10
51.10.2 Depositing a load ......................................................... 51-11
51.10.3 Inspection .................................................................... 51-11
51.11 Parameters ................................................................................ 51-12
51.11.1 Parameter 1 ................................................................. 51-12
51.11.2 Parameter 2 ................................................................. 51-12
51.11.3 Parameter 3 ................................................................. 51-13
51.11.4 Parameter 4 ................................................................. 51-13
51.11.5 Parameter 5 ................................................................. 51-13
51.11.6 Parameter 7 ................................................................. 51-13
51.11.7 Parameter 8 ................................................................. 51-14
51.11.8 Parameter 9 ................................................................. 51-14
51.12 Programming parameters .......................................................... 51-15
51.13 Error codes ................................................................................ 51-17

52- TV equipment – 9390 ....................................................................... 52-1

52.1 General ........................................................................................ 52-1
52.2 Camera mounted on fork ............................................................. 52-2
52.2.1 Colour camera A51 ........................................................ 52-2
52.2.2 Colour monitor A50 ........................................................ 52-2
52.2.3 Voltage converter A10 ................................................... 52-4

53- Truck Logging System, code lock – 9420 ..................................... 53-1

53.1 General ........................................................................................ 53-1
53.2 EV 1,EV 16 and S 16 Keyboard version....................................... 53-1
53.2.1 Login using a code (5 digit) ........................................... 53-1
53.2.2 Logout ............................................................................ 53-1
53.2.3 Login with fault reporting (5+1 digit) .............................. 53-2
53.2.4 Login with extra code (5+3 digit) .................................... 53-2
53.2.5 Login with extra code and fault reporting (5+3+1 digit) . 53-2
53.2.6 Changing the personal three digit code ......................... 53-3
53.3 EV1, EV16 and S16 code card version ........................................ 53-3
53.3.1 Login .............................................................................. 53-3
53.3.2 Logout ............................................................................ 53-3
53.3.3 Circuit diagram .............................................................. 53-5
53.4 Collision sensor............................................................................ 53-8
53.4.1 Circuit diagram ............................................................ 53-10
53.5 Trouble shooting ........................................................................ 53-12
53.5.1 EV1 .............................................................................. 53-12
53.5.2 EV16 and S16 ............................................................. 53-12

54- Instructions for destruction ........................................................... 54-1

54.1 General ........................................................................................ 54-1
54.1.1 Procedure ...................................................................... 54-1
54.1.2 Abbreviations ................................................................. 54-2
54.1.3 Sorting ........................................................................... 54-2
54.2 Frame/chassis (0300) .................................................................. 54-3
54.2.1 Dismantling .................................................................... 54-3
54.2.2 Material handling ........................................................... 54-3
54.3 Operator's seat, cushion (0620) ................................................... 54-4
54.3.1 Dismantling .................................................................... 54-4
54.3.2 Material handling ........................................................... 54-4

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 Table of contents
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.4 Driver controls (0640) .................................................................. 54-5

54.4.1 Dismantling .................................................................... 54-5
54.4.2 Material handling ........................................................... 54-5
54.5 Interior fittings (0680) ................................................................... 54-6
54.5.1 Dismantling .................................................................... 54-6
54.5.2 Material handling ........................................................... 54-7
54.6 Rollover guard/head guard (0810) ............................................... 54-7
54.6.1 Dismantling .................................................................... 54-7
54.6.2 Material handling ........................................................... 54-7
54.7 Finger/foot protectors (0820) ....................................................... 54-8
54.7.1 Dismantling .................................................................... 54-8
54.7.2 Material handling ........................................................... 54-8
54.8 Finger/foot protectors (0820) ....................................................... 54-9
54.8.1 Dismantling .................................................................... 54-9
54.8.2 Material handling ........................................................... 54-9
54.9 Finger protectors (0820) ............................................................ 54-10
54.9.1 Dismantling .................................................................. 54-10
54.9.2 Material handling ......................................................... 54-10
54.10 Electric motors (1700) ................................................................ 54-11
54.10.1 Dismantling .................................................................. 54-11
54.10.2 Material handling ......................................................... 54-11
54.11 Electric fan motor (1740)............................................................ 54-12
54.11.1 Dismantling .................................................................. 54-12
54.11.2 Material handling ......................................................... 54-12
54.12 Drive unit, final gear (2500) ........................................................ 54-13
54.12.1 Dismantling .................................................................. 54-13
54.12.2 Material handling ......................................................... 54-13
54.13 Wheels (3500)............................................................................ 54-14
54.13.1 Dismantling .................................................................. 54-14
54.13.2 Material handling ......................................................... 54-14
54.14 Electric steering system (4300).................................................. 54-15
54.14.1 Dismantling .................................................................. 54-16
54.14.2 Material handling ......................................................... 54-16
54.15 General electric equipment (5100)............................................. 54-17
54.15.1 Dismantling .................................................................. 54-17
54.15.2 Material handling ......................................................... 54-17
54.16 Control system, drive function (5300) ........................................ 54-18
54.16.1 Dismantling .................................................................. 54-18
54.16.2 Material handling ......................................................... 54-18
54.17 Power system, drive function (5400) .......................................... 54-19
54.17.1 Dismantling .................................................................. 54-19
54.17.2 Material handling ......................................................... 54-19
54.18 Control system, operation function (5500) ................................. 54-20
54.18.1 Dismantling .................................................................. 54-20
54.18.2 Material handling ......................................................... 54-20
54.19 Steering/protective electronics (5700) ....................................... 54-21
54.19.1 Dismantling .................................................................. 54-21
54.19.2 Material handling ......................................................... 54-21
54.20 Hydraulic unit (6100) .................................................................. 54-22
54.20.1 Dismantling .................................................................. 54-22
54.20.2 Material handling ......................................................... 54-22

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54.21 Hydraulic system, fitted on the chassis (6200) ........................... 54-23

54.21.1 Dismantling .................................................................. 54-23
54.21.2 Material handling ......................................................... 54-23
54.22 Hydraulic system, fitted on the mast (6300) ............................... 54-24
54.22.1 Dismantling .................................................................. 54-24
54.22.2 Material handling ......................................................... 54-24
54.23 Hydraulic cylinders (6600).......................................................... 54-25
54.23.1 Dismantling .................................................................. 54-26
54.23.2 Material handling ......................................................... 54-26
54.24 Main mast and mast (7100)........................................................ 54-27
54.24.1 Dismantling .................................................................. 54-27
54.24.2 Material handling ......................................................... 54-27
54.25 Lift fork (7410) ............................................................................ 54-28
54.25.1 Dismantling .................................................................. 54-28
54.25.2 Material handling ......................................................... 54-28
54.26 Optional electric equipment (9300) ............................................ 54-29
54.26.1 Dismantling .................................................................. 54-29
54.26.2 Material handling ......................................................... 54-29
54.27 Optional electric equipment (9400) ............................................ 54-30
54.27.1 Dismantling .................................................................. 54-30
54.27.2 Material handling ......................................................... 54-30

© TIEE SARL Service Manual 7FBRE 1- 17

 Table of contents
T-code Valid from serial number Date Order number
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1- 18 Service Manual 7FBRE © TIEE SARL

 General product information – M2.1
Presentation of TOYOTA’s reach trucks
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

2- General product information –

M2.1

2.1 Presentation of TOYOTA’s reach

trucks
TOYOTA’s reach truck program is intended for handling pallets indoors
or alternatively other types of loads using other load carriers. The
trucks are operated seated in a protected and ergonomic operator posi-
tion. The reach trucks are available in different size classes and have
as standard a lifting capacity of up to 2500 kg and a lifting height of up
to 10.5 m.
The trucks are equipped with a 48 V electrical system. The travel and
lifting speeds are transistor controlled to provide smooth operations. In
addition, the travel function and the different hydraulic functions have
additional controls which further enhance these features. Different
speeds and steering can be set using parameters to give the best pos-
sible individual setting for the functions.

2.2 Application areas for TOYOTA’s

reach trucks
TOYOTA’s reach trucks are solely designed and manufactured to han-
dle goods. The trucks should be fitted with the appropriate accessories
relevant to the application.

2.3 Prohibited applications for

TOYOTA’s reach trucks
TOYOTA’s reach trucks are designed for handling goods indoors.
Unless the truck is specially equipped, it is not permitted to use the
truck for other purposes including the following applications:
- In areas that contain dust or gases which can cause fires or ex-
plosions
- As a tow-truck for trailers
- To tow other trucks
- To transport/lift passengers
- To drive on gravel or grass

© TIEE SARL Service Manual 7FBRE 2- 1

 General product information – M2.1
Truck data
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

2.4 Truck data

The table provides information regarding some technical data, which is
of value with daily use of the truck.

Truck type 7FBRE16 7FBRE20 7FBRE25

Rated capacity, kg 1600 2000 2500
Operating speed without load and without sup- 11,2 10,4 11,0
port arm brake, km/h
Operating speed with rated load and without 10,1 9,7 10,0
support arm brake, km/h
Operating speed without rated load and with 11,2 10,4 11,0
support arm brake, km/h
Operating speed with rated load and with sup- 11,2 10,4 11,0
port arm brake, Km/h
Max. operating gradient with rated load, % 10 10 7
Rate of lifting, without load, m/s 0,5 0,48 0,5
Rate of lifting, with rated load, m/s 0,33 0,30 0,27
Rate of lowering, without load, m/s 0,46 0,46 0,44
Rate of lowering, with rated load, m/s 0,50 0,49 0,47
Weight without battery, kg 2315 1 2995 2 3885 3
Battery (5h discharge) 360/480/600 480/600/750 600/800/900
Weight of battery, kg 700/865 865/1075 1075/1270
Continuous noise level, dB (A) < 70 < 70 < 70

Vibration level, m/s2 0,5 0,5 0,5

1) h3 = 5700 mm
2) h = 7000 mm
3
3) h = 9000 mm
3

The truck’s lifting capacity, lift height and weight can be found on the
truck’s identification plate.

2- 2 Service Manual 7FBRE © TIEE SARL

 General product information – M2.1
Truck dimensions
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

2.5 Truck dimensions

The diagrams show external dimensions for 7FBRE16,
7FBRE20 and 7FBRE25.

b14 b4
b5
e

h4
h3

h1
h2

h6
I7

Wa

m1
b1
h13

I
h8

Dimensions (mm) 7FBRE16 7FBRE20 7FBRE25

b1 Chassis width 1270/1470/1670 1270/1470/1670 1270/1470/1670
b4 Width between support arms, min./max 900/1050/1100/ 900/1100/1300 900/1100/1300
1300
b5 Width across fork, min./max. 250-718 270-718 275-718
e Fork arm width 100 120 125
h1 Mast height, min 2057-3898 2057-3898 2271-4171
h2 Free lift 1416-3257 1416-3257 1691-3591
h3 Lift height 4400-9500 4400-9500 4800-10500
h4 Mast height, max 5040-10140 5040-10140 5381-11081
h6 Height over cab 2166 2266 2266
l Fork length 1150 1150 1150
I7 Truck length excl. forks 1811 1886 2011
m1 Floor clearance 70 70 70
Wa Turning radius 1640 1690 1815

© TIEE SARL Service Manual 7FBRE 2- 3

 General product information – M2.1
Identification plate, truck
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

2.6 Identification plate, truck

The illustration shows the identification plate used on the truck.

Item Text Unit

A MODEL
B SERIAL NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V

2.7 Capacity plate

The illustration shows the capacity plate used on the truck.

Item Text Unit

H SERIAL NO
I LIFT HEIGHT mm
J ACTUAL CAPACITY kg
K LOAD CENTRE DISTANCE mm
L ALWAYS DRIVE THE TRUCK WITH
LOWERED FORKS AND RETRACTED
MAST EXCEPT WHEN COLLECTING
OR DEPOSITING A LOAD

2- 4 Service Manual 7FBRE © TIEE SARL

 General product information – M2.1
Modification plate
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

2.8 Modification plate

The illustration shows the modification plate which is found on the truck
if it is supplied as non-standard or if it has been modified after leaving
the manufacturer. The plate includes information according to the table
below.

Item Text
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

2.9 Identification plate, mast

The illustration shows the mast identification plate which can be found
on the side of the mast. The plate shows information according to the
table below.
A
B Item Text
C A Type
B Serial number
C Date

© TIEE SARL Service Manual 7FBRE 2- 5

 General product information – M2.1
Main components
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

2.10 Main components

1. Hydraulic valves:
The valves are located to provide easy access.
2. Battery:
48 V with different Ah values.
3. Recharging connector:
The battery is recharged via this permanently attached recharging
connector.
4. Control circuit fuse:
10 A, part no. 161640-100.
Fuse for electrical steering wheel:
30 A, part no. 161640-300.
5. Hydraulic unit:
Pump motor, pump and oil tank integrated in a compact unit.
6. Drive unit with brake:
Drive motor, gears and drive wheel combined into a compact unit.
Electronic steering and a 360° steering angle which facilitates the
handling of loads.
7. Electrical steering motor:
Mounted with the drive gear to provide a compact design.
8. Identification plate:
With model designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, battery volt-
age and manufacturer.
9. Operator’s seat:
The seat is fully adjustable to provide optimal operator comfort.
10. Serial number:
The serial number plate fitted to the chassis.
11. Cover:
Easily swivelled to provide good access for servicing.
12. Pedals:
Accelerator with optional direction selector, travel brake and safety
pedal.
13. Control console:
The control console can be adjusted to a suitable height and angle
to obtain a comfortable working position. The steering, hydraulic
functions, horn, height pre-selector and travel direction and any ex-
tra hydraulic functions are all controlled from this console.
14. Instrument panel:
This provides information on the truck’s running time, time indica-
tion, error codes, travel direction, parking brake, steering angle, op-
erator identification and battery status. The instrument panel also
houses the emergency switch off, ignition key, switches for acces-
sories and buttons for operator parameters.
15. Mast:
The mast is a clear-view model and is equipped with an identification
plate with type designation, serial number and date of manufacture.
16. Electronics:
All the electronics collected in a protected compartment.

2- 6 Service Manual 7FBRE © TIEE SARL

 General product information – M2.1
Main components
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

17. Drive motor fuse:

7FBRE16: 125 A, part no. 29584.
7FBRE20 och 7FBRE25: 160 A, part no. 29223.
18. Pump motor fuse:
7FBRE16: 200 A, part no. 29673.
7FBRE20: 250 A, part no. 29221.
7FBRE25: 300 A, part no. 29674.
.

16
17
18

8
15

10
14
13 11
1
12

2,3

6
© TIEE SARL Service Manual 7FBRE 2- 7
 General product information – M2.1
Warning and information plates and symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

2.11 Warning and information plates

and symbols
The figure shows the position and significance of the plates and sym-
bols located on the truck.

1. Modification plate
2. Identification plate, truck
3. Capacity plate
4. Serial number
5. Hydraulic oil filling
6. Parking brake and travel direction selector (accessories)
7. Lifting points
8. Hydraulic controls: lift/lowering, mast in/out, fork tilt, sideshift
and additional hydraulic functions
9. Do not walk under elevated load
10. Maximum height for rated capacity
11. Identification plate, mast
TOYOTA
A
B
C

10
11 2 3
9
TOYOTA INDUSTRIAL EQUIPMENT EUROPE S.A.R.L.

4 H

6
7

2- 8 Service Manual 7FBRE © TIEE SARL

 General product information – M2.2
Presentation of TOYOTA’s reach trucks
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

3- General product information –

M2.2

3.1 Presentation of TOYOTA’s reach

trucks
TOYOTA’s reach truck program is intended for handling pallets indoors
or alternatively other types of loads using other load carriers. The
trucks are operated seated in a protected and ergonomic operator posi-
tion. TOYOTA’s reach trucks are available in different size classes and
have as standard a lifting capacity of up to 1400 kg and a lifting height
of up to 6.3 m.
The trucks are equipped with a 48 V electrical system. The travel and
lifting speeds are transistor controlled to provide smooth operations. In
addition, the travel function and the different hydraulic functions have
additional controls which further enhance these features. Different
speeds and steering can be set using parameters to give the best pos-
sible individual setting for the functions.

3.2 Application areas for TOYOTA’s

reach trucks
TOYOTA’s reach trucks are solely designed and manufactured to han-
dle goods. The trucks should be fitted with the appropriate accessories
relevant to the application.

3.3 Prohibited applications for

TOYOTA’s reach trucks
TOYOTA’s reach trucks are designed for handling goods indoors.
Unless the truck is specially equipped, it is not permitted to use the
truck for other purposes including the following applications:
- In areas that contain dust or gases which can cause fires or ex-
plosions
- As a tow-truck for trailers
- To tow other trucks
- To transport/lift passengers
- To drive on gravel or grass

© TIEE SARL Service Manual 7FBRE 3- 1

 General product information – M2.2
Truck data
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

3.4 Truck data

The table provides information regarding some technical data, which is
of value with daily use of the truck.

Truck type 7FBRE12 7FBRE14

7FBRE12C 7FBRE14C
Rated capacity, kg 1200 1400
Travel speed without load, km/h 11,2 11,2
Travel speed with rated load, km/h 10,1 10,1
Gradient with rated load, % 10 10
Lift speed, without load, m/s 0,35-0,45 0,35-0,45
Lift speed, with rated load, m/s 0,25-0,30 0,25-0,30
Lowering speed, without load, m/s 0,45 0,45
Lowering speed, with rated load, m/s 0,45 0,45
Weight without battery, kg 19151 20402
Battery (5h discharge) 292-300 292-300
360-450 360-450
480-600 480-600
Weight of battery, kg 510 510
610 610
780 780
Continuous noise level, dB (A) < 70 < 70

Vibration level, m/s2 0,5 0,5

1)
h3 = 6000 mm Triplex
2)
h3 = 6300 mm
The truck’s lifting capacity, lift height and weight can be found on the
truck’s identification plate.

3- 2 Service Manual 7FBRE © TIEE SARL

 General product information – M2.2
Truck dimensions
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

3.5 Truck dimensions

The diagrams show external dimensions for 7FBRE12, 12C and
7FBRE14, 14C.

b14 b4
b5
e

h4
h3

h1
h2

h6
I7

Wa

m1
b1
h13
I
h8

Dimensions (mm) 7FBRE12, 12C 7FBRE14, 14C

b1 Chassis width 1120 1120
b4 Width between support arms 880 880
b5 Width across fork 250-720 250-720
e Fork width 100 100
h1 Height of mast, min Dx Tele: 2194-2604
Dx HiLo: 2194-2604
Tx HiLo: 1930-2647 2057-2690
h2 Free lift Dx HiLo: 1725-2125
Tx HiLo: 1457-2174 1416-2091
h3 Lift hight 3350-6000 4400-6300
h4 Height of mast, max Dx Tele: 3849-4659
Dx HiLo: 3849-4659
Tx HiLo: 4654-6504 5040-6940
h6 Load guard height 2166 2166
l Fork length 1150 1150
I7 Truck length excl. fork 1810 1810
m1 Floor clearance 70 70
Wa Turning radius 1654 1654

© TIEE SARL Service Manual 7FBRE 3- 3

 General product information – M2.2
Identification plate, truck
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

3.6 Identification plate, truck

The illustration shows the identification plate used on the truck.

Item Text Unit

A MODEL
B SERIAL NO
C RATED CAPACITY kg
D WEIGHT WITHOUT BATTERY kg
E BATTERY WEIGHT MAX kg
MIN kg
F BATTERY VOLTAGE V

3.7 Capacity plate

The illustration shows the capacity plate used on the truck.

Item Text Unit

H SERIAL NO
I LIFT HEIGHT mm
J ACTUAL CAPACITY kg
K LOAD CENTRE DISTANCE mm
L ALWAYS DRIVE THE TRUCK WITH
LOWERED FORKS AND RETRACTED
MAST EXCEPT WHEN COLLECTING
OR DEPOSITING A LOAD

3- 4 Service Manual 7FBRE © TIEE SARL

 General product information – M2.2
Modification plate
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

3.8 Modification plate

The illustration shows the modification plate which is found on the truck
if it is supplied as non-standard or if it has been modified after leaving
the manufacturer. The plate includes information according to the table
below.

Item Text
A Modification plate
B Type
C Serial number
D Place of manufacture
E Place of manufacture
F Modification number
G Date

3.9 Identification plate, mast

The illustration shows the mast identification plate which can be found
on the side of the mast. The plate shows information according to the
table below.
A
B Item Text
C
A Type
B Serial number
C Date

© TIEE SARL Service Manual 7FBRE 3- 5

 General product information – M2.2
Main components
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

3.10 Main components

1. Hydraulic valves:
The valves are located to provide easy access.
2. Battery:
48 V with different Ah values.
3. Recharging connector:
The battery is recharged via this permanently attached recharging
connector.
4. Control circuit fuse:
10 A, part no. 161640-100.
Fuse for electrical steering wheel:
30 A, part no. 161640-300.
5. Hydraulic unit:
Pump motor, pump and oil tank integrated in a compact unit.
6. Drive unit with brake:
Drive motor, gears and drive wheel combined into a compact unit.
Electronic steering and a 360° steering angle which facilitates the
handling of loads.
7. Electrical steering motor:
Mounted with the drive gear to provide a compact design.
8. Identification plate, truck:
With model designation, serial number, year of manufacture,
weight without battery, battery weight, rated capacity, battery volt-
age and manufacturer.
9. Operator’s seat:
The seat is fully adjustable to provide optimal operator comfort.
10. Serial number:
The serial number plate fitted to the chassis.
11. Cover:
Easily swivelled to provide good access for servicing.
12. Pedals:
Accelerator with optional direction selector, travel brake and safety
pedal.
13. Control console:
The control console can be adjusted to a suitable height and angle
to obtain a comfortable working position. The steering, hydraulic
functions, horn and travel direction and any extra hydraulic func-
tions are all controlled from this console.
14. Instrument panel:
This provides information on the truck’s running time, time indica-
tion, error codes, travel direction, parking brake, steering angle, op-
erator identification and battery status. The instrument panel also
houses the emergency switch off, ignition key, switches for acces-
sories and buttons for operator parameters.
15. Mast:
The mast is a clear-view model and is equipped with an identification
plate with type designation, serial number and date of manufacture.
16. Electronics:
All the electronics collected in a protected compartment.
3- 6 Service Manual 7FBRE © TIEE SARL
 General product information – M2.2
Main components
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

17. Drive motor fuse:

125 A, part no. 29584.
18. Pump motor fuse:
160 A, part no. 29223.

16
17
18

8
15
9
1
14 10

13 11

2,3

12

7
5

© TIEE SARL Service Manual 7FBRE 3- 7

 General product information – M2.2
Warning and information plates and symbols
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

3.11 Warning and information plates

and symbols
The figure shows the position and significance of the plates and sym-
bols located on the truck.
1. Modification plate
2. Identification plate, truck
3. Capacity plate
4. Serial number
5. Hydraulic oil filling
6. Parking brake and travel direction selector (accessories)
7. Lifting points
8. Hydraulic controls: lift/lowering, mast in/out, fork tilt and addi-
tional hydraulic functions
9. Signs about risk of crushing
10. Maximum height for rated capacity
11. Identification plate, mast
TOYOTA
A
B
C

10
11 2 3
9
TOYOTA INDUSTRIAL EQUIPMENT EUROPE S.A.R.L.

4 H

6
7

3- 8 Service Manual 7FBRE © TIEE SARL

 Technical data – M4.1
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

4- Technical data – M4.1

Model 7FBRE16, 16C 7FBRE20, 20C 7FBRE25, 25C
Drive motor
Type TSP 112/4-130-T TSP 112/4-4-165-T TSP 112/4-165-T
Output, kW 5.5 7.5 7.5
Duty cycle, % 60 60 60
Insulation class F F F
Transmission/drive gear
Type 2-stage angle 2-stage angle 2-stage angle
transmission transmission transmission
Gear ratio 19,2:1 20,89:1 20,89:1
Oil volume, Litre 2.8 3.3 3.3
Oil type Hypoid oil Hypoid oil Hypoid oil
Normal temperature SAE 80W90 SAE 80W90 SAE 80W90
< -15° C: SAE 75W SAE 75W SAE 75W

Wheels
Drive wheels diameter 310x120 diameter 310x120 diameter 350x130
Support arm wheel diameter 265x108 diameter 350x108 diameter
diameter 300x100 350x108
Max. weight on support arm wheels 1835/4350 2240/5470 3225/7045
without load/with load (kg)
Max. weight on drive wheel without 1785/1480 2200/1910 2725/2150
load/with load (kg)
Max. support arm wheel pressure (MPa) 4,5 4,6 5,3
Max. drive wheel pressure (Mpa) 3,3 3,4 3,9
Hydraulic system
Pump motor, Type TSP 112/4-150-T TSP 112/4-150-T TSP 112/4-195-T
Output, kW 10.0 10.0 14.0
Duty cycle, % 15 15 15
Insulation class F F F
Pump flow, Litre/minute 30 26 35
Tank volume, Litre 30/38 38 38
Oil type:
Normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
<-15° ISO-L-HV32 ISO-L-HV32 ISO-L-HV32

© TIEE SARL Service Manual 7FBRE 4- 1

 Technical data – M4.1
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Model 7FBRE16, 16C 7FBRE20, 20C 7FBRE25, 25C

Hydraulic pressure
Pressure at rated load, bar 150 180 185
Overflow pressure, bar 165 195 200
Steering motor
Type 36-4830312J 36-4830312J 36-4830312J
Output 0.20 0.20 0.20
Duty cycle, % 100 100 100
Minimum carbon brush length, mm 9 9 9
Minimum commutator diameter, mm 22.9 22.9 22.9
Insulation class B B B
Fuses
F1, Drive motor 125 A/29584 160 A/29223 160 A/29223
F3, Pump motor 200 A/29673 250 A/29221 300 A/29674
F60, Control voltage A5 10 A/122308-100 10 A/122308-100 10 A/122308-100
F61, Steering servo 30 A/122308-300 30 A/122308-300 30 A/122308-300
F62, Input from main contactors 10 A/122308-100 10 A/122308-100 10 A/122308-100
F63, Extra equipment 10 A/122308-100 10 A/122308-100 10 A/122308-100
Batteries
Dimensions WxLxH See C-code 5110 See C-code 5110 See C-code 5110
Capacity
Weight
Driving speed
Without load, km/h 11,2 10,4 ---
With rated load, km/h 10,1 9,7 ---
Without load, with support arm brakes, 12.0 12.0 12.0
km/h
With rated load, with support arm 12.0 12.0 12.0
brakes, km/h

4- 2 Service Manual 7FBRE © TIEE SARL

 Technical data – M4.1
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Model 7FBRE16, 16C 7FBRE20, 20C 7FBRE25, 25C

Lifting/lowering speed
Lifting without load, m/s 0.50 0.50 0.50
Lifting with 1000 kg load, m/s 0.37 0.35 0.37
Lifting with rated load, m/s 0.33 0.30 0.27
Lowering without load, m/s 0.46 0.46 0.44
Lowering with 1000 kg load, m/s 0.53 0.53 0.50
Lowering with rated load, m/s 0.50 0.49 0.47
Power consumption, Driving
Driving without load, Ampere 68 80 107
Driving with rated load, Ampere 68 86 116

Model 7FBRE16, 16C 7FBRE20, 20C 7FBRE25, 25C

Power consumption, Free lift
Ampere Bar Ampere Bar Ampere Bar
Lifting without load 115 36 111 40 168 42
Lifting with rated load 251 135 285 158 263 140
Power consumption, Main lift
Ampere Bar Ampere Bar Ampere Bar
Lifting without load 140 54 145 64 211 75
Lifting with rated load 269 153 290 170 300 175
Tilting without load
Tilting with rated load
Mast in/out without load 198/155 103/65 180/145 93/62 170/133 73/52
Mast in/out with rated load 211/160 110/60 190/150 111/69 170/135 80/64
Side shift forks without load 120/100 46/30 118/97 50/32 180/162 51/67
Side shift forks with rated load 233/195 130/100 200/252 142/107 330/274 187/172
NOTE!
The above values are recommended values. Variations may occur be-
tween different trucks.
Some data in the table may be missing because corresponding tests
have not been carried out or the data is not available at the present
time.

© TIEE SARL Service Manual 7FBRE 4- 3

 Technical data – M4.1
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

This page is intentionally left blank

4- 4 Service Manual 7FBRE © TIEE SARL

 Technical data – M4.2
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

5- Technical data – M4.2

Model 7FBRE12, 12C 7FBRE14, 14C

Drive motor
Type TSP 112/4-130-T TSP 112/4-130-T
Output, kW 5.5 5.5
Duty cycle, minutes 60 60
Insulation class F F
Transmission/drive gear
Type 2-stage angle transmission 2-stage angle transmission
Gear ratio 19,2:1 19,2:1
Oil volume, Litre 2.8 2.8
Oil type Hypoid oil Hypoid oil
Normal temperature SAE 80W90 SAE 80W90

< -15° C: SAE 75W SAE 75W

Wheels
Drive wheels diameter 310x120 diameter 310x120
Support arm wheel diameter 300x100 diameter 300x100
Max. weight on support arm wheels 1420/3330 1640/3930
without load/with load (kg)
Max. weight on drive wheel without load/ 1630/1340 1690/1300
with load (kg)
Max. support arm wheel pressure (MPa) 4,7 5,2
Max. drive wheel pressure (Mpa) 3,1 3,2

© TIEE SARL Service Manual 7FBRE 5- 1

 Technical data – M4.2
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Model 7FBRE12, 12C 7FBRE14, 14C

Hydraulic system
Pump motor, Type TTL 180C-P3A TTL 180C-P3A
Output, kW 7.4 7.4
Duty cycle, % 20 20
Minimum carbon brush length, mm 14 14
Minimum commutator diameter, mm 77 77
Insulation class B B
Pump flow, Litre/minute (Loaded) 24 24
Tank volume, Litre 30 30
Oil type:
Normal temperature ISO-L-HM32 ISO-L-HM32
<-15° ISO-L-HV32 ISO-L-HV32
Hydraulic pressure
Pressure at rated load, bar 130 130
Overflow pressure, bar 160 130
Steering motor
Type 36-4830312J 36-4830312J
Output 0.20 0.20
Duty cycle, % 100 100
Minimum carbon brush length, mm 9 9
Minimum commutator diameter, mm 22.9 22.9
Insulation class B B
Fuses
F1, Drive motor 125 A/29584 125 A/29584
F3, Pump motor 160 A/29223 160 A/29223
F60, Control voltage A5 10 A/122308-100 10 A/122308-100
F61, Steering servo 30 A/122308-300 30 A/122308-300
F62, Input from main contactors 10 A/122308-100 10 A/122308-100
F63, Extra equipment 10 A/122308-100 10 A/122308-100
Batteries
Dimension WxLxH See C-code 5110
Capacity
Weight

5- 2 Service Manual 7FBRE © TIEE SARL

 Technical data – M4.2
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Model 7FBRE12, 12C 7FBRE14, 14C

Driving speed
Without load, km/h 11,2 11,2
With rated load, km/h 10,1 10,1
Lift/lowering speed
Lifting without load, m/s 0.35-0.45 0.35-0.45
Lifting with rated load, m/s 0.25-0.30 0.25-0.30
Lowering without load, m/s 0.45 0.45
Lowering with rated load, m/s 0.45 0.45
Power consumption, Driving
Driving without load, Ampere 63 65
Driving with classified load, Ampere 63 67

Model 7FBRE12, 12C 7FBRE14, 14C

Power consumption, Free lift
Ampere Bar Ampere Bar
Lifting without load, Ampere 58 28 88 30
Lifting with classified load, Ampere 149 103 190 117
Power consumption, Main lift
Lifting without load, Ampere 72 40 105 45
Lifting with rated load, Ampere 182 135 200 125
Tilting without load
Tilting with rated load
Mast in/out without load 90/75 50/40 100/95 44/40
Mast in/out with rated load 103/80 54/42 108/100 49/44
Side shift forks without load 82/82 45/45 99/83 39/31
Side shift forks with classified load 150/150 90/90 186/156 113/90

NOTE!
The above values are recommended values. Variations may occur be-
tween different trucks.
Some data in the table may be missing because corresponding tests
have not been carried out or the data is not available at the present
time.

© TIEE SARL Service Manual 7FBRE 5- 3

 Technical data – M4.2
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

5- 4 Service Manual 7FBRE © TIEE SARL

 Introduction, maintenance – P1
Safety regulations with maintenance work
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

6- Introduction, maintenance – P1
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with TOYOTA’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use TOYOTA approved spare parts when service and repair work
are carried out.

6.1 Safety regulations with

maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system

© TIEE SARL Service Manual 7FBRE 6- 1

 Introduction, maintenance – P1
Cleaning and washing
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.
• Store and dispose of changed oil in accordance with local directives
• Do not release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal
• Disconnect the battery when welding on the truck
NOTE!
The battery can be damaged.
When welding using an electric power source the welding current can
enter the battery.
The battery should therefore be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

6.2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the battery con-
nector.

6- 2 Service Manual 7FBRE © TIEE SARL

 Introduction, maintenance – P1
Cleaning and washing
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

6.2.1 External cleaning

• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion
• Rinse off loose grime using tepid water
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the chapter
Maintenance and lubrication chart.

6.2.2 Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing
NOTE!
Risk of short-circuiting.
The electrical system can be damaged.
Electrical components must not be cleaned with a high pressure
washing unit.
• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water

6.2.3 Electrical components

• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors, connec-
tions, solenoid valves, etc. using a damp cloth and a cleaning agent
NOTE!
Risk of short-circuiting.
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

© TIEE SARL Service Manual 7FBRE 6- 3

 Introduction, maintenance – P1
Safe lifting
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

6.3 Safe lifting

All lifting must be carried out on a flat, non-slip and firm surface. Avoid
new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving during
the lift. If the lift applies to the brake wheel, chock the other wheels
so that the truck stands still
• Select a lifting point so that the lift is as easy as possible (one corner
at a time). If the truck has marked lifting points on the under side of
the chassis these can be used to obtain a well balanced lift
• Ensure that the surface under the jack is clean and free from oil and
grease
• Ensure that your hands and the jack’s lever are free from oil and
grease
• Use the lever that belongs to the jack. A lever that is too short re-
quires more force than is necessary. If the lever is too long there is a
risk of the jack being overloaded
• Support the truck:
- as close to the part of the chassis that is lifted as possible to re-
duce the falling height if the truck tips over
- so that the truck cannot roll
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

6- 4 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.1
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

7- Preventive Maintenance – P2.1

7.1 Maintenance chart

Pos. Work to carry out
no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
0000 Chassis
0000.1 Check for cracks or damage X
0340.1 Check door locking and lubricate door A
hinges
0350.1 Lubricate the runners in the reach car- F
riage
0390.1 Check the battery mounting and wear to U X
the battery lock.
0390.2 Check the locking of the roller bed X
0620.1 Check the mounting of the seat and X
adjustment functions.
0640.1 Check joystick functions U X
0640.2 Check the steering wheel function U X
0640.3 Check the brakes U X
0640.4 Check pedal function U X
0640.5 Check the horn U X
0810.1 Check the attachment of the machine X
housing and the protective roof.
0840.1 Check the emergency switch off U X
1700 Motors
1700.1 Check for any loose connections X
1700.2 Check and tighten mounting bolts X
1700.3 Check for noise in the bearings X
1730.1 Check steering motor’s carbon brushes X

© TIEE SARL Service Manual 7FBRE 7- 1

 Preventive Maintenance – P2.1
Maintenance chart
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
2550 Drive unit
2550.1 Check the oil level X
2550.2 Change the oil C C
2550.3 Check for abnormal noise and leakage U X
2550.4 Check the mounting on the support arm X
2550.5 Lubricate the gear ring H
3180 Brakes
3180.1 Check the brake discs for wear X
3180.2 Check for play in released position X
3180.3 Check the braking torque X
3370.1 Check the brake discs for wear X
3370.2 Check for play in released position X
3370.3 Check the braking torque X
3500 Wheels
3530.1 Remove string and other detritus U X
3530.2 Check for drive wheel wear and its bolts U X
3550.1 Remove string and other detritus U X
3550.2 Check the support arm wheel’s rotation U X
and its mounting
3550.3 Check for wear on the support arm wheels U X
4100 Control console
4100.1 Check the mounting and control console U X
locking mechanism.
4100.2 Check the gas cartridge’s capacity and U X
locking mechanism

7- 2 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.1
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
5000 Electrical panel
5000.1 Clean and check the mounting X
5000.2 Tighten cable connections X
5000.3 Check the emergency switch functions X
5000.4 Check error code log and operation times U X
5190.1 Check contactor points X
5190.2 Check movement in the contactor X
5280.1 Check electrical limiting functions X
5110 Battery
5110.1 Check electrolyte levels (10-15 mm over U X
the cell plates)
5110.2 Check connections on the battery, truck U X
and charger
5110.3 Check the cell and pole guards U X
5110.4 Check fluid density U X
5110.5 Check temperature X
5110.6 Remove overflow fluid from the battery X
trough
5110.7 Check for wear to the locking catch U X
6000 Hydraulic System
6110.1 Check the tank, mounting and leakage X
6110.2 Check oil levels X
6110.3 Clean or replace the oil B
6120.1 Check the hoses, pipes and couplings U X
6120.2 Check for wear to hoses in the mast and X
reach carriage
6130.1 Change air and oil filters X
6170.1 Check overflow pressure X

© TIEE SARL Service Manual 7FBRE 7- 3

 Preventive Maintenance – P2.1
Maintenance chart
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
6600 Cylinders
6600.1 Check for leakage U X
6600.2 Check the mountings X
7100 Mast and reach carriage
7100.1 Check the lowering speed X
7100.2 Check for cracks or damage X
7110.1 Lubricate mast beams by the runners F
7120.1 Check for wear on lifting chains and X
sprockets
7120.2 Check adjustment of lifting chains. Check X
chain bolts and chain mounting. Tighten
lock nuts and inspect safety cotter
7120.3 Lubricate lifting chains D
7150.1 Check for play on rollers X
7190.1 Check and tighten mast mounting X
7200.1 Check the function of accessories U X
7400.1 Check for wear to the forks and other lift- U X
ing devices
7400.2 Check for damage and deflection on the U
forks and other lifting devices
U represents what is found in the chapter Daily service and function
checks and may be carried out by the operator.
X shows what is to be done upon the different service occasions. Other
letters show grade of oil or grease.
When points are carried out according to higher hour intervals, even the
points at lower time intervals are to be carried out, unless otherwise
stated above.

7- 4 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.1
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

0640.5
0640.2
0640.1
0840.1

0390.2 0390.1 0350.1

0810.1

0000.1 0620.1

0640.3
0640.4
0810.1
0340.1

© TIEE SARL Service Manual 7FBRE 7- 5

 Preventive Maintenance – P2.1
Maintenance chart
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

7- 6 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.1
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

5000.4 5280.1
5000.3

4100.1
4100.2

5110.4 5000.1
5110.5 5000.2
5110.6

5110.3
5110.1
5110.2

5190.1
5190.2 5000.3

5110.7

© TIEE SARL Service Manual 7FBRE 7- 7

 Preventive Maintenance – P2.1
Maintenance chart
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

7- 8 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.1
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

7120.1
7120.3
6600.1
6600.2

7120.2
7100.1
7100.2
7100.2 7100.1
7190.1 7110.1
7150.1

7200.1
7400.1 7190.1
7400.2

© TIEE SARL Service Manual 7FBRE 7- 9

 Preventive Maintenance – P2.1
Maintenance chart
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

This page is intentionally left blank

7- 10 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.2
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

8- Preventive Maintenance – P2.2

8.1 Maintenance chart

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
0000 Chassis
0000.1 Check for damage and crack formation X
0340.1 Check the door lock and oil the hinges A
0350.1 Lubricate runners on the reach carriage F
0390.1 Check that the battery is secured and the U X
check the battery locks for signs of wear
0390.2 Check the lock on the roller table X
0620.1 Check the seat mounting and the setting X
devices
0640.1 Check the function of the driving controls U X
0640.2 Check the function of the steering wheel U X
0640.3 Check the function of the brakes U X
0640.4 Check the function of the pedals U X
0640.5 Check the function of the horn U X
0810.1 Check the machine housing and safety X
roof mounting
0840.1 Check the emergency switch off U X

© TIEE SARL Service Manual 7FBRE 8- 1

 Preventive Maintenance – P2.2
Maintenance chart
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
1700 Motors
1700.1 Check for loose connections X
1700.2 Check the mounting bolts X
1700.3 Check for abnormal bearing noise X
1710.1 Check the pump motor carbon brushes X
1730.1 Check the steering motor carbon brushes X
2550 Drive unit
2550.1 Check the oil level X
2550.2 Change the oil C C
2550.3 Check for abnormal noise and leakage U X
2550.4 Check the mounting on the support arm X
2550.5 Lubricate the gear ring H
3370 Brakes
3370.1 Check the brake disc for wear X
3370.2 Check for play in the released position X
3370.3 Check the brake torque X
3500 Wheels
3530.1 Remove string and other rubbish U X
3530.2 Check for drive wheel wear and the bolts U X
3550.1 Remove string and other rubbish U X
3550.2 Check the support arm wheels’ rotation U X
and mounting
3550.3 Check support arm wheel for wear U X
4100 Control console
4100.1 Check the mounting and control console U X
locking mechanism.
4100.2 Check the gas cartridge’s capacity and U X
locking mechanism

8- 2 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.2
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
5000 Electrical panel
5000.1 Clean and check the mounting X
5000.2 Tighten cable connections X
5000.3 Check the emergency driving functions X
5000.4 Check the error code register and operat- U X
ing times
5190.1 Check contactor points X
5190.2 Check the contactor’s movement X
5280.1 Check the electrical limit functions X
5110 Battery
5110.1 Check the electrolyte level (10-15 mm U X
above the cell plates)
5110.2 Check the connections on the battery, U X
truck and charger
5110.3 Check the cell and pole guard U X
5110.4 Check the fluid density U X
5110.5 Check the temperature X
5110.6 Extract excess fluid from the battery tray X
5110.7 Check the locking catch for wear U X
6000 Hydraulic system
6110.1 Check the tank for leakage and its mount- X
ings
6110.2 Check the oil level X
6110.3 Clean or change oil B
6120.1 Check hoses, pipes and couplings U X
6120.2 Check the hoses on the mast and fork X
carriage for wear
6130.1 Change air and oil filter X
6170.1 Check overflow pressure X

© TIEE SARL Service Manual 7FBRE 8- 3

 Preventive Maintenance – P2.2
Maintenance chart
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Pos. Work to carry out

no. Intervals in hours 5 20 250 500 1000 3000
Intervals in Days/Weeks/Months 1D 1W 3M 6M 12 M 36 M
6600 Cylinders
6600.1 Check for leakage. U X
6600.2 Check the mountings. X
7100 Mast and reach carriage
7100.1 Check the lowering speed X
7100.2 Check for damage and crack formation X
7110.1 Lubricate mast beams on runners F
7120.1 Check for wear on the lifting chains and X
sprockets
7120.2 Check the lift chains adjustment. Check X
the chain bolts and mountings.
Tighten locking nuts and inspect the
safety pins.
7120.3 Lubricate the lift chains D
7150.1 Check for play on the rollers X
7190.1 Tighten the mast mounting X
7200.1 Check extra functions U X
7400.1 Check for wear to the forks and other lift- U X
ing devices
7400.2 Check for damage and bends on forks U
and other lifting devices
7420.1 Side shift F
U represents what is found in the chapter Daily service and function
checks and may be carried out by the operator.
X shows what is to be done upon the different service occasions. Other
letters show grade of oil or grease.
When points are carried out according to higher hour intervals, even the
points at lower time intervals are to be carried out, unless otherwise
stated above.

8- 4 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.2
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

0640.5
0640.2 0640.1
0840.1

0390.2 0390.1 0350.1

0810.1

0620.1

0000.1

0640.3
0640.4

0810.1

0340.1

© TIEE SARL Service Manual 7FBRE 8- 5

 Preventive Maintenance – P2.2
Maintenance chart
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

8- 6 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.2
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

5000.4
5280.1

5000.3

4100.1
4100.2

5110.4
5110.5
5110.6
5000.1
5110.3 5000.2

5110.1
5110.2

5190.1
5190.2
5110.7

© TIEE SARL Service Manual 7FBRE 8- 7

 Preventive Maintenance – P2.2
Maintenance chart
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

8- 8 Service Manual 7FBRE © TIEE SARL

 Preventive Maintenance – P2.2
Maintenance chart
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

© TIEE SARL Service Manual 7FBRE 8- 9

 Preventive Maintenance – P2.2
Maintenance chart
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

8- 10 Service Manual 7FBRE © TIEE SARL

 Oil and grease specification – P3
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

9- Oil and grease specification – P3

Pos. Lubricant Specification Application area

> - 15°C < - 15°C
A Grease 26777 (Spray) 26777 (Spray) Bearings and bushings
B Hydraulic oil ISO-L-HM32 ISO-L-HV32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease 165148 (Spray) 163588 (Spray) Chains and wires
F Grease 055-70111 055-74320 Sideshift forks
G Grease Topas NB 52 Topas NB 52 Steering motor gear
H Grease Grafloscan Grafloscan Gear ring
A-G1 (Klüber) A-G1 (Klüber)

© TIEE SARL Service Manual 7FBRE 9- 1

 Oil and grease specification – P3
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

9- 2 Service Manual 7FBRE © TIEE SARL

 Tools –P4
Super Seal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

10- Tools –P4

10.1 Super Seal

3
3

Tools Number Use

159232 Tools for fitting pins/sleeves

159229 Tools for loosening locks (1)

159230 Tools for fitting secondary locks

2 pole (2)

159231 Tools for fitting secondary locks

4 pole (2)

159228 Tools for removing pins/sleeves

(3)

© TIEE SARL Service Manual 7FBRE 10- 1

 Tools –P4
Super Seal
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

10.1.1 AMP connector

PT = Power Timer (4.8, 5.8, 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)

Figure Number Use

151080 (PT) Tool for removing pins/sleeves

213296 (JPT) Tool for removing pins/sleeves

213298 (MPT) Tool for removing pins/sleeves

1=163787 (JPT) Tool for fitting sleeves

2=163788 (JPT)

1=213336 (MPT)
1 2=213337 (MPT)
2
1=213336 (JPT) Tool for fitting pins
2=213549 (JPT) For 1.5-2.5 mm2

1
2

10- 2 Service Manual 7FBRE © TIEE SARL

 Tools –P4
Super Seal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

10.1.2 AMP microtimer

Tool Number Use

141199 Tool for fitting pins/sleeves

650006 Tool for removing pins/sleeves

© TIEE SARL Service Manual 7FBRE 10- 3

 Tools –P4
Super Seal
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

10.1.3 Diverse tools

Tool Number Use
179915 Service instrument (CAN)

1=163793 Service instrument for program

2=163792 changes

182147-008 TruckCom program

V08-15912 Doorstop tool

08-15444 Drive motor/Pump motor

10- 4 Service Manual 7FBRE © TIEE SARL

 Tools –P4
Super Seal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Tool Number Use

10-15639 Socket for transmission nuts

08-13022 Puller, transmission

08-13585 Press tool for support arm wheel

© TIEE SARL Service Manual 7FBRE 10- 5

 Tools –P4
Super Seal
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Tool Number Use

08-13585-1 Manual press tool for support
arm wheel

08-13585-2 Tool for wheel axle

Tool for wheel axle

08-13585-1/5.1 A=30
08-13585-1/5.2 A=40
A

08-13585-1/4 Tool for wheel axle

808-413 Socket for support arm wheel

808-4XX

V08-14044 Pressing tool for the support

arm wheels

10- 6 Service Manual 7FBRE © TIEE SARL

 Tools –P4
Super Seal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Tool Number Use

V08-14044/1 Pressing tool for the support
arm wheel bearings

V08-14044/2 Socket for support arm wheel

Compl=V1015191 Oil cleaning

1=V10-15191-1 1=Filter for cleaning
2=V10-15191-2 2=Filter for removing water
3=V10-15191-3 3=Pipe
-1
-2 4=V10-15191-4 4=Pipe

-3
-4

219730 Pressure measurement for

hydraulics

11-999-8 Lifting tool for battery

Max. 1,500 kg

© TIEE SARL Service Manual 7FBRE 10- 7

 Tools –P4
Super Seal
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Tool Number Use

11-1242 Lifting tool for mast

72
0

11-1091 Lifting tool for mast

11-1133/2 Lifting tool for mast

84
0

10- 8 Service Manual 7FBRE © TIEE SARL

 Tools –P4
Super Seal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Tool Number Use

11-1020 Lifting tool for mast runner

7
41

11-1021 Lifting tool for mast runner

0
38

© TIEE SARL Service Manual 7FBRE 10- 9

 Tools –P4
Super Seal
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

10- 10 Service Manual 7FBRE © TIEE SARL

 Cab heating/ventilation – 0630
Air conditioning unit
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

11- Cab heating/ventilation – 0630

11.1 Air conditioning unit

In order to achieve the greatest possible operator comfort the ventila-
tion and heat can be adjusted to suit your requirements.

11.1.1 Ventilation
The fan can be set to three different speeds.
• Turn the control knob (3) to the required position.
P P

11.1.2 Main heater

• Turn the control knob (2) to 1 to start the heater.

11.1.3 Auxiliary heater

Extra heat may be required when starting a cold truck and when driving
between cold and warm areas.
• Press the button (1) and the heater will give off heat under approx. 7
3 1 2 4 minutes, after which the heater will be turned off. Press once again if
you wish to restart the heater. The LED on the pushbutton/time relay
is lit when the extra heater is connected.
The time can be adjusted on the time relay inside the heater.
• The interval is adjusted using switch 5.
4 6

2 8 • The time is adjusted using knob 6.

6
1 10 The higher the fan speed, the greater the amount of hot air
provided in the cab.

5 1m

11.1.4 Temperature
The temperature can be set from approximately 5 to 30 degrees, using
the thermostat (4).
• Set desired temperature in the cabin using the thermostat (4).
LED

© TIEE SARL Service Manual 7FBRE 11- 1

 Cab heating/ventilation – 0630
Air conditioning unit
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

11.1.5 Air direction

C There are four different air vents that can be used to direct the air flow
B
D to avoid fogging the windows and to provide maximum operator com-
A fort.
• Turn control (A) to open/close the vent and (B) to direct the air flow.
• Press button (C) to open/close the vents and (D) to direct the air
flow.
The air vent in the elbow pad cannot be adjusted but can receive
increased airflow by increasing the fan speed and closing vents A, C
and E to some degree.
• Turn control E to increase/decrease airflow to the floor.
The quantity of outside air mixing with the air inside the cabin can be
adjusted by loosening screw F and sliding the plate behind it from side
to side.
P P

11.1.6 Fuses
There are five fuses in the heater. 1 x 5 ampere for the fan and electron-
ics and 4 x 30 amperes for the heating element.

11.1.7 Air filter

Loosen the four screws (A) and remove the cover plate.
Replace the filter with a new one and reinstall the cover plate.

F
E

5A
30 A
30 A G
30 A
30 A

11- 2 Service Manual 7FBRE © TIEE SARL

 Cab heating/ventilation – 0630
Air conditioning unit
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

11.1.8 Emergency exit (12)

If the truck breaks down with the door blocked and cannot be moved,
you can evacuate the cab through the roof.
• Loosen the catches in the roof and lift up the hatch.
• Climb on the seat and arm rests to reach the roof.
WARNING!
Control panel as a step.
The control panel can move.
Never climb on the control panel.
• Call for help to get down from the roof.
WARNING!
Risk of slipping.
The roof can be slippery.
Get down from the roof in a safe manner. Make sure you get help.

11.1.9 Lighting
In the light fitting there are two 24 volts tubes.
• Switch on the roof light by using the switch to the side of the lamp.
For further information see electric diagram C-code 5000

© TIEE SARL Service Manual 7FBRE 11- 3

 Cab heating/ventilation – 0630
Air conditioning unit
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

11- 4 Service Manual 7FBRE © TIEE SARL

 Driver Protection – 0840
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

12- Driver Protection – 0840

12.1 General
To increase the truck’s stability tilt stops are fitted to some trucks. Tilt
stops are also available as an option on other trucks.
It is however permissible to temporarily remove tilt stops during trans-
port of the truck, for instance between different warehouses, but the
truck may not then 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 with proper distance to the floor if
they have been temporarily removed.
The tilt stops are located on the rear corners of each support arm and
consist of lugs, shims, bolts and washers.
.

© TIEE SARL Service Manual 7FBRE 12- 1

 Driver Protection – 0840
Tilt Stops
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

12.2 Tilt Stops

12.2.1 Inspection and Adjustment

To ensure safe operation of the truck, it is important to check the space
between the tilt stops and the floor regularly.
• Park the truck on a flat surface.
• Measure the distance between the tilt stop and the floor (max. 15
mm).
.

• If the tilt stop scrapes the floor or if the distance is too great, the lugs
must be adjusted.
• Lift up the rear edge of the support arm using a jack and place a
wooden block under the support arm to prevent the truck from top-
pling over.
• Break the seal.
• Remove the bolts and washers.
• Re-shim the stop so that the distance between it and the floor is as
close to 15 mm as possible. However, the distance must not exceed
15 mm. Each shim is 4 mm.
• Fit the remaining shims between the tilt stop and the bolt's washer.

• Refit the bolts and washers.

• Using a torque wrench, tighten bolts to 77.7 Nm.

12- 2 Service Manual 7FBRE © TIEE SARL

 Driver Protection – 0840
Tilt Stops
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

12.2.2 Removing the tilt stops

Some tilt stops can be removed. Carefully follow the observations in the
table below.

Truck Lift height Comments

7FBRE16, 1–2 Not equipped with tilt stops
7FBRE16–3 The tilt stops must not be removed
7FBRE25, 1–2 -7.000 mm The tilt stops can be removed
7FBRE25, 1–2 -8.000 mm The tilt stops can be removed
7FBRE12, 14, 1–3 -max lift height The tilt stops can be removed

© TIEE SARL Service Manual 7FBRE 12- 3

 Driver Protection – 0840
Tilt Stops
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

12- 4 Service Manual 7FBRE © TIEE SARL

 Electric pump motor – 1710.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

13- Electric pump motor – 1710.1

13.1 General
The pump motor is a three-phase AC motor. In the motor, there is a
thermoelement measuring the motor temperature, as well as a bearing
with an integrated measuring unit for measuring rotational speed and
direction.
The pump motor is available in two sizes on the trucks.
P112—150 are used on 7FBRE16 and 7FBRE20.
P112—195 are used on 7FBRE25.
This service manual includes instructions for replacing bearings, axle
seals and the temperature sensor.

13.2 Dismantling the pump motor

© TIEE SARL Service Manual 7FBRE 13- 1

 Electric pump motor – 1710.1
Dismantling and assembling the pump motor
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

13.3 Dismantling and assembling the

pump motor
• Loosen the handle beside the driver seat and swing the door out-
wards.
3
6 13.3.1 Dismantling
7 • Lower the forks to the lowest position to reduce pressure in the hos-
es and pump.
12 • Disconnect the battery plug.
4 • Pump the oil out of the hydraulic tank (3) with filter pump V10-15191.

• Remove the support (4) so that the bolts (5) for the pump mounting
(12) are accessible.
• Remove the temperature/speed measuring contacts (6) and power
cables (7) from the motor (8).
• Remove the hydraulic hose (9) and loosen the hose clamp for the
hydraulic hose (10) which is attached to the tank.
• Fasten a lifting eye in the motor axle.
• Remove the bolts (5) holding the pump mounting (12) to the chassis.
• Lift out the hydraulic pump and place it on a clean surface.
• Remove both mounting attachments (12) from the pump motor (8).
• Remove the screws and dismount the pump (13).
• Remove the carrier.

13

13- 2 Service Manual 7FBRE © TIEE SARL

 Electric pump motor – 1710.1
Dismantling and assembling the pump motor
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

3 13.3.2 Assembling
6 • If the O-ring on the pump is damaged, it should be replaced.
7 • Replace the carrier between the pump and the pump motor (8).
• Replace the pump unit (13) on the pump motor (8).
12 • Replace both mounting (12) attachments on the pump motor (8).
4
• Screw a lifting eye into the end of the motor axle and connect it to an
overhead crane.
• Lift the hydraulic pump into the truck while at the same time refitting
the hydraulic hose (10) on the tank (3).
• Tighten the hose clamp.
• Fasten the two pump mountings (12) to the chassis using the bolts
(5).
• Unscrew the lifting eye.
• Refit the hydraulic hose (9) and the temperature/speed metering
contacts (6) and the power cables (7).
• Fill the hydraulic tank (3) with new oil.
• Close the door and tighten the handle.

13

© TIEE SARL Service Manual 7FBRE 13- 3

 Electric pump motor – 1710.1
Bearing replacement
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

13.4 Bearing replacement

19 16 6 2 1 26 25 10 36

13 22 17 9 4 11 24 27

3
8
23

D N

30 28 20 21

13.4.1 Dismantling
Motors without pumps.
• Loosen the screws (23) and remove the protective plate (8).
• Loosen the stud screws (20) using tool 08-15444.
• Remove the shield (3) and washer (7).
If both bearings are to be replaced follow the points below. When only
replacing the pulse sensor bearing continue with A.
• Remove the screws (22).
• Lift the rotor (4) out of the stator (1).
• Dismount the shield (2) radial seal (19).
• Remove the circlip (16) and support ring (17).
• Pull off the bearing with a puller.
A)
• Pull off bearing (5) with a puller.

13- 4 Service Manual 7FBRE © TIEE SARL

 Electric pump motor – 1710.1
Bearing replacement
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

13.4.2 Assembling
Ensure all parts are intact and clean before assembly.
Follow all instructions if both bearings have been replaced
• Place the bearing cap (9) on the rotor axle's D-side.
• Press the bearing (6) on the rotor axle.
• Press the bearing (5) on the rotor axle's N-side.
• Mount the support ring (17) and circlip (16) on the axle's
D-side.
• Fit the gasket (19) with the assembly device.
NOTE
Always use a new gasket when fitting the rotor axle.
• Install the rotor in the end shield (2).
• Tighten the bearing cap (9) using the screws (22) to a torque of 6
Nm.
• Fit the rotor (4) in the stator (1).
• Put the washer (7) on the bearing (5).
Ensure that the terminal block assembly 11 is in position
• Install the end shield (3).
• Tighten the stud screws (20) and nuts (21) to a torque of
5 Nm.
• Fit the ferrite block on the sensor cable.
• Fit the protective plate (8) on the N-side.
• Secure the cables from the thermocontact and the sensor bearing to
one of the power cables.
If only the pulse sensor bearing is replaced:
• Press the bearing (5) on the rotor axle's N-side.
• Put the washer (7) on the bearing (5).
Ensure that the terminal block assembly 11 is in position
• Install the end shield (3).
• Tighten the stud screws (20) and nuts (21). With a torque wrench,
tighten the nuts to 5 Nm.
• Fit the ferrite block on the sensor cable.
• Fit the protective plate (8) on the N-side.
• Secure the cables from the thermocontact and the sensor bearing to
one of the power cables.

© TIEE SARL Service Manual 7FBRE 13- 5

 Electric pump motor – 1710.1
Installation instructions for external temperature sensor
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

13.5 Installation instructions for

external temperature sensor
Number 170384

A fully functional temperature sensor mounted inside the motor should

have a resistance value of approx. 550 ohm at a temperature of 20
degrees.
The temperature sensor mounted on the outside has a resistance value
of approx. 670 ohm at a temperature of 20 degrees.
• The temperature sensor can be mounted to the right or left of the ter-
minal block, depending on which side is easiest to access.

13- 6 Service Manual 7FBRE © TIEE SARL

 Electric pump motor – 1710.1
Installation instructions for external temperature sensor
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

• Scrape the surface clean where the new temperature sensor is to be

mounted.
• Place the temperature sensor as shown in the picture.

• Apply metallic lacquer over the sensor. Ensure that the entire sensor
is covered by the metallic lacquer.

• Fasten the metallic lacquer and the sensor with masking tape and al-
low it to harden.

© TIEE SARL Service Manual 7FBRE 13- 7

 Electric pump motor – 1710.1
Installation instructions for external temperature sensor
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Remove the masking tape. The temperature sensor should now be

fixed in place and covered entirely by metallic lacquer.
• Remove the ferrite block from the old sensor and mount it on the ca-
ble to the new sensor.
• Remove the contact from the broken sensor, which is attached to the
motor.
• Place the new sensor contact in the old bracket and connect it to the
cables.
• Fasten the old contact and its cables using a cable tie so it cannot
damage anything.

13- 8 Service Manual 7FBRE © TIEE SARL

 Electric Pump Motor – 1710.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

14- Electric Pump Motor – 1710.2

14.1 General
The pump motor is a single phase DC motor.
7FBRE12, 12C and 7FBRE14, 14C uses TTL 180C-P3A.
This service manual includes instructions for replacing bearings, axle
seals and carbon brushes.

14.2 Dismantling the Pump Motor

14.2.1 Connection

© TIEE SARL Service Manual 7FBRE 14- 1

 Electric Pump Motor – 1710.2
Removing and Replacing the Pump Motor
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

14.3 Removing and Replacing the Pump

Motor
• Loosen the handle beside the driver seat and swing the door out-
wards.

14.3.1 Dismantling
• Drop the forks to the lowest position to reduce pressure in the hoses
and pump.
• Disconnect the battery leads.
• Pump the oil out of the hydraulic tank (3) with filter pump V10-15191.
• Remove the support (4) so that the bolts (5) for the pump mounting
(12) are accessible.
• Loosen the bolts for the fan cover (6) and remove it.
• Loosen the power cables (7) from the motor (8).
• Remove the hydraulic hose (9) and loosen the hose clamp for the
hydraulic hose (10) attached to the tank.
• Fasten a lifting eye to the motor axle.
• Remove the bolts (5) holding the pump mounting (12) to the chassis.
• Lift out the hydraulic pump and place it on a clean surface.
• Remove both mountings (12) from the pump motor (8).
• Remove the screws and dismount the pump (13).
• Remove the carrier.

13

14- 2 Service Manual 7FBRE © TIEE SARL

 Electric Pump Motor – 1710.2
Bearing replacement
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

14.3.2 Assembling
• If the O-ring on the pump is damaged, it should be replaced.
• Assemble the carrier between the pump and the pump motor (8).
• Assemble the pump module (13) on the pump motor (8).
• Assemble both mounting (12) attachments on the pump motor(8).
• Screw a lifting eye into the end of the motor axle and connect it to an
overhead crane.
• Lift the hydraulic pump into the truck while at the same time refitting
the hydraulic hose (10) to the tank (3).
• Tighten the hose clamp.
• Fasten the two pump mountings (12) to the chassis using the bolts
(5).
• Unscrew the lifting eye.
• Refit the hydraulic hose (9), the fan cover (6) and the power cables
(7).
• Fill the hydraulic tank with new oil.
• Close the door and tighten the handle.

14.4 Bearing replacement

© TIEE SARL Service Manual 7FBRE 14- 3

 Electric Pump Motor – 1710.2
Bearing replacement
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

14.4.1 Dismantling (D side)

Motors without pumps.
• Loosen the bolts (1) and remove the bearing plate (2).
• Dismantle the radial seal (3).
• Remove the washer (4).
• Pull off bearing (5) using a puller.

14.4.2 Assembling
Ensure all parts are intact and clean before re-assembly.
• Press the bearing (5) on the rotor axle.
NOTE
Always use a new gasket when mounting the rotor axle.
• Install seal (3) with the assembly device.
• Place the washer (4) on the bearing (5) or in the bearing plate.
• Fit the bearing plate (2) and the bolts/washers (1).

14.4.3 Dismantling (N side)

• Loosen the bolts (6) and remove the fan (7).
• Loosen the nuts/washers (8) and bolts (9) and remove the terminal
block (10).
• Remove the connection cables (11) from the brush-rocker to the ar-
mature windings.
• Loosen the bolts/washers (12) and remove the disc for the bearing
cover (13).
• Loosen the bolts/washers (14).
• Remove the bearing plate (15).
• Remove the circlip (16).
• Pull off bearing (17) using a puller.

14- 4 Service Manual 7FBRE © TIEE SARL

 Electric Pump Motor – 1710.2
Bearing replacement
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

14.4.4 Assembling (N side)

Ensure all parts are intact and clean before assembling.
• Press the bearing (17) on the rotor axle.
• Fit the circlip (16) and bearing plate (15).
• Fit the bolts/washers (14).
• Fit the bolts/washers (12) and the disc for the bearing cover (13)
• Fit the connection cables (10) between the brush-rocker and arma-
ture windings.
• Fit the terminal block (10), bolts (9) and nuts (8).
• Fit the fan (7) and bolts (6).

14.4.5 Carbon brushes and brush holders

14.4.1 New carbon brushes should always be ground in
Normally carbon brushes are supplied pre-ground for motor TTL 180C
P3a (rounded to fit the commutator), if not, the brushes should be
ground as follows:
• Place a piece of medium grade sandpaper (not emery cloth) be-
tween the carbon brush and the commutator with the paper side fac-
ing the commutator.
• The carbon brush is loaded with normal spring pressure. Let the
sandpaper slide against the commutator surface. After grinding lift
out the carbon brush. Now blow clean the carbon brush and holders.
Final grinding should be done using a sandstone.

Commutator
The commutator should have an equal patina, which can vary accord-
ing to the operating conditions. If it is uneven and burnt black, it should
be polished using fine sandpaper (never emery cloth).

Machining the commutator

When it is necessary to machine a worn or uneven commutator, you
must do this correctly.
To do this correctly the cutting speed must be at least 200 m/min
(applies to hard metal) with a feed of 0.8-0.1 mm
The cutting speed should be significantly higher when machining with a
diamond tipped tool, which gives the best result. In both cases the cut-
ting depth should be limited to 0.05 mm.
For a newly treated commutator the max. throw must not exceed 0.02
mm with max unevenness of 4 mm. When running, a throw of 0.04 mm
can be accepted if it is a question of ovality. If it is a question of segment
displacement this should not exceed 0.02 mm.

© TIEE SARL Service Manual 7FBRE 14- 5

 Electric Pump Motor – 1710.2
Bearing replacement
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

The commutator is designed so that it can be machined several times.

Minimum diameter is 77 mm. As a guideline machining should take
place after replacing the carbon brush set three times.
After machining the mecanite should be cleaned from between the seg-
ments to a depth of 0.6 mm. There should be no mecanite residue
remaining on the sides of the segments. Final scraping and cleaning
should take place as illustrated below.

600
0,6 R0,2

14- 6 Service Manual 7FBRE © TIEE SARL

 Electric Steering Motor – 1730
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

15- Electric Steering Motor – 1730

15.1 General
The steering motor is located on the drive assembly cowling. It receives
signals from the steering generator located in the drive panel. The
steering motor is equipped with a gear working directly upon the gear
ring on the drive axle. It is also equipped with two carbon brushes.

15.2 Replacing the Steering Motor

• Loosen the handle beside the driver seat and swing the door out-
wards.

15.2.1 Dismantling
• Shut off the truck using the key.
• Disconnect the steering motor electrical contact from the tank con-
sole.
• Unscrew the screws holding the gear wheel.
• Lift away the steering motor.
• Unscrew the screws holding the gear wheel.
• Pull off the gear with a gear puller.

15.2.2 Assembling
• Replace the O-rings as necessary.
• Tap the gear wheel into place on the steering motor.
• Tighten the gear wheel to 10 Nm.
• Mount the steering motor in the truck.
• Tighten the screws on steering motor to 40 Nm.
• Reconnect the contact.

© TIEE SARL Service Manual 7FBRE 15- 1

 Electric Steering Motor – 1730
Removing and replacing the carbon brushes
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

15.3 Removing and replacing the

carbon brushes
• Unscrew the two plastic plugs on the upper surface of the steering
motor.
• Take out the carbon and examine for wear.
• Replace the carbon as necessary.
• Insert the carbon and screw in the plastic plugs.
• Close the door and tighten the handle.

15- 2 Service Manual 7FBRE © TIEE SARL

 Electric drive motor – 1760
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

16- Electric drive motor – 1760

16.1 General
The drive motor is a three-phase AC motor. In the motor, there is a ther-
moelement measuring the motor temperature, as well as a bearing with
an integrated sensor for measuring rotational speed and direction.
The drive motor is available in two sizes on the truck.
On 7FBRE16 and 7FBRE12, 14 the model D112–130 is used.
On 7FBRE20, 25 model D112–165 is used.
This service manual includes instructions for replacing bearings, axle
seals and the temperature sensor.

16.2 Dismantling the drive motor

© TIEE SARL Service Manual 7FBRE 16- 1

 Electric drive motor – 1760
Dismantling and assembling the drive motor
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

63 16.3 Dismantling and assembling the

14
31 drive motor
60 • Loosen the handle beside the driver seat and swing the door out-
wards.

61
16.3.1 Dismantling the drive motor
• Cut the power by turning off the key and removing the battery plug.
• Remove the temperature, braking and speed measurement con-
tacts (14, 31, 63) and power cables (60) from the motor (61).
• Fasten a lifting eye to the motor axle.
• Loosen and remove the motor mounting bolts (62).
29
27 • Lift out the motor using an overhead crane and place it on a clean
surface.
NOTE:
Risk of damage to the gear wheel (51).
62 7
The gear wheel on the end of the motor is easily damaged.
Lift out the motor with care.
51
• Cover the hole to the transmission when the motor is removed to
54 prevent anything from falling inside the transmission housing.

Removing the gear wheel

• Tap loose the nut (54) and unscrew it using tool 10-15639.
• Pull off the gear wheel (51) using a gear puller.
• Remove the key (7) holding the gear wheel (51) in place.
• Remove the circlip (27) holding the bearing bracket (29) in place.

55 6 33 37 • Pull off the bearing bracket (29) using a gear puller.

Removing the brakes

• Loosen the screws (37) so that the brakes (33) can be removed.
• Remove the outer circlip (16) from the motor axle.
• Remove the brake hub, key (6), plate and inner circlip (16).

16

16- 2 Service Manual 7FBRE © TIEE SARL

 Electric drive motor – 1760
Dismantling and assembling the drive motor
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

16.3.2 Assembling the drive motor

16.3.1 Assembling the brakes
• Refit the inner circlip (16) and key (6).
• Check that the friction disc (55) is centred in relation to the magnet
housing before you try to install the brakes It may be necessary to
charge the magnet coils with 48 V DC to position the brake disc.
• Fit the brake assembly onto the motor. Check that the splines on the
friction disc were not damaged during installation.
• Tighten the mounting screws (38) for the brake assembly.
• Refit the outer circlip (16).

Assembling the gear wheel

• Refit the bearing cage (29) on the motor axle.
29
• Fit the circlip (27).
27
• Fit the key (7).
• Fit the gear wheel (51).
62 7 • Fit a new nut (54).

51 • Use tool 10-15639 and tighten to a torque of 60 Nm.

54 • Lock the nut with a centre punch in the key track.

• Attach a lifting eye to the motor axle and lift the motor axle into the
transmission using an overhead crane.
NOTE:
Risk of damage to the gear wheel (51).
The gear wheel on the end of the motor is easily damaged.
63
Lift the motor in carefully.
14
31 • Tighten the motor (61) into the transmission to a torque of 20 Nm.
60 • Reconnect the temperature, braking, and the speed measurement
contacts (14, 31) and power cables (60) to the motor.
• Remove the lifting eye.
61 • Close the door and tighten the handle.
• For adjustment of the brakes, see chapter 3100.

© TIEE SARL Service Manual 7FBRE 16- 3

 Electric drive motor – 1760
Bearing replacement
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

16.4 Bearing replacement

14 31

23 24 8 55 33
54 51 12 11 2 4 10 1 9 22 25 3 34 6 38

7 27 26 50 28 29 30 21 20 17 5 18 16

16.4.1 Dismantling
16.4.1 N-side
• Loosen the stud screws (20) using tool 08-15444.
• Remove the screws (34).
• Remove the shield (3).
• Remove the circlip (16) and support ring (18).
• Pull off the bearing (5) with a gear puller.

D-side
• Remove the circlip (26) from the bearing housing.
• Pull off the bearing housing (29) with a gear puller.
• Pull the bearing (28) off from the bearing housing with a Kukko ball
bearing puller.
• Remove the seal (30) if it leaks.

16- 4 Service Manual 7FBRE © TIEE SARL

 Electric drive motor – 1760
Bearing replacement
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

16.4.2 Assembling
Ensure all parts are intact and clean before re-assembly.

N-side
• Press the bearing (5) on the rotor axle.
• Replace the bearing cap (8) on the motor axle.
• Install the flange ring (17).
• Refit the washer (18) and circlip (16).
• Screw the bearing cap (8) and shield (3) together using the screws
(34) to a torque of 6 Nm.
• Fit the insulation hose on the sensor bearing cable.
• Place the terminal block (10) between the shields.
• Tighten the stud bolts (20) to a torque of 5 Nm.
• Tie the cables for the thermocontact and the sensor bearing to the
middle power cable.

D-side
• Install a gasket (30) on the bearing housing (29).
• Press the bearing (28) into the bearing housing.
• Fit the circlip (26).

© TIEE SARL Service Manual 7FBRE 16- 5

 Electric drive motor – 1760
Installation instructions for external temperature sensor
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

16.5 Installation instructions for

external temperature sensor
Number 170384

A fully functional temperature sensor mounted inside the motor should

have a resistance value of approx. 550 ohm at a temperature of 20
degrees.
The temperature sensor mounted on the outside has a resistance value
of approx. 670 ohm at a temperature of 20 degrees.

16- 6 Service Manual 7FBRE © TIEE SARL

 Electric drive motor – 1760
Installation instructions for external temperature sensor
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

• The temperature sensor can be mounted to the right or left of the

connection terminal block, depending on which side is easiest to ac-
cess.
• Scrape the surface clean where the new temperature sensor is to be
mounted.
• Place the temperature sensor as shown in the picture.

• Apply metallic lacquer over the sensor. Ensure that the entire sensor
is covered by the metallic lacquer.

© TIEE SARL Service Manual 7FBRE 16- 7

 Electric drive motor – 1760
Installation instructions for external temperature sensor
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

• Fasten the metallic lacquer and the sensor with masking tape and al-
low it to harden.

• Remove the masking tape. The temperature sensor should now be

fixed in place and covered entirely by metallic lacquer.
• Remove the ferrite block from the old sensor and mount it on the ca-
ble to the new sensor.
• Remove the contact from the broken sensor, which is attached to the
motor.
• Place the new sensor contact in the old bracket and connect it to the
cabling.
• Fasten the old contact and its cabling using a cable tie so it cannot
damage anything.

16- 8 Service Manual 7FBRE © TIEE SARL

 Mechanical drive gear unit – 2550
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

17- Mechanical drive gear unit –

2550

17.1 General
This type of truck is equipped with a drive gear unit mounted on the
chassis with 6 bolts.
The transmission is integrated with the motor, brakes, and sensor
measuring speed, steering wheel direction and direction of travel, as a
complete drive assembly. The drive assembly is equipped with 360°
steering.
The transmission in this truck is a two-stage angle transmission with
conical roller bearings on the drive shaft and pinion. The bearings are
pre-tensioned approximately 5/100ths of a mm to minimise the risk of
play in the bearings.
This service instruction includes directions for dismantling and assem-
bling the drive transmission, filling and changing the oil and measures
in the event of leakage. A complete renovation of the drive transmission
is so extensive that specially trained personnel must do this in the work-
shop.

17.2 Components/data for the drive

assembly/transmission
The drive transmission’s main components and data are shown in the
following diagram and table.

© TIEE SARL Service Manual 7FBRE 17- 1

 Mechanical drive gear unit – 2550
Components/data for the drive assembly/transmission
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

17.2.1 Component placement

17- 2 Service Manual 7FBRE © TIEE SARL

 Mechanical drive gear unit – 2550
Components/data for the drive assembly/transmission
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Pos. No. Component

1 Drive motor
2 Drive assembly cowl
3 Steering bearings
4 Upper transmission cover with gear ring
5 Gear wheel, primary step
6 Pinion nut
7 Pinion
8 Pinion bearing
9 Shims, pinion bearing
10 Lower transmission cover
11 Drive shaft nut
12 Nut washer
13 Crown wheel
14 O-ring
15 Drive shaft bearings
16 Shims, drive shaft bearings
17 Sealing ring protection
18 Drive shaft sealing ring
19 Drive shaft
20 Transmission housing

17.2.2 Technical data

Type of truck 7FBRE16 7FBRE20, 25

7FBRE12, 14
Transmission 2-stage angle transmission 2-stage angle transmission
Gear ratio 19,20:1 20,89:1
Oil volume, litre 2.8 3.3
Oil type Hypoid oil Hypoid oil
Viscosity, normal temperature SAE 80W/90 SAE 80W/90
Viscosity, < -15o C SAE 75W SAE 75W

© TIEE SARL Service Manual 7FBRE 17- 3

 Mechanical drive gear unit – 2550
Components/data for the drive assembly/transmission
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

17.2.3 Dismantling the transmission

17- 4 Service Manual 7FBRE © TIEE SARL

 Mechanical drive gear unit – 2550
Replacing the drive motor/drive transmission
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

63 17.3 Replacing the drive motor/drive

14
31 transmission
60 • Loosen the handle beside the driver seat and swing the door out-
wards.

61
17.3.1 Dismantling the drive motor
• Cut the power by turning off the key and removing the battery plug.
• Remove the temperature, braking and speed measurement con-
tacts (14, 31, 63) and power cables (60) from the motor (61).
• Fasten a lifting eye in the motor axle.
• Dismantle the motor’s mounting bolts (62).
• Lift out the motor using an overhead crane and place it on a clean
surface.
NOTE!
Risk of damage to the gear wheel (A).
The gear wheel on the end of the motor is easily damaged.
Carefully lift out the motor.
• Cover the hole in the transmission when the motor has been re-
29 moved to prevent anything from falling inside the transmission hous-
27 ing.
Dismantling the gear wheel
• Tap out the nut (54) lock and unscrew the nut using tool 10-1515639.
62 7
• Pull off the gear wheel (51) using a puller.
51 • Remove the key (7) holding the gear wheel (51) in place.
54 • Remove the circlip (27) holding the bearing bracket (29) in place.
• Pull off the bearing cage (29) using a puller.

© TIEE SARL Service Manual 7FBRE 17- 5

 Mechanical drive gear unit – 2550
Replacing the drive motor/drive transmission
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

17.3.2 Dismantling the drive transmission

• Unscrew the four screws holding the support and lift it out of the way.
• Hoist the machine using a pneumatic jack and put it on blocks.
• If the truck is equipped with a steering wheel indicator: Disconnect
the indicator for centred steering (8) and steering wheel direction (9).
• Disconnect the contact to the steering motor and loosen the contact
(10) from its bracket on the tank plate.
• Unscrew the screws (11) for the steering motor (12) and remove it
from the drive transmission.
• Remove the bolts (14) holding the transmission cowl (15) on the
chassis.
• Remove the transmission (17) with its cowl (15) from the truck.
• Unscrew the drive wheel.
• Remove the bolts (18) holding the drive transmission (17) to its cowl
(15) and lift off the cowl (15).
• Dismantling the steering bearing (16): Unscrew the hexagon
socket bolts (19) and remove the steering bearing (16) from the
transmission (17).

17.3.3 Assembling the transmission

• Assembling the steering bearing (16): Fit the steering bearing
(16) using the 15 hexagon socket bolts (19) on the drive transmis-
sion (17) with LOCTITE 242, to a torque of 25 Nm.
• Always replace the lift valve (20) when the steering bearing has
been removed or when fitting a new bearing.
• Attach the new drive transmission (17) to the cowl (15). Oil the bolts
(18) and tighten them to a torque of 80 Nm.
• Secure the drive wheel, torque 130 Nm.
• Insert the drive transmission (17) into position on the truck.
• Fasten the drive transmission (17) with its cowl (15) to the chassis
with the 6 bolts (14), torque 222 Nm.
• Fit new O-rings and, if necessary, new plastic seals on the steering
motor.
• Fit the steering motor (12) on the drive transmission cowl; the tight-
ening torque on the screws (11) should be 40 Nm.
• Connect the contacts to the steering motor (10).
• If the truck is equipped with a steering wheel indicator: Turn the
steering wheel until an edge is visible through the hole for the cen-
tred steering indicator (8).
• Screw in the centred steering indicator (8) so that it bottoms on the
edge. Then turn it back 1 1/2 turns and lock it in place with a lock nut.

17- 6 Service Manual 7FBRE © TIEE SARL

 Mechanical drive gear unit – 2550
Replacing the drive motor/drive transmission
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

• Screw in the steering wheel direction indicator (9) (red indicator di-
odes towards the battery compartment) until it stops, then turn it
back 1 1/4 turns and lock it in place with a lock nut.

17.3.4 Installing the drive motor

If you replaced the drive transmission (17), also replace the gear wheel
(51) on the drive motor.
If you replaced the drive motor, use the old gear wheel on the new
motor.

Assembling the gear wheel

29
• Replace the bearing cage (29) on the motor axle.
27
• Fit the circlip (27).
• Fit the key (7).
62 7 • Replace the gear wheel (51).

51 • Fit a new nut (54).

54 • Use tool 10-15639 and tighten to a torque of 60 Nm.
• Lock the nut with a centre punch in the keyway.
• Attach a lifting eye to the motor axle and lift into the transmission us-
ing an overhead crane.
NOTE!
Risk of damaging the gear wheel (A).
The gear wheel on the end of the motor is easily damaged.
Carefully lift in the motor.
• Secure the motor (61) in the transmission with a torque of 20 Nm.
• Reconnect the temperature, braking, and the speed measurement
contacts (14, 31) and power cables (60) to the motor.
• Remove the lifting eye.
• Close the door and tighten the handle.
• Brake adjustment, see C-code 3100.

© TIEE SARL Service Manual 7FBRE 17- 7

 Mechanical drive gear unit – 2550
Checking/replacing the oil
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

17.4 Checking/replacing the oil

17.4.1 Checking/refilling the oil

• The oil level in the transmission should be checked after every 250
operating hours.
• Check the oil level in the transmission by removing the oil-refill plug
on the upper part of the transmission housing.
• Fill the oil right up to the opening to reach the correct level.
Hypoid oil MP in the drive transmission.
• SAE 80W/90 for operations in normal temperature.
SAE 75W for operations in cold stores, < -15o C.
• Oil volume:
7FBRE16: approx. 2.8 litres.
7FBRE20, 25: approx. 3.3 litres.
7FBRE12, 14: approx. 2.8 litres.

17.4.2 Changing the Oil

Replace the oil in the transmission for the first time after 50-100 operat-
ing hours and then every 3000 operating hours.

• To drain the old oil, remove the lower transmission cowl completely.
• Replace the O-ring seal with every oil change. Make sure the new
O-ring is not damaged when fitted.
• Fit the cover and tighten the bolts to a torque of 25 Nm. The bolts
should be greased before assembly.
• Fill with oil as instructed in the chapter "Checking/refilling the oil."

17- 8 Service Manual 7FBRE © TIEE SARL

 Mechanical drive gear unit – 2550
Repairs
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

17.5 Repairs

17.5.1 Replacing the drive shaft sealing ring

Replacing the drive shaft sealing ring is easiest when the drive assem-
bly is removed from the truck.
Follow the instructions below if oil leaks from the drive shaft.

Dismantling
• Remove the drive assembly from the truck as described in the sec-
tion "Replacing the drive motor/drive transmission".
• Remove the lower transmission cowl (2) and drain the oil.
• Loosen the drive shaft nut.
Remove the nut and spacer ring.
• Carefully tap out the drive shaft using a hammer and brass drift.
• Pull off the bearing from the drive shaft using tool 08-13022.
NOTE!
A standard claw puller cannot be used to remove the bearing.
Use a puller such as a KUKKO bearing puller.
• Check whether the spacer washers (6) on the bearing are damaged.
If the puller damaged them, measure the spacer washers' combined
thickness and replace them before assembling.
• Remove the sealing ring ring (7) from the drive shaft.

7 6 5 2

© TIEE SARL Service Manual 7FBRE 17- 9

 Mechanical drive gear unit – 2550
Repairs
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Assembling
Follow the instructions below when assembling after replacing the drive
shaft sealing ring.

• Insert the drive shaft's outer bearing (1) into place in the transmis-
sion housing.
• Push the new sealing ring into the transmission housing. Be careful
when pushing in the sealing ring to seat it properly in position.
• Place the axle bearing’s spacer washers on the drive shaft, building
the same total thickness as the original ones. Ensure only undam-
aged spacer washers are used.
• Press the drive shaft , with the spacer washers, into the transmis-
sion.
Check that the drive shaft splines correspond with the splines in the
crown wheel.
• Place the distance ring on the end of the drive shaft, and put the
shaft nut into position.
Always use a new nut. The drive shaft nut should be oiled before it
is placed on the shaft.
Tighten the nut to a torque of 700 Nm and lock it in place by centre
punching the keyway in the shaft.
• Replace the O-ring before installing the lower cowl. Make sure it is
not damaged. Fit the cowl and tighten the bolts to a torque of 25 Nm.
The bolts should be greased before assembly.
• Fill with oil as set out in the instructions for refilling.

17- 10 Service Manual 7FBRE © TIEE SARL

 Mechanical drive gear unit – 2550
Repairs
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

17.5.2 Leakage from the upper cover

Follow instructions below in the event of leakage from the transmis-
sion's upper cowl:

• Remove the transmission from the truck as described in the section

"Replacing the drive motor/drive transmission"
• Loosen all bolts holding the upper cowl on the transmission housing.
• Remove the cover from the transmission housing and clean the
sealant surfaces carefully, both on the cowl and the transmission
housing.
• Apply sealant such as Curil K2 to the surfaces. Follow the instruc-
tions on the package.
• Fit the cover and tighten the bolts to a torque of 46 Nm.
The bolts should be greased prior to assembly.
• Fill with oil as set out in the instructions for refilling.
• Assemble the drive transmission/drive motor and fit the drive as-
sembly in the truck as described in the section "Replacing the drive
motor/drive transmission."

17.5.3 Leakage from the lower cover

• Drain the remaining oil from the transmission.
• Dismantle the cover from the transmission.
• Replace the sealing ring on the drainage plug and the O-ring on the
cover.
• Mount the cover and tighten the bolts to a torque of 25 Nm. Make
sure the O-ring is not damaged. The bolts should be greased before
assembly.

© TIEE SARL Service Manual 7FBRE 17- 11

 Mechanical drive gear unit – 2550
Repairs
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

17.5.4 Replacing wheel bolts

The wheel bolts on the transmission are stud bolts. To replace the
wheel bolts, proceed as follows:

• Pull out the battery's emergency disconnector.

• Remove the bumper by the drive wheel from the chassis.
• Lift the machine using a jack and put it on blocks.
• Dismantle the drive wheel.
• Wheel bolts with damaged threads are removed using the stud bolt
tool.
• Broken wheel bolts:
• Method 1: Drill a hole in the centre of the bolt and screw out the bolt
using a screw extractor for M14 bolts.
• Method 2: If the bolt will not come loose with a screw extractor, the
bolt must be drilled out.
- Centre punch the centre of the bolt, be precise when centring the
punch.
- Drill a pilot hole through the bolt using a 5 mm bit.
Drill out the bolt using an 11.5 mm bit.
- Try to remove the remains of the bolt with pliers or the like. If that
does not work, remove the remains by clearing the threads with a
screw tap M14x1.5.
• Apply LOCTITE 270 on the threads of the wheel bolts.
Mount the new wheel bolt with a stud bolt tool.
Tightening torque: 80 Nm
• Fit the drive wheel. Tighten the wheel nuts to 130 Nm.
• Remove the blocks and lower the truck.
• Fit the bumper.
• Connect the emergency battery disconnector.

17- 12 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

18- Travel brake system – 3100.1

With support arm brake

18.1 General
The truck’s travel brake system consists of three separate subsystems.
• Regenerative motor braking using the drive motor.
• Two analogue electromechanical multiple disc brakes fitted in the
support arm wheels.
• A single stage electromechanical disc brake fitted on the motor.

18.2 Operating description

The travel brake system’s primary braking function is the regenerative
motor brake from the drive motor. Braking can be actuated in three dif-
ferent ways:
• When the accelerator is released
• By switching the travel direction using the travel direction selector,
normal motor braking.
• By pushing down the brake pedal.

© TIEE SARL Service Manual 7FBRE 18- 1

 Travel brake system – 3100.1
Operating description
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

18.2.1 Releasing the accelerator

The regenerative motor brake is automatically engaged when the
accelerator is released.
The braking force can be set via a parameter by the driver, see C-code
5710.
The motor braking force is regulated progressively in relation to the
speed and the amount the accelerator is released. This functions as fol-
lows:
• Braking at a high speed, the accelerator is released completely,
gives a high braking force.
• Braking at a low speed, the accelerator is released completely, gives
a low braking force.
• Braking at a high speed, the accelerator is released halfway, gives
medium braking force.

18.2.2 Travel direction selector

The braking force is regulated by the position of the accelerator, i.e. the
more the pedal is pressed down the greater the braking effect.

18.2.3 Pressing down the brake pedal

Full regenerative motor braking is obtained when the brake pedal is
pressed down 50% of its stroke length.
If the brake pedal is pressed down more than 50%, further braking force
is obtained as the multiple disc brakes in the support arm wheels are
activated.
When the brake pedal is pressed down between 85-90%, the electro-
mechanical disc brake is also activated on the drive motor at the same
time as the motor brake is reduced corresponding to the disc brake’s
braking force to avoid heavy jerking or wheel locking, see fig.

18.2.4 Parking brake

The parking brake is activated/is active when:
• The parking brake is activated automatically when the truck is
stopped when driving and the truck brakes to a stop with the help of
the brake pedal.
The brakes are released when the accelerator is pressed down.
• The parking brake is activated automatically with a few seconds of
delay when the driver leaves the truck.
• The parking brake remains active after the ignition switch is
switched on.

18- 2 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.1
Operating description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

18.2.5 Emergency braking

Emergency braking of the truck takes place in the event of a fault with
the control system or a serious fault in the electrical systems.
• The electromechanical disc brake on the drive motor is the primary
emergency brake.
• The motor brake can act with emergency braking under the condi-
tion that the voltage supply works.

© TIEE SARL Service Manual 7FBRE 18- 3

 Travel brake system – 3100.1
Electromechanical disc brake, drive motor
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

18.3 Electromechanical disc brake,

drive motor
The brake is a single stage electromechanical spring force brake that
releases when the magnetic coil is energised.
The brake acts as a parking brake, emergency and a third travel brake
at the end of the brake pedal’s stroke.

18.3.1 Assembling

• Fit the brake on the motor shaft.

• Fit the O-ring (10) in the groove on the hub
• Ensure that the friction disc (4) is centred in relation to the magnet
housing before you try to install the brakes.
It may be necessary to energise the magnet coil with 48 V DC to po-
sition the brake disc.
• Fit the brake assembly onto the motor. Check that the splines on the
friction disc were not damaged during installation.
• Fit and tighten the brake unit’s three securing bolts.
• Check the play between the magnet housing and the pressure plate
with the brake applied, should be 0.25-0.40 mm.
The play may need to be adjusted, see section adjustment.
• Connect the brake cable (11) to the truck’s electrical system.
• Switch on the ignition switch and release the parking brake.
Check that the friction disc rotates freely.
Cut the voltage and check that the pressure plate locks the friction
disc and that the play (0.25-0.40 mm) is correct.
NOTE!
The seat switch must be made.
Use the strap contact 159747 to strap the switch so that you can work
without the need of sitting on the seat.
Bear in mind safety, the system is energised.

18- 4 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.1
Maintenance
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

18.3.2 Dismantling
• Dismantle the brake in the reverse order.
• Place the brake on a clean and dry workbench with the magnet
housing (1) facing upward.
• Unscrew the 3 adjuster screws (8) gradually to reduce the spring
tension equally.
• The brake unit can now be dismantled fully for inspection of the com-
ponent parts.

18.3.3 Inspection
Investigate the parts regarding damage and/or wear.
• Check the brake disc (4) and the wear surfaces on the pressure
plates (2) and (5) extra carefully.
• Check the springs (7) and the spacers (6) with regard to damage.
NOTE!
Bear in mind the spacer nut is made of brass.
• Check for signs of damage to the splines on the hub (3) and friction
disc (4).
• Check for signs of swelling or damage to the magnet (1) and pres-
sure plate (2).

18.3.4 Assembling
• Clean the parts carefully.
• Assemble the brake in the reverse order to dismantling.
• Bear in mind the following:
- That the hole in the pressure plate (2) aligns with the correspond-
ing hole in the magnet housing.
- That the right number of springs have been fitted.
- That the play 0.25-0.40 mm is set correctly, some adjustment
may be necessary.

18.4 Maintenance
The brake is included as a checkpoint in the truck’s maintenance chart,
for intervals see the maintenance chart section P2.
Maintenance comprises inspection and adjustment of the play between
the pressure plate and magnet housing, wear, braking force and clean-
ing.
NOTE!
The friction surfaces must not come into to contact with oil or grease
as this will seriously reduce the brake’s braking force.

© TIEE SARL Service Manual 7FBRE 18- 5

 Travel brake system – 3100.1
Maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

18.4.1 Adjusting the play

• The play must be checked every 1000 operating hours.
• The play (A) is measured between the magnet housing and the
pressure plate in three positions, by the adjuster sleeves (6) with the
brakes actuated.
• Nominal play with correct adjustment is 0.25-0.40 mm.
• Maximum permitted play is 0.50 mm before adjustment is neces-
sary.
Tools
• Feeler gauges, 14 mm box spanner and 6 mm allen key
• Loosen the three bolts (8).
• Adjust the play using the three adjuster sleeves (6) to 0.25-0.40 mm.
Measure, using the feeler gauges, by the side of the adjuster sleeve
when adjusting.
Turning anticlockwise reduces and clockwise increases the play.
• Tighten the bolts to 20 Nm.
• Recheck the play after tightening the bolts.
Repeat the adjustment if necessary until the play is correct.
• Check the play all the way around the pressure plate. Maximum per-
mitted deviation from the set play is 0.075 mm.

18.4.2 Wear
• Check the friction disc for wear every 3000 operating hours.
• Strip the brake as set out in the section “Dismantling”.
• Measure the thickness of the friction disc. Minimum thickness = 8.0
mm.

18- 6 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.1
Maintenance
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

18.4.3 Check the braking force

The braking force must be checked at least every 1000 operating
hours.
• Lift up the truck so that the drive wheel is free of the ground
• Open the motor compartment covers.
Tools
• Torque wrench set to90 Nm and a M12 flange bolt, or a normal bolt
and flat washer
NOTE!
The bolt quality shall be at least 10.9.

• Screw in the M12 bolt in the hole (for the lifting hole) in the motor ax-
le.
• Turn the motor axle using the torque wrench until the brakes re-
lease.
• If the brake releases before the torque wrench trips the braking force
is too low.
• Adjust the brake play to the right value, see adjusting the play.
• Check the braking force again using the torque wrench.

© TIEE SARL Service Manual 7FBRE 18- 7

 Travel brake system – 3100.1
Multiple disc brake, support arm
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

18.5 Multiple disc brake, support arm

The brake is an analogue electromagnetic multiple disc brake, that is
the brake is applied by energising the magnet coil. The current in the
magnet coil is regulated by a potentiometer in the brake pedal and
thereby regulates the braking force. The multiple discs are of steel. The
brake acts as a secondary travel brake and is applied when the driver
needs to brake heavily, >50% of the available braking force.
The brake is assembled inside the support arm wheel on a hub with
splines and a locking heel that takes up the braking force.
The support arm wheel must be dismantled from the truck to check and
maintain the brake, see C-code 3550, except when inspecting the actu-
al magnet coil, which can be done with the wheel fitted. All instructions
given below assume that the wheel has been dismantled.

18.5.1 Assembling
• Check that the brakes apply and releases as they should. Connect
the brakes to 48 V D.C. Switch the current on and off.
• Check that the play between the end plate (6) and pressure plate (2)
is 1.0-1.25 mm with the current switched on (brakes applied). The
play may need to be adjusted, see section adjustment.
NOTE!
Check the play at the same time in two positions at 180 degree spac-
ing.
• Fit the brake in the support arm wheel. Make sure that the inner disc
splines are aligned correctly so that they go on the splines on the
wheel hub without resistance.
• Assemble the wheel in the support arm according to instruction C-
code 3550.
Ensure the locking heel (8) is positioned in it cut-out in the support
arm.
• Connect the brake cable (14) and check the brake function by press-
ing down the brake pedal fully.

18- 8 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.1
Multiple disc brake, support arm
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

18.5.2 Dismantling

• Lift the brake out of the support arm wheel.

• Place the brake on a clean and dry work bench with the magnet
housing (6) facing upward.
NOTE!
Exercise care so that the components and cables are not damaged
during this and the following work.
• Loosen and remove the sex M6x40 socket head screws (12) and
their washers
• Remove the aluminium end plate (6).
NOTE!
Note the number of shim washers (11) on each spacer (5).
• Lift off the pressure plate (2) and the disc assembly that consists of 3
outer discs (3) and 2 inner discs (4).
• Remove the brass disc (7).

© TIEE SARL Service Manual 7FBRE 18- 9

 Travel brake system – 3100.1
Maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

18.5.3 Inspection
• Check the thickness of the discs.
The nominal thickness of a new disc = 2.0 mm
Wear limit = 1.4 mm
• When replacing discs. Replace all inner and outer discs at the same
time. Not individually.
• Also check that the discs are flat and that the splines or cut-outs are
not damaged.
• Check the magnet coil’s electrical resistance. Nominal 47.7 Ohm at
20o C
NOTE!
The resistance measurement can be performed with the brake/wheel
in the truck.

18.5.4 Assembling
• Clean the parts carefully.
NOTE!
Clean only with a wire brush and dry cloth.
• Assemble the brake in the reverse order.
• Connect the brake to 48 V D.C.
• Check the play between the end plate and pressure plate (brake ap-
plied). Adjust the play if necessary.

18.6 Maintenance
The brake is included as a checkpoint in the truck’s maintenance chart,
for intervals see the maintenance chart section P2.
Maintenance comprises inspection and adjustment of the play between
the pressure plate and end plate, wear and the magnet coil’s resistance
and cleaning.
• Cleaning and inspection/adjusting of the play shall be carried out
every 1000 operating hours.
• Check for wear and the magnet coil’s resistance shall be carried out
every 3000 operating hours.

18- 10 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.1
Maintenance
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

18.6.1 Adjusting the play

• Dismantle the support arm wheel from the truck and remove the
brake.
• Connect the brake to 48 V D.C.

• Check the play, measurement A, with the brake applied.

NOTE!
Check the play at the same time in two positions at 180 degree spac-
ing.
• Maximum permitted play = 2.25 mm
• Nominal play of newly adjusted brakes shall be 1.0-1.25 mm.
• Before adjusting, dismantle the aluminium end plate.
• Remove the shim washers, when adjusting due to wear, or add shim
washers when fitting new discs.
Each shim washer is 0.127 mm thick.
• Fit the aluminium end plate, connect to 48 V D.C. and check the
play.
• When the play lies within the nominal permitted value, fit the brake in
the wheel and the wheel on the truck.

© TIEE SARL Service Manual 7FBRE 18- 11

 Travel brake system – 3100.1
Maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

18- 12 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

19- Travel brake system – 3100.2

Without support arm brakes

19.1 General
The truck’s travel brake system consists of two separate subsystems.
• Regenerative motor braking using the drive motor.
• A single stage electromechanical disc brake fitted on the motor. This
is also the truck’s parking brake.

19.2 Operating description

The travel brake system’s primary braking function is the regenerative
motor brake from the drive motor. Braking can be actuated in three dif-
ferent ways:
• When the accelerator is released
• By switching the travel direction using the travel direction selector,
normal motor braking.
• By pushing down the brake pedal.

19.2.1 Releasing the accelerator

The regenerative motor brake is automatically engaged when the
accelerator is released.
The braking force can be set via a parameter by the driver, see
C-code 5710.
The motor braking force is regulated progressively in relation to the
speed and the amount the accelerator is released. This functions as fol-
lows:

© TIEE SARL Service Manual 7FBRE 19- 1

 Travel brake system – 3100.2
Operating description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

• Braking at a high speed, the accelerator is released completely,

gives a high braking force.
• Braking at a low speed, the accelerator is released completely, gives
a low braking force.
• Braking at a high speed, the accelerator is released halfway, gives
medium braking force.

19.2.2 Travel direction selector

The braking force is regulated by the position of the accelerator, i.e. the
more the pedal is pressed down the greater the braking effect.

19.2.3 Pressing down the brake pedal

Full regenerative motor braking is obtained when the brake pedal is
pressed down 80% of its stroke length.
If the brake pedal is pressed down between 80-100%, further braking
force is obtained as the electromechanical disc brake on the drive
motor is activated.
In the limit area, at 80%, the motor brake reduces corresponding to the
braking torque to avoid heavy jerking or wheel locking, see fig.

19- 2 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.2
Electromechanical disc brake, drive motor
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

19.2.4 Parking brake

The parking brake is activated/is active as follows:
• The parking brake is activated automatically when the truck is
stopped when driving and the truck brakes to a stop with the help of
the brake pedal. The brakes are released when the accelerator is
pressed down.
• The parking brake is activated automatically with a few seconds of
delay when the driver leaves the truck.
• The parking brake remains active after the ignition switch is
switched on.

19.2.5 Emergency brake

Emergency braking of the truck takes place in the event of a fault with
the control system or a serious fault in the electrical systems.
• The electromechanical disc brake on the drive motor is the primary
emergency brake.
• The motor brake can act with emergency braking under the condi-
tion that the voltage supply works.

19.3 Electromechanical disc brake,

drive motor
The brake is a single stage electromechanical spring force brake that
releases when the magnetic coil is energised. The brake acts as a park-
ing brake, emergency and secondary travel brake at the end of the
brake pedal’s stroke.

19.3.1 Assembling

• Fit the brake on the motor axle.

• Ensure that the friction disc (4) is centred in relation to the magnet
housing before you try to install the brakes.
It may be necessary to energise the magnet coil with 48 V DC to po-
sition the brake disc.
• Fit the brake assembly onto the motor. Check that the splines on the
friction disc were not damaged during installation.
© TIEE SARL Service Manual 7FBRE 19- 3
 Travel brake system – 3100.2
Electromechanical disc brake, drive motor
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

• Fit and tighten the brake unit’s three securing bolts.

• Check the play between the magnet housing and the pressure plate
with the brake applied, should be 0.25-0.40 mm.
The play may need to be adjusted, see section adjustment.
• Connect the brake cable (11) to the truck’s electrical system.
• Switch on the ignition switch and release the parking brake.
Check that the friction disc rotates freely.
Cut the voltage and check that the pressure plate locks the friction
disc and that the play (0.25-0.40 mm) is correct.
NOTE!
The seat switch must be made.
Use the strap contact 159747 to strap the switch so that you can work
without the need of sitting on the seat.
Bear in mind safety, the system is energised.

19.3.2 Dismantling
• Dismantle the brake in the reverse order.
• Place the brake on a clean and dry workbench with the magnet
housing (1) facing upward.
• Unscrew the 3 adjuster screws (8) gradually to reduce the spring
tension equally.
• The brake unit can now be dismantled fully for inspection of the com-
ponent parts.

19.3.3 Inspection
Investigate the parts regarding damage and/or wear.
• Check the brake disc (4) and the wear surfaces on the pressure
plates (2) and (5) extra carefully.
• Check the springs (7) and the spacers (6) with regard to damage.
NOTE!
Bear in mind the spacer nut is made of brass.
• Check for signs of damage to the splines on the hub (3) and friction
disc (4).
• Check for signs of swelling/deformation or damage to the magnet (1)
and pressure plate (2).

19- 4 Service Manual 7FBRE © TIEE SARL

 Travel brake system – 3100.2
Maintenance
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

19.3.4 Assembling
• Clean the parts carefully.
• Assemble the brake in the reverse order to dismantling.
• Bear in mind the following:
- That the hole in the pressure plate (2) aligns with the correspond-
ing hole in the magnet housing.
- That the right number of springs have been fitted.
- That the play 0.25-0.40 mm is set correctly, some adjustment
may be necessary.

19.4 Maintenance
The brake is included as a checkpoint in the truck’s maintenance chart,
for intervals see the maintenance chart section P2.
Maintenance comprises inspection and adjustment of the play between
the pressure plate and magnet housing, wear, braking force and clean-
ing.
NOTE!
The friction surfaces must not come into to contact with oil or grease
as this will seriously reduce the brake’s braking force.

19.4.1 Adjusting the play

• The play must be checked every 1000 operating hours.
• The play (A) is measured between the magnet housing and the
pressure plate in three positions, by the adjuster sleeves (6) with the
brakes actuated.
• Nominal play with correct adjustment is 0.25-0.40 mm.
• Maximum permitted play is 0.50 mm before adjustment is neces-
sary.
Tools
• Feeler gauges, 14 mm box spanner and 6 mm allen key
• Loosen the three bolts (8).
• Adjust the play using the three adjuster sleeves (6) to 0.25-0.40 mm.
Measure, using the feeler gauges, by the side of the adjuster sleeve
when adjusting.
Turning anticlockwise reduces and clockwise increases the play.
• Tighten the bolts to 20 Nm.
• Recheck the play after tightening the bolts.
Repeat the adjustment if necessary until the play is correct.
• Check the play all the way around the pressure plate. Maximum per-
mitted deviation from the set play is 0.075 mm.

© TIEE SARL Service Manual 7FBRE 19- 5

 Travel brake system – 3100.2
Maintenance
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

19.4.2 Wear
• Check the friction disc for wear every 3000 operating hours.
• Strip the brake as set out in the section "Dismantling”.
• Measure the thickness of the friction disc. Minimum thickness = 8.0
mm.

19.4.3 Check the braking force

The braking force must be checked at least every 1000 operating
hours.
• Lift up the truck so that the drive wheel is free of the ground
• Open the motor compartment covers.
Tools
• Torque wrench set to 90 Nm and a M12 flange bolt, or a normal bolt
and flat washer
NOTE!
The bolt quality shall be at least 10.9.

• Screw in the M12 bolt in the hole (for the lifting hole) in the motor axle.
• Turn the motor axle using the torque wrench until the brakes re-
lease.
• If the brake releases before 90 Nm is reached the braking force is
too low.
• Adjust the brake play to the right value, see adjusting the play.
• Check the braking force again using the torque wrench.

19- 6 Service Manual 7FBRE © TIEE SARL

 Drive wheel – 3530
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

20- Drive wheel – 3530

20.1 General
The drive wheel consists of a cast rim with a vulcanised tread. When
changing the drive wheel you must ensure that you tighten the wheel
nuts to the correct torque.
On the 7FBRE truck two different sizes of wheel have been used.
One with the dimensions diameter 310x120 mm and one 350x130 mm.
The smaller wheel (310 mm) is used on 7FBRE16 and 7FBRE12, 14.
The larger wheel (350 mm) is used on 7FBRE20, 25.

20.2 Dismantling the drive wheel

• Lift up the truck on blocks so that the drive wheel is off the ground.
• Unscrew the four bolts holding the guard plate.
• Remove the guard plate.
• Unscrew the nuts holding the drive wheel in position.
• Lift off the drive wheel.

20.3 Assembling the drive wheel

• Lift on the new drive wheel.

• Apply MOLYKOTE grease number 055-73040 on the wheel bolts.
• Position the spherical washers (1) on the wheel bolts.
• Tighten the wheel nuts (2) to 130 Nm.
• Fit the guard plate.
• Remove the blocks.

© TIEE SARL Service Manual 7FBRE 20- 1

 Drive wheel – 3530
Assembling the drive wheel
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

20- 2 Service Manual 7FBRE © TIEE SARL

 Fork/support arm wheel – 3550.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

21- Fork/support arm wheel – 3550.1

21.1 General
On the 7FBRE five different kinds of support arm wheels are used. The
wheel is fitted to the support arm with a through axle and clamping
sleeve. The axle has a threaded hole for use with dismantling and
assembling.

Type of truck Wheel diameter, Brake/No brake

mm
7FBRE16 265 No
7FBRE16 300 No
7FBRE16 300 Yes
7FBRE20 350 No
7FBRE20, 25 350 Yes

© TIEE SARL Service Manual 7FBRE 21- 1

 Fork/support arm wheel – 3550.1
Dismantling the wheel
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

21.2 Dismantling the wheel

• Lift up the truck and support using blocks so that the support arm
wheel runs free of the ground.
• Unscrew the two bolts holding the guard plate above the wheel.
• Remove the guard plate.
For wheels without brakes
• Pull out the wheel axle using tool 08-13585. Use the short punch.
• Lift out the wheel.

For wheels with brakes

• Loosen the connector/cable to the support arm brake.
• Loosen the locking bolt for the brake shoe.
• Pull out the wheel axle using tool 08-13585. Use the short punch.
• Lift out the wheel.
• Take the brake unit out of the wheel.

21- 2 Service Manual 7FBRE © TIEE SARL

 Fork/support arm wheel – 3550.1
Assembling the wheel
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

21.3 Assembling the wheel

265 mm and 300 mm wheels without brakes

300 mm wheel with brake and 350 mm wheel

For wheels without brakes

• Place the brake unit in position in the wheel.
• 265 mm wheel and 300 mm wheels without brakes.
Place the spacers (1) in position on the hub.
• Lift the wheel in position in the support arm.
NOTE!
On wheels with brakes, guide in the brake’s locking shoe in its cut-out
in the support arm.
• To centre the wheel vertically, use a jack to adjust the height of the
support arm.
• Check that the wheel axle (3) is not damaged. Minor longitudinal
scratches can be tolerated.
If the axle ends have been damaged the axle should be ground or
replaced.

© TIEE SARL Service Manual 7FBRE 21- 3

 Fork/support arm wheel – 3550.1
Assembling the wheel
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Fit a new clamping ring (2) on the wheel axle (3).

WARNING
Loose wheel.
If the wheel is refitted using the old clamping ring the wheel can be-
come loose while driving.
Always fit the wheel with a new clamping ring on the wheel axle.
• Fit the extension punch on tool 08-13585 and insert it through the
wheel hub and support arm.

• Secure the wheel axle using the punch and carefully insert the axle.
Make sure the axle is not inserted too far. When the axle is correctly
positioned it should be centred in the support arm’s wheel bracket.
• Lower the truck.

For wheels with brakes

• Tighten the locking bolt for the brake’s locking shoe and connect the
brake cable. Secure the cable with a tie on the guard plate bracket
so that it does not rub against the wheel.
• Fit the cover plate.

21- 4 Service Manual 7FBRE © TIEE SARL

 Fork/support arm wheel – 3550.1
Dismantling/assembling the wheel bearings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

21.4 Dismantling/assembling the wheel

bearings

21.4.1 265 mm wheel and 300 mm wheels

without brakes.
Dismantling the bearing
• Remove the spacers (1).
• Remove the retainer rings (2).
• Press out the sleeve (3).
• Use a “soft” punch of brass or the like to knock out the bearing (4).

Assembling the bearing

• Press in the bearing (4). Use an assembly sleeve of the same out-
side diameter as the bearing’s outer ring, 90 mm.
• Check that the sleeve (3) is not damaged.
• Fit one of the retainer rings (2) on the sleeve.
• Press in the sleeve until the retainer ring stops against the bearing.
• Fit the other retainer ring.
• Place the spacers (1) in position on the hub.

© TIEE SARL Service Manual 7FBRE 21- 5

 Fork/support arm wheel – 3550.1
Dismantling/assembling the wheel bearings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

21.4.2 300 mm wheel with brake and 350 mm

wheel
Dismantling the bearing
• Loosen the sleeve nut (1). Tools: Sleeve no. 808-413.
• Remove the lock washer (2).
• Press out the sleeve (3).
• Pull off the bearing from the sleeve (4) and remove the seal (5).
• Remove the seal (6) and bearing (7).
• Use a “soft” punch of brass or the like to knock out the bearing cups
(8) from the hub.

1 2 6 7 8 8 3 4 5

7 6 5 4
1 1 3

Assembling the bearing

• Fit the bearing cups in the hub.
Use an assembly sleeve of the same outside diameter as the bear-
ing cup’s outer ring, 80 mm.
• Place the sealing ring (5) on the sleeve.
• Press the sleeve in the bearing (4).
• Grease the bearing using bearing grease and place the sleeve with
bearing in the wheel. Guide in the sealing ring in position on the hub.
• Press on the bearing (7) on the other side of the wheel.
• Fit the sealing ring (6) on the hub.
• Fit the lock washer (2) and sleeve nut (1).
• Tighten the nuts to 50 Nm.
Tool 808-413 and a torque wrench
The threads should be greased prior to assembly.
• Lock the nut by folding at least one of the washer’s ears into the nut’s
cut-outs.

21- 6 Service Manual 7FBRE © TIEE SARL

 Fork/support arm wheel – 3550.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-404,689-692

22- Fork/support arm wheel – 3550.2

22.1 General

22.2 Dismantling the wheel

• Lift up the truck and support using blocks so that the support arm
wheel runs free of the ground.
• Unscrew the bolts (1) holding the guard plate (2).
• Remove the guard plate.
• Remove the O-ring (3).
• Fold up the locking tabs on the washer (5) and remove the nut (4).
Carefully remove the wheel (7) so that the axle is not damaged.
If necessary the front and rear plates (10, 11) can be removed.

© TIEE SARL Service Manual 7FBRE 22- 1

 Fork/support arm wheel – 3550.2
Assembling the drive wheel
T-code Valid from serial number Date Order number
403-404,689-692 423260- 2005-07-01 201004-040

22.3 Assembling the drive wheel

• Press the wheel on axle using tool 08-14044.
• Fit the lock washer (5) and nut (4).
• Tighten the nut (4) so that the bearing rotates without any play. The
threads should be greased prior to assembly.
• Lock the nut by folding down one of the washer’s tabs into the nut’s
cut-outs.
• Fit the O-ring (3).
• Fit the guard plate (2) and secure in position with the bolts (1).

22.4 Dismantling the wheel bearing

• Remove the sealing ring (9) and the inner part of the bearing (6, 8).
• Use a “soft” punch of brass or the like to knock out the bearing cups
(6, 8).

22.5 Assembling the wheel bearing

• Fit the bearing cups in the hub using assembly tool 08-14044-2.
• Grease the bearing with bearing grease and fit the wheel.
• Fit the sealing rings in the hub using assembly tool 08-14044-1.

22- 2 Service Manual 7FBRE © TIEE SARL

 Mechanical steering system – 4100
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

23- Mechanical steering system –

4100

23.1 General
The steering generatoris fitted in the steering panel and has direct
contact with the steering wheel. When you turn the steering wheel the
steering generator sends voltage to the steering motor via the electron-
ic card.

23.2 Replacing the steering generator

23.2.1 Dismantling
• Loosen the bolts on the lower panel and remove it.
• Disconnect the connector on the steering generator.
• Dismantle the steering wheel by unscrewing the bolts around the
steering generator.
• Loosen the bolts in the driving disc and remove it from the steering
generator.
• Unscrew the bolts holding the steering generator on the steel brack-
et.

23.2.2 Assembling
• Bolt the steering generator onto the steel bracket.
• Secure the driving disc on the steering generator’s shaft.
• Replace the O-ring on the driving disc if necessary.
• Bolt the steering wheel onto the steel bracket.
• Connect the steering generator’s electrical connector.
• Bolt on the lower panel.

© TIEE SARL Service Manual 7FBRE 23- 1

 Mechanical steering system – 4100
Replacing the steering generator
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

23- 2 Service Manual 7FBRE © TIEE SARL

 Steering angle sensor – 4350
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

24- Steering angle sensor – 4350

24.1 General
These instructions apply to adjustment of the steering angle sensor
mounted on the driving gear.

24.2 Procedure
The information supplied by the two directional arrows in the display
changes as the sensor detects a change between the high and low lev-
el in the driving gear.
The two-way sensor uses the gear wheel to calculate the steering
angle and displays the value in the display's compass rose.
NOTE:
The sensor may be damaged if it is adjusted against an incorrect sur-
face.
Always adjust the sensor against the upper surface.

© TIEE SARL Service Manual 7FBRE 24- 1

 Steering angle sensor – 4350
Procedure
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

24.2.1 Adjustment of directional sensor

Adjust the sensor to a detection range of 1 mm.
• Screw the sensor onto the machined surface until the two touch
each other.
• Then unscrew one full rotation.
• Verify that the LED on the sensor/logic card lights when it is in front
of the machined surface.

1 mm

24- 2 Service Manual 7FBRE © TIEE SARL

 Steering angle sensor – 4350
Procedure
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

24.2.2 Adjustment of the steering angle

sensor
Roughly adjust the sensor to a detection range of ~1.1 mm.
• Measure the supply voltage to the sensor, i.e. connector 810 on the
A5 logic card.
• Screw the sensor onto the large plate until it touches the right part of
the cog.
• Then unscrew one full rotation.
• Make sure the sensor is mounted with the LEDs set horizontal and
the red LED facing the fork direction.
• Fine-adjust by turning the outer, large plate.
• Measure the voltage on both sensor outputs while the steering
wheel is turning and the gear rotating.
• To achieve a correct on/off switching pulse, the voltage on the sen-
sor outputs, or connectors 210 and 211 on the A5 logic card, should
be half that of the supply voltage.
• Finally tighten the large nut and the sensor mounting screws.

1,1 mm

© TIEE SARL Service Manual 7FBRE 24- 3

 Steering angle sensor – 4350
Procedure
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

24- 4 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25- Electrical system – 5000.1

25.1 General

25.1.1 Electrical panel

© TIEE SARL Service Manual 7FBRE 25- 1

 Electrical system – 5000.1
List of symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.2 List of symbols

Symbol Description Symbol Description

Battery

Brake coil, Brake coil,

normally released normally engaged

Switch, Switch,
normally open normally closed

Push-button switch Push-button switch,

normally open normally closed

Switch non locking, Switch non locking,

normally open normally closed

Push-button switch locking, Emergency switch

normally open

Key switch, Push-button switch,

normally open locking and non locking

Magnet proximity switch, Magnet proximity switch,

normally open normally closed

Pressure sensor switch, Pressure sensor switch,

normally open normally closed

Capacitive sensor, Capacitive sensor,

normally open normally closed

25- 2 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
List of symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Symbol Description Symbol Description

Inductive sensor, Inductive sensor,
normally open normally closed

Pulse sensor

Seat warmer Temperature sensor

with thermostat

Motor, D.C. series motor,

general armature winding

D.C. series motor Motor,

permanent magnet

Three phase motor, (AC)

Series winding Shunt winding

Transducer, AC/DC Transducer, DC/DC

Variable resistor Fixed resistor

(potentiometer)

Contactor Horn

Lamp Valve

Fuse Diode

© TIEE SARL Service Manual 7FBRE 25- 3

 Electrical system – 5000.1
List of symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Symbol Description Symbol Description

Zener diode Light emitting diode (LED)

Contact Contact, multi polar

Capacitor Measuring cable

25- 4 Service Manual 7FBRE © TIEE SARL

 1 2 3 4 5 6 7 8

© TIEE SARL
201004-040
Order number

A A

X1 G1 48 V X1 SHUNT WIRE
1 + - 40
Sh. 3 Sh. 2
Date

ELECTRONIC CARD
B MEASURING WIRES A5 B
2005-07-01

72
603 INP. BATT. INDI CURRENT -(+)

71
602 INP. BATT. INDI -, CURRENT -(-)

70
601 INP. BATT. INDI +
MAIN CONTACTOR
423260-

Service Manual
C K10 C
40 A1 A2 31
804 OUT. MAIN CONTACTOR
ONLY AT FBRE25 ONLY AT FBRE16/20
10A
F62
2 1 2 1 23
808 INP. MAIN CONTACTOR

4 3

7FBRE
8
Sh. 2
Valid from serial number

D D
S1 X30
22 3 4 34
Sh. 2 101 INP. SETUP SELECT

S2 X30
3 4 35
102 INP. SETUP UP
25.3 Electrical diagram

S3 X30
3 4 36
103 INP. SETUP DOWN

E E
T-code
403-408

F 215350 F
1/11 PROD C
Electrical system – 5000.1
Electrical diagram

1 2 3 4 5 6 7 8

25- 5
 1 2 3 4 5 6 7 8

25- 6
T-code
TRANSISTORPANEL, DRIVE
A1 403-408
A A
125A / 160A
F1
8
Sh. 1 7 B + +
2
U DRIVE MOTOR
40 M1
B
Electrical diagram

Sh. 1 4 - U
THERMO ELECTRICAL SENSOR IN M1 3 V M
X26 V
14 W M
3~A
7
B B
B1
X26 4
W
11
4

ELECTRONIC CARD
10 A5
3
SPEED MEASURING IN M1
U11 117
423260-

X27 X27 12 401 OUT CAN +15VDC

R Bl 12
Electrical system – 5000.1

5
B
+
C 118 C
X27 X27 13 402 OUT CAN GND
Bk Wh 13

Service Manual
6
A
-
119
10 403 OUT/IN CAN H

X30
22 120
Sh. 1 3 1 11 404
Valid from serial number

7FBRE
D SERVICE KEY INTERFACE D
X41
X45 X31
1 117

X45 X31
2 118 117
Date

Sh. 7
X45 X31
3 119 118
Sh. 7
X45 X31
2005-07-01

4 120 119
Sh. 7
E R100 120 E
Sh. 7
201004-040

215350
2/11 Prod C
Order number

F F

© TIEE SARL
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

© TIEE SARL
201004-040

A A
Order number

ELECTRONIC CARD
A5
10A
F60
1 21
Sh. 1 5 805 +48VDC
Date

X30
24
807 INP. KEY
B B
S23
2005-07-01

1 3 43
110 INP. LEFT FOOT SWITCH

KEY EMERGENCY SWITCH OFF

X30 S17 S21 X30
15 61a 24 1 2 22
809 +48VDC SUPPLY OUTPUTS

C C
423260-

X25 S28 X25

Service Manual
3 4 39
111 INP. DRIVE, CHANGE DIRECTION

22
Sh. 2 4 X32
45
104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
3

7FBRE
X32
2 46
105 INP. DRIVE, STEER WHEEL DIR., CREEP
1

X18 S27 X18

Valid from serial number

D 1 3 47 D
106 INP. DRIVE, FORK DIRECTION

X18 S29 X18

1 3 48
107 INP. DRIVE, STEER WHEEL DIRECTION

X25 S89 X25

1 3 49
203 INP. SEAT SWITCH

E E
T-code
403-408

215350
F 3/11 ProdC F
Electrical system – 5000.1
Electrical diagram

1 2 3 4 5 6 7 8

25- 7
 1 2 3 4 5 6 7 8

25- 8
T-code
403-408
A A

ELECTRONIC CARD
A5

27 27
Electrical diagram

Sh. 6 507 POT FEED 7-7,5 VDC

X19

1
X19
50
R1 501 INP. SPEED REFERENCE VALUE

3
B B

2
X19
28 28
Sh. 6 508 POT 0V
423260-

M12
Bl - + R 107
Electrical system – 5000.1

M 307 OUT. FAN POWER, ELECTRIC PANEL

C C

Service Manual
X30 X32 S18 X32
Valid from serial number

7FBRE
22 3 4 54 40
Sh. 3 5 Sh. 2 5
+ -
IN HORN
D H1 D
Date

FAN PUMPMOTOR
X35 M10 X35
+ M
-
2005-07-01

E E
201004-040
Order number

F F
215350
4/11 Prod C

© TIEE SARL
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A ELECTRONIC CARD A

© TIEE SARL
A5
201004-040
Order number

29 29
Sh. 10 810 +15VDC

30 30
Sh. 10 811 0VDC

S66
X21 X21
Br Bk 58
210
Date

INP. STEER WHEEL ANGLE A

B X21 Wh
B

Bl
X21
2005-07-01

59
211 INP. STEER WHEEL ANGLE B

S65
X30 X20 X20
22 Br Bk 57
Sh. 4 6 209 INP. STEER WHEEL REFERENCE 180 DEG.
X20

Bl
806
C C
423260-

Service Manual
40 40
Sh. 4 6 902 0VDC
30A
F61
1 25
Sh. 3 11 901 +48VDC STEER SERVO

7FBRE
M6 X24
Bk R 60
M 903 OUT. + STEER MOTOR
D D
X24
Valid from serial number

61
904 OUT. - STEER MOTOR

U1 X32
R BK 62
M 509 INP. STEERING WHEEL TACHO +

X34
129
511 0VDC FOR TACHO

E E
T-code
403-408

215350
5/11 Prod C
F F
Electrical system – 5000.1
Electrical diagram

1 2 3 4 5 6 7 8

25- 9
 1 2 3 4 5 6 7 8

25- 10
T-code
403-408
A EMERGENCY MODE A
X30 S131
22 1 2
Sh. 5 7 ELECTRONIC CARD
A5

X37 Y1 X37
40 64
Sh. 5 7 802 OUT. PARKING BRAKE
Electrical diagram

DISPLAY
B A6 B
X31
121
SERIE + 1 405 SERIE +

X31
122
SERIE - 2 406 SERIE -
RS 485
X31
125
423260-

RX + 3 407 TX+
Electrical system – 5000.1

X31
C 126 C
RX - 4 408 TX-

Service Manual
27
Sh. 4 8
X36

1
X36
51
R2 502 INP. BRAKE REFERENCE VALUE
Valid from serial number

7FBRE
2
X36
28
D Sh. 4 8 D

STANDARD ON 7FBRE25.

X39 Y5 X39
Date

X38 X38
63
801 OUT. SUPPORT ARM BRAKE
Y6
2005-07-01

X40 X40

E E
126
Sh. 10

125
Sh. 10
201004-040
Order number

F F
215350
6/11 Prod C

1 2 3 4 5 6 7 8

© TIEE SARL
 1 2 3 4 5 6 7 8

A A

© TIEE SARL
201004-040

TRANSISTORPANEL, PUMP
Order number

A2

200A / 250A / 300A

F3
8 5
Sh. 2 B + + U PUMP MOTOR
M3
U
40 6 V M
Date

Sh. 6 9 B - V
B W M
3~A
B

7
8 ID W
2005-07-01

THERMO ELECTRICAL SENSOR IN M3

X12 X12
19
7

B2

16 117
4 12 Sh. 2
C C
423260-

15 118

Service Manual
3 13 Sh. 2
SPEED MEASURING IN M3
U12
X13 X13
R Bl 17 119
5 10 Sh. 2
B
+
X13 X13
Bk Wh 18 120

7FBRE
6 11 Sh. 2
A
-
D D
Valid from serial number

X30 R101
22
Sh. 6 9 1

E E
T-code
403-408

F F
Electrical system – 5000.1
Electrical diagram

1 2 3 4 5 6 7 8

25- 11
 1 2 3 4 5 6 7 8

25- 12
T-code
403-408
A A

X32 X11
27
Sh. 6
Electrical diagram

Ye
X11
R11

R
X32 X11

Gr
28
Sh. 6
B B
ELECTRONIC CARD

Ye
X11
A5
R12

R
X33

Gr
82
503 INP. JOYSTICK FORK

Ye
X11 X33
423260-

83
R13 504 INP. JOYSTICK REACH CARRIAGE

R
Electrical system – 5000.1

Gr
X33
C 84 C
505 INP. JOYSTICK TILT

Service Manual
Ye
X11
R14 X33

R
85
506 INP. JOYSTICK SPARE 1

Gr
X33
86

Ye
Valid from serial number

X11 510 INP. JOYSTICK SPARE 2

7FBRE
R15

Gr
202 OUT. DATA COLLECT, LIFT
D D

208 OUT. DATA COLLECT, DRIVE

Date
2005-07-01

E E

215350
201004-040

8/11 Prod C
Order number

F F

© TIEE SARL
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A EMERGENCY MODE A

© TIEE SARL
100~E / 25W
201004-040

X30 S132 R102

22 1 2 ELECTRONIC CARD
Order number

Sh. 7 10 A5

X14 X17 Y10 X17 X14

40 Bk 1 3Wh 88
Sh. 7 10 803 OUT. FORK LOWER

X17 X14
Bk 1 2Gr 89
701 OUT. FORK LIFT
Date

B EMERGENCY MODE B
S133
1 2
2005-07-01

Y12 X17 X14

Bk1 2R 90
702 OUT. REACH CARRIAGE, IN

Y13 X17 X14

Bk 1 2Bl 91
703 OUT REACH CARRIAGE, OUT

C Y14 X17 X14 C

Bk1 2Or 92
423260-

704 OUT. TILT DOWN

Service Manual
Y15 X17 X15
Bk 1 2Ye 93
705 OUT. TILT UP

X29 X50 Y16 X50 X29 X17 X15

1 2 94
706

7FBRE
OUT. SPARE 1A

Y17 X50 X29 X17 X15

D 1 2 95 D
707 OUT. SPARE 1B
Valid from serial number

Y16
Bk1 2Gn WITHOUT INTEGRATED SIDESHIFT

Y17
Bk 1 2Vi

Y18 X16 X15

2 1 96
708 OUT. SPARE 2A
E E
T-code

Y19
403-408

X16 X15
2 1 97
709 OUT. SPARE 2B

215350
F 9/11 Prod C
F
Electrical system – 5000.1
Electrical diagram

1 2 3 4 5 6 7 8

25- 13
 1 2 3 4 5 6 7 8

25- 14
T-code
403-408
A LIFT HEIGHT INDICATOR
A
A8
X30 X45X8 X8 X45 X31
22
Sh. 9 11 3 +48V RX+ 5

X8 X45 X31
125
4 0V RX- 2
Electrical diagram

Sh. 6

126
Sh. 6
B X8 B
X45
X30

ELECTRONIC CARD
PRE SELECTION HEIGHT UNIT A5
A7
X32 X33
40 125
6 7 407
423260-

Sh. 9 11 0V RX+ TX+

Electrical system – 5000.1

X32 X34
126
C 4 +48V RX- 3 408 TX- C

Service Manual
RS 485
X34
127
TX+ 1 409 RX+ HEIGHT UNIT
40

X34
128
TX- 5 410 RX- HEIGHT UNIT
Valid from serial number

7FBRE
U10
X14 X16 X28 X28 X16 X15
29 R Wh 98
D Sh. 5 301 INP. HEIGHT COUNTER A D
A
+
X14 X16 X28 X28 X16 X15
30 Bk Bl 99
Sh. 5 302 INP. HEIGHT COUNTER B
B
-
Date

S45
X14 X16 X16 X15
Br Bk 106
303 INP. HEIGHT REFERENCE
X14 X16

Bl
2005-07-01

E MAST, LOWER POS.

E
X43 S46 X43
Br Bl

215350
10/11 Prod C
201004-040
Order number

F F

© TIEE SARL
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

OPTIONS
A A

© TIEE SARL
201004-040
Order number

EXTERNAL EQUIPMENT
WORKING LIGHT
10A X42 X42
F63 X30 S99 E4 E3
1 26 1 1 26 1 5 191 192
Sh. 5

X30
40 40 2 2 40
Sh. 10
Date

B B
2005-07-01

SEAT HEATER
X25 E10 X25
22
Sh. 10

C C
423260-

Service Manual
S32
X15 X16 X16 X15
98
301 INP. LIFT LIMIT SPECIAL HEIGHT

7FBRE
X30 X32 S33 X33
D 5 1 100 D
205 INP. OVERRIDE
Valid from serial number

S31
X30 X14 X16 X52 X52 X16 X14
79
206 INP. SPEED REDUCTION

E E
T-code
403-408

215350
F 11/11 Prod C F
Electrical system – 5000.1

3 6 7 8
Electrical diagram

1 2 4 5

25- 15
 Electrical system – 5000.1
Electrical diagram
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.3.1 List of components

Symbol Designation - Function Diagram

A1 Frequency converter, M1 5
A2 Frequency converter, M3 5
A5 Electronic card 5
A6 Display 1
A7 Height selector 2
A8 Height indication display 8

B1 Temperature sensor, M1 5
B2 Temperature sensor, M3 5

E10 Seat warmer 4

E3, E4 Working light 8

F1 Fuse – drive motor, 125/160 A 5

F3 Fuse – pump motor, 200/250/300 A 5
F60 Fuse – control current for A5 card, 10 A 5
F61 Fuse – steering motor, 30 A 5
F62 Fuse – control current for K10, 10 A 5
F63 Fuse – control current for extra equip- 5
ment, 10/16 A

G1 Battery 48 V 8

H1 Horn 5

K10 Main contactor 5

M1 Drive motor 5
M3 Pump motor 5
M6 Steering motor 5
M10 Fan for pump motor 5
M12 Fan for electrical panel 5

25- 16 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Symbol Designation - Function Diagram

R1 Potentiometer, driving 5
R2 Potentiometer, brake 5
R11 Potentiometer, fork lift/fork lowering 2
R12 Potentiometer, reach carriage 2
R13 Potentiometer, tilt 2
R14 Potentiometer, extra hydraulic function 2
R15 Potentiometer, extra hydraulic function 2
R100 Resistance, service key 8
R101 Resistance, service key 5
R102 Resistance, emergency lowering, forks 5

S1 Micro switch, operator number/program- 1

ming
S2 Micro switch, operator number/stepping 1
up
S3 Micro switch, operator number/stepping 1
down
S17 Key switch 1
S18 Micro switch, horn 2
S21 Emergency switch 1
S23 Safety switch, left foot pedal 3
S26 Micro switch, travel direction with crawl 2
speed
S27 Micro switch, travel direction (foot), fork 3
direction
S29 Micro switch travel direction (foot), steer- 3
ing wheel direction
S31 Micro switch, speed reduction, driving 8
S32 Micro switch, max lifting height 8
S33 Micro switch, max lifting height, bypass 1
coupling
S45 Micro switch, height indication 7
S46 Magnet switch, lowering between free lift 7
and main lift
S65 Pulse sensor, steer wheel centre 5
S66 Pulse sensor, steer wheel direction 5
S89 Micro switch, seat 4
S99 Micro switch, working light 1

© TIEE SARL Service Manual 7FBRE 25- 17

 Electrical system – 5000.1
Electrical diagram
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Symbol Designation - Function Diagram

S131 Micro switch, release parking brake 5
S132 Micro switch, emergency lowering, forks 5
S133 Micro switch, emergency retraction of 5
mast

U1 Tachometer, steering 2
U10 Pulse sensor, height meter 7
U11 Pulse sensor, drive motor 5
U12 Pulse sensor, pump motor 5

X1 Contact 8
X8 Contact 8
X11 Contact 2
X12 Contact 5
X13 Contact 5
X14 Contact 5
X15 Contact 5
X16 Contact 6
X17 Contact 6
X18 Contact 5
X19 Contact 5
X20 Contact 5
X21 Contact 5
X23 Contact 5
X24 Contact 5
X25 Contact 4
X26 Contact 5
X27 Contact 5
X28 Contact 7
X29 Contact 6
X30 Contact 5
X31 Contact 5
X32 Contact 5
X33 Contact 5
X34 Contact 5
X35 Contact 5

25- 18 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Symbol Designation - Function Diagram

X36 Contact 5
X37 Contact 5
X38 Contact 5
X39 Contact 8
X40 Contact 8
X41 Contact 8
X42 Contact 5
X43 Contact 6
X45 Contact 1
X50 Contact 8
X52 Contact 6

Y1 Magnet, parking brake 5

Y5 Magnet, support arm brake 8
Y6 Magnet, support arm brake 8
Y10 Magnet valve, lifting/lowering 6
Y12 Magnet valve, reach carriage in 6
Y13 Magnet valve, reach carriage out 6
Y14 Magnet valve, tilt down 6
Y15 Magnet valve, tilt up 6
Y16 Magnet valve, extra hydraulic function 6
1A
Y17 Magnet valve, extra hydraulic function 6
1B
Y18 Magnet valve, extra hydraulic function 6
2A
Y19 Magnet valve, extra hydraulic function 6
2B

© TIEE SARL Service Manual 7FBRE 25- 19

 Electrical system – 5000.1
Electrical diagram
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.3.2 Diagram 1
S99
S33
A6

S1
S2
S3
S17
S21

X45

25.3.3 Diagram 2
R15
A7 R14
R13
R12
R11
S18

U1

S26

X11

25- 20 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.3.4 Diagram 3
S27
S29
S23

25.3.5 Diagram 4

S89
E10
X25

© TIEE SARL Service Manual 7FBRE 25- 21

 Electrical system – 5000.1
Electrical diagram
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.3.6 Diagram 5
X24
X21
X20
S133 S132 S131

X32
R102 X33
X38
X34
X37
X15
X30 X14
X42
X31

F63 F62 F61 F60

A5 M12 F1 A1 F3 A2

R101

K10
R1
X19
R2
X36 H1

M10
X35
M3
U12
B2

X18 S66 S65 M6 M1 Y1 X12

B1 X27 X26
U11
X13

25- 22 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.3.7 Diagram 6
X16 X17 X29 X43

Y13 X52
Y14 Y18
Y17
Y19

Y16 Y15 Y12 Y10

25.3.8 Diagram 7

S45

U10

X28

S46

© TIEE SARL Service Manual 7FBRE 25- 23

 Electrical system – 5000.1
Electrical diagram
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.3.9 Diagram 8
E4 E3

X8
A8
X41
R100

X39 Y5

Y6
X40

S31

G1 S32
X50
X1
Y16
Y17

25- 24 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Description of function
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.4 Description of function

The electronic card on TOYOTA 7FBRE holds the microprocessor
which senses switches, steering voltage, etc. and gives instructions to
the external electronics, contactors and valves etc.
To hold the preprogrammed information in the electronic unit when the
battery is disconnected, the unit receives its power from an internal bat-
tery. Any faults registered by the microprocessor are shown on the dis-
play. The error codes are explained in connection with the electronic
card. The electronic card’s inputs and outputs are marked with the con-
nection number and can easily be connected/disconnected using the
contactors. The inputs and outputs, which have two fixed positions,
have LEDs as indicators, green for input and red for output, the rest
are yellow.

Signal name Diode number

The name given to the input/out- The diode showing which input/
put on the card according to the output is active on the card
circuit diagram

25.4.1 Ignition key in the 0 position

When the battery is connected to the truck via the charger plug the
electronic card (A5) is fed with 48 V current and the LEDs are lit accord-
ing to the table. LEDs 210, 211, 301 and 302 light depending on wheth-
er the sensor is activated or not. Voltage +7.35 V goes from A5 to
potentiometer R1 in the accelerator, brake control R2 and hydraulic
controls R11-R15.

Signal name Diode number

STEER WHEEL ANGLE 210, 211
HEIGHT COUNTER 301, 302
+48 V 805
STEER PWR
POWER OK
+48 V STEER

© TIEE SARL Service Manual 7FBRE 25- 25

 Electrical system – 5000.1
Description of function
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.4.2 Ignition key in 1 position

The truck receives voltage when the operator turns the key to the 1
position. In order to use the travel direction selector and the hydraulics,
the driver must be seated in the truck so that the switch S89 closes.
Voltage goes through the control fuse F60, ignition switch S17 and
emergency switch S21 to electronic card A5, frequency converters A1
and A2, height electronics A7 and A8 plus fan M10 which then starts.
Electronic card A5 checks that the internal safety function works and
closes the main contactor K10 which provides voltage to the drive and
pump motors. The electronic card A5 begins communicating with A7
and A8 and sends voltage 32 V to fan M12 which then rotates at half
speed.
A5 checks that the voltage from the potentiometers is 3.65 V and sends
check pulses to tachometer U1 and steering motor M6. If the seat has a
built in warmer, voltage +48 V is also sent to the thermostat and seat
warmer E10.
The display comes on and presents the software’s version number and
then switches to its normal mode: time, running time, battery status and
any error codes.
The time the truck has the key in position 1 is measured and stored in
the electronic unit.
The LEDs will light according to the table.
• No. 706–711 comes on if the valves are not fitted to the truck.
• No. 110, 203 and 305 come on if the switches are actuated.
LEDs on the frequency converter will light.
.

Signal name Diode number

LEFT FOOT SWITCH 110
SEAT SWITCH 203
SPARE 1A, 1B 706, 707
SPARE 2A, 2B 708, 709
SUPPORT ARM BRAKE 801 (dimly lit)
FORK LOWER 803 (dimly lit)
MAIN CONTACTOR 804
+48 V KEY
+48 V ESO
+48 V_SR

25- 26 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Description of function
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.4.3 Selection of travel direction

There are three ways to select the travel direction.

With the steering console

When control S26 is pressed down the voltage is sent from the switch
to A5. If the control is held down for at least three seconds the truck will
travel at creep speed.

Signal name Diode number

DRIVE, FORK DIRECTION 104
DRIVE, STEER WHEEL 105
DIRECTION

With the left-hand handle

When control S28 is pressed the voltage goes from the switch to A5
which results in the truck changing travel direction. This control can
only be used to change the direction of travel after the choice has been
made on the steering console. It is not possible to activate the creep
speed function with this control.

Signal name Diode number

DRIVE, 111
CHANGE DIRECTION

With the speed control

When the right-hand pedal (in direction of forks) is pressed the voltage
goes from the switch S27 to A5. The truck changes direction by press-
ing the left-foot pedal. The pedals can not be used to activate the creep
speed function.

Signal name Diode number

DRIVE, FORK DIRECTION 106
DRIVE, STEER WHEEL 107
DIRECTION

The display shows the direction of travel.

© TIEE SARL Service Manual 7FBRE 25- 27

 Electrical system – 5000.1
Description of function
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.4.4 Driving
When the accelerator R1 is activated the drive motor brake will be
released. If the safety switch S23 is not active when the parking brake
is released a buzzer is sounded from the display.
If the operator presses the speed control when the key is turned to posi-
tion 1 the control must be returned to the neutral position before the
truck can be driven.
When the accelerator pedal is pressed the potentiometer R1 is activat-
ed and the more the pedal is pressed the lower the voltage which is
sent from R1 to A5. The voltage decreases from 3.7 to 1.7 V which
gives 0–100% speed. A1 regulates the drive motor’s revolutions with
the help of information from A5. Voltage goes via A1’s fuse F1 and is
converted to 3 phase AC which is then sent to M1.
If the switch for speed reduction S31 is active so that there is voltage on
A5’s input, the preprogrammed max. speed will apply. The speed is
measured on the drive motor by means of sensor U11.
If the travel direction control on the steering console is pressed down
for at least three seconds the truck will travel at creep speed.
If the driver leaves the seat for more than three seconds the voltage
from A5 to Y1 is discontinued and the parking brake is activated.
The drive motor’s running time is measured and recorded in the elec-
tronic unit.

Signal name Diode number

PARKING BRAKE 802

25.4.5 Steering
When the steering wheel is turned the voltage goes from the tachometer
(U1) to A5 which progressively supplies current to the steering motor (M6).
The result of this is that the faster steering movement the quicker the steer-
ing motor rotates. This progressivity also means that the higher the driving
speed, the lower the steering speed. The speed is measured on the drive
motor by means of sensor U11.
When the steering is turned the steering wheel sensor S65 is activated
and voltage flows to A5. The opposite travel direction is shown on the
display. The electronics automatically show the correct travel direction
through switch S65 giving a signal during 180° of the 360 possible. The
S65 must pass one of the reference points so that the electronics
knows the direction of the steering wheel and shows the travel direc-
tion. The function is initiated by turning the steering. This must be done
at the first start and after servicing.
LEDs 209, 210 and 211 light depending on whether the sensor is acti-
vated or not.

Signal name Diode number

STEER WHEEL REF. 180° 209
STEER WHEEL ANGLE A 210
STEER WHEEL ANGLE B 211

25- 28 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Description of function
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.4.6 Steering wheel indicator

When the steering wheel is turned, S66 signals to A5 which shows the
travel direction on the display. The sensor S65 must pass one of the ref-
erence points so that the electronics knows the direction of the steering
wheel and shows the travel direction. The function is initiated by turning
the steering. This must be done at first start and after servicing. When
the travel direction is changed by means of the switch the arrows
change on the display.
LEDs 209, 210 and 211 light depending on whether the sensor is acti-
vated or not.

Signal name Diode number

STEER WHEEL REF. 180° 209
STEER WHEEL ANGLE A 210
STEER WHEEL ANGLE B 211

25.4.7 Braking
Braking can be done in different ways.

Auto plug braking

When the operator releases the accelerator the drive motor will auto-
matically slow the truck to the desired speed. The auto plug braking
function and braking force can be selected using parameters.

Motor brake (electric)

When the operator changes travel direction with the use of the controls,
the drive motor acts as a generator/brake and feeds the voltage back to
the battery. The braking force is determined with the help of the accel-
erator pedal. The electronic card A5 receives information from A1 as to
whether braking has occurred and regulates A1.

Foot brake
When the operator presses the brake pedal the potentiometer R2 is
activated. The voltage increases from 1.7 V to 4.1 V which gives 0–
100% braking force. When the pedal is pressed up to half way the truck
is slowed down by the drive motor. On trucks with support arm brakes,
these will begin to slow the truck down further as the brake pedal is
pressed further down. When the brake pedal is fully depressed the
parking brake will also be activated. LED 801 will be dimly lit at first and
fully lit when full braking force is reached.

Signal name Diode number

SUPPORT ARM BRAKE 801

© TIEE SARL Service Manual 7FBRE 25- 29

 Electrical system – 5000.1
Description of function
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Parking brake
If the truck is standing still when the brake pedal is pressed the parking
brake will be activated.
If the driver leaves the seat for more than three seconds the voltage
from A5 to Y1 is discontinued and the parking brake is activated.

25.4.8 Fork lift

When the operator activates the potentiometer R11 A5 receives a volt-
age 3,7–6,6 V on the input, the proportional valve Y10 opens and
sends a signal to transistor regulator A2. The pump motor M3 starts
and gives oil to the lift cylinders.
If the battery guard measures a remaining capacity of 20% or lower in
the battery the lift speed is reduced.
The lift speed is reduced during the change over from free lift to main
lift. The speed of M3 is measured by sensor U12.

Signal name Diode number

FORKLIFT 701

25.4.9 Maximum height

Truck with maximum height switch.
When the forks reach the height switch S32 and A5 receives a signal,
the lift will be stopped. If the forks are to be lifted above this height the
switch S33 should be pressed down, which gives a signal to A5 and the
lift continues. The start must take place within fifteen seconds.

Signal name Diode number

LIFT LIMIT SPECIAL HEIGHT 301
OVERRIDE 205

25- 30 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Description of function
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.4.10 Maximum height

Truck with pulse counter.
When the forks reach the main lift zone A5 receives a signal from
switch S45 to start counting pulses from transmitter U10. The forks will
stop when the preprogrammed heights (2 heights) are reached. If the
forks are to be lifted above this height, switch S33 must be pressed
which sends a signal to A5 and the lift continues. The start must take
place within fifteen seconds.
LEDs 301, 302 and 303 light depending on whether the sensor is acti-
vated or not.

Signal name Diode number

HEIGHT COUNTER 301
HEIGHT COUNTER 302
HEIGHT REFERENCE 303

25.4.11 Fork lowering

When the operator activates the potentiometer R11 voltage goes 3.7–
0.66 V to A5 which opens the proportional valve Y10 and the operator
can lower the forks at a variable speed.
If the truck is fitted with a pulse counter, the lifting speed is reduced dur-
ing change over from main lift to free lift. The LED is dimly lit in neutral
and increases in strength to be fully lit when lowering begins.
Without the transmitter the speed will be reduced when S46 is activat-
ed.

Signal name Diode number

FORK LOWER 803

25.4.12 Mast out/in

When the operator activates the hydraulic lever R12 voltage (out = 3.7–
0.77 V or in = 3.7–6.6 V) goes to A5 which opens the directional valve
Y12/Y13 and sends a signal to the frequency converter A2. The pump
motor M3 starts and sends oil to the reach cylinder. The speed of the
pump motor is reduced before the mast reaches the end position.

Signal name Diode number

REACH CARRIAGE IN 702
REACH CARRIAGE OUT 703

© TIEE SARL Service Manual 7FBRE 25- 31

 Electrical system – 5000.1
Description of function
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

25.4.13 Fork tilt up/down

When the operator activates the hydraulic lever R13 voltage (up = 3.7–
6.6 V or down = 3.7–0.66 V) goes to A5 which opens the directional
valve Y14/Y15 and sends a signal to the frequency converter A2. The
pump motor M3 starts and gives oil to the tilt cylinder.

Signal name Diode number

TILT DOWN 704
TILT UP 705

25.4.14 Hydraulic function 4

When the operator activates the hydraulic lever R14 voltage (3.7–6.7 V
or 3.7–0.66 V) goes to A5 which opens the directional valve Y16/Y17
and sends a signal to the frequency converter A2. The pump motor M3
starts and gives oil to the extra function.

Signal name Diode number

SPARE 1A 706
SPARE 1B 707

25.4.15 Hydraulic function 5

When the operator activates the hydraulic lever R15 voltage (3.7–6.7 V
or 3.7–0.66 V) goes to A5 which opens the directional valve Y16/Y17
and sends a signal to the frequency converter A2. The pump motor M3
starts and gives oil to the extra function.

Signal name Diode number

SPARE 2A 708
SPARE 2B 709

25.4.16 Height indication

The measurement starts in the main lift zone when the reference switch
S45 is activated and gives a signal to A5.The pulse sensor U10 sends
pulses to A5 which starts by showing the programmed free lift height on
the display A8.

Signal name Diode number

HEIGHT COUNTER 301
HEIGHT COUNTER 302
HEIGHT REFERENCE 303

25- 32 Service Manual 7FBRE © TIEE SARL

 Electrical system – 5000.1
Description of function
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

25.4.17 Height selection

Measurement begins in the main lift zone when the reference switch
(S45) is activated and sends a signal to A5. The pulse sensor (U10)
sends pulses to A5 which starts by showing the programmed free lift
height on the displays (A7 and A8). The forks stop at the first pro-
grammed height when A5, via the pulse sensor (U10), has reached the
right height. The forks are stopped by A5 which regulates the speed of
the pump motor with A2 and valves for lifting/lowering of the forks. The
operator picks up/puts down loads manually. When the operator once
again activates the potentiometer for lifting/lowering the forks continue
to the next programmed level. See C-code 9000.

Signal name Diode number

HEIGHT COUNTER 301
HEIGHT COUNTER 302
HEIGHT REFERENCE 303

25.4.18 Operator - ID
Logging in can be done in two different ways.

Without pin code

• Press one of the switches I, II, or III to select operator 1 to 3.

With pin code

• Press switches I, II, and III the 4-digit combination (e.g. I, II, III and
III) to select driver 1 to 10.
To program operator combination, see C-code 5710.

Signal name Diode number

SETUP SELECT 101
SETUP UP 102
SETUP DOWN 103

© TIEE SARL Service Manual 7FBRE 25- 33

 Electrical system – 5000.1
Description of function
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

This page is intentionally left blank

25- 34 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

26- 14Electrical System – 5000.2

26.1 General

26.1.1 Electrical Panel

© TIEE SARL Service Manual 7FBRE 26- 1

 14Electrical System – 5000.2
Symbol list
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

26.2 Symbol list

Symbol Description Symbol Description
Battery

Brake coil, normally released Brake coil, normally applied

Switch, normally open Switch, normally closed

Push-button switch, normally Push-button switch, normally

open closed

Momentary switch, normally Momentary switch, normally

open closed

Latching, push-button switch, Emergency switch

normally open

Key switch, normally open Push-button switch, latching

and momentary

Electro-magnetic switch, nor- Electro-magnetic switch, nor-

mally open mally closed

Pressure-sensitive switch, Pressure-sensitive switch,

normally open normally closed

Capacitive switch, normally Capacitive switch, normally

open closed

Inductive sensor, normally Inductive sensor, normally

open closed

Pulse generator

26- 2 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Symbol list
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Symbol Description Symbol Description

Seat heater with thermostat Thermoelectric sensor

Motor, general Series motor, armature wind-

ing, DC

Series motor, DC Motor, permanent magnet

Three-phase motor, AC

Series winding Shunt winding

Converter, AC/DC Converter, AC/DC

Variable resistor (potentiome- Resistor

ter)

Contactor Horn

Lamp Valve

Fuse Diode

Zener diode Light emitting diode (LED)

Contact Contact, multiple-poles

Capacitor Feed cable

© TIEE SARL Service Manual 7FBRE 26- 3

26- 4
T-code
1 2 3 4 5 6 7 8 689-692

A A

X1 G1 48 V X1 SHUNT WIRE
Electrical diagram

1 + - 40
Sh. 3 Sh. 2

ELECTRONIC CARD
B MEASURING WIRES A5 B

72
603 INP. BATT. INDI CURRENT -(+)

Electrical diagram (3
71
423260-

602 INP. BATT. INDI -, CURRENT -(-)

70
601 INP. BATT. INDI +
14Electrical System – 5000.2

MAIN CONTACTOR

Service Manual
C K10 C
A1 A2 31
804 OUT. MAIN CONTACTOR
10A
F62
2 1 23
808 INP. MAIN CONTACTOR
Valid from serial number

7FBRE
8
Sh. 2

S1 X30
D 22 3 4 34 D
Sh. 2 101 INP. SETUP SELECT

S2 X30
3 4 35
102
Date

INP. SETUP UP

S3 X30
26.3 Electrical diagram

3 4 36
103 INP. SETUP DOWN
2005-07-01

E E
201004-040

201339
1/10 Prod A
F F
Order number

1 2 3 4 5 6 7 8

© TIEE SARL
 1 2 3 4 5 6 7 8

A TRANSISTORPANEL, DRIVE A
A1

© TIEE SARL
201004-040
Order number

125A
F1
8
Sh. 1 7 B + +
2
U DRIVE MOTOR
40 M1
Sh. 1 4 B - U
3 V M
THERMO ELECTRICAL SENSOR IN M1X26 V
Date

B 14
7
W M
3~A
B
B1
X26 4
W
11
2005-07-01

ELECTRONIC CARD
10 A5
3
SPEED MEASURING IN M1
U11 117
X27 X27 12 401 OUT CAN +15VDC
R Bl 12
5
C B C
+
118
423260-

X27 X27 13 402 OUT CAN GND

Service Manual
Bk Wh 13
6
A
-
119
10 403 OUT/IN CAN H

X30
22 120
1 11 404

7FBRE
Sh. 1 3 OUT/IN CAN L

D D
Valid from serial number

SERVICE KEY INTERFACE

X41
X45 X31
1 117

X45 X31
2 118

X45 X31
3 119 119
Sh. 7
X45 X31
4 120 120
E Sh. 7 E
T-code

R100
689-692

201339
2/10 Prod A
F F
14Electrical System – 5000.2
Electrical diagram

1 2 3 4 5 6 7 8

26- 5
26- 6
1 2 3 4 5 6 7 8
T-code
689-692
A A

ELECTRONIC CARD
A5
7,5A
F60
1 21
Electrical diagram

Sh. 1 5 805 +48VDC

X30
24
807 INP. KEY
B B
S23
1 3 43
110 INP. LEFT FOOT SWITCH

KEY EMERGENCY SWITCH OFF

X30 S17 S21 X30
15 61a 24 1 2 22
809 +48VDC SUPPLY OUTPUTS
423260-

C C
14Electrical System – 5000.2

Service Manual
22
Sh. 2 4 X32
45
104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
3
X32
2 46
105 INP. DRIVE, STEER WHEEL DIR., CREEP
1
Valid from serial number

7FBRE
X18 S27 X18
1 3 47
106 INP. DRIVE, FORK DIRECTION
D D
X18 S29 X18
1 3 48
107 INP. DRIVE, STEER WHEEL DIRECTION

X25 S89 X25

1 3 49
Date

203 INP. SEAT SWITCH

2005-07-01

E E
201004-040
Order number

F F

© TIEE SARL
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

© TIEE SARL
201004-040

ELECTRONIC CARD
A5
Order number

27 27
Sh. 6 507 POT FEED 7-7,5 VDC
X19

1
X19
50
R1 501 INP. SPEED REFERENCE VALUE

2
Date

B X19
B
28 28
Sh. 6 508 POT 0V
2005-07-01

X30 X22 S56 X22

22 Br Bl 80
Sh. 3 5 207 INP. REACH CARRIAGE, LOW SPEED IN

HORN

C H1 C
X32 S18 X32 M12
423260-

Service Manual
3 4 54 R Bk Bl - + R 107
M 307 OUT. FAN POWER, ELECTRIC PANEL
Ye

7FBRE
D D
FAN PUMPMOTOR
Valid from serial number

X35 M10 X35

+ M
-

40
Sh. 2 5

E E
T-code
689-692

201339
4/10 Prod A

F F

1 2 3 4 5 6 7 8
14Electrical System – 5000.2
Electrical diagram

26- 7
26- 8
1 2 3 4 5 6 7 8
T-code
689-692
A A
ELECTRONIC CARD
A5

29
810 +15VDC
Electrical diagram

30
811 0VDC

B S66 B
X21 X21
Br Bk 58
210 INP. STEER WHEEL ANGLE A
Wh

Bl
X21 X21
59
211 INP. STEER WHEEL ANGLE B

S65
X30 X20 X20
423260-

22 Br Bk 57
Sh. 4 6 209 INP. STEER WHEEL REFERENCE 180 DEG.
X20

Bl
C C
806
14Electrical System – 5000.2

Service Manual
40 40
Sh. 4 6 902 0VDC
30A
F61
1 25
Sh. 3 10 901 +48VDC STEER SERVO
Valid from serial number

7FBRE
M6 X24
Bk R 60
M 903 OUT. + STEER MOTOR
D D
X24
61
904 OUT. - STEER MOTOR

U1 X32
Date

Bk R 62
M 509 INP. STEERING WHEEL TACHO +

X34
129
2005-07-01

511 0VDC FOR TACHO

E E
201004-040

201339
F 5/10 Prod A F
Order number

1 2 3 4 5 6 7 8

© TIEE SARL
 1 2 3 4 5 6 7 8

A A

© TIEE SARL
201004-040
Order number

EMERGENCY MODE
X30 S131
22 1 2
Sh. 5 7 ELECTRONIC CARD
A5

X37 Y1 X37
40 64
802
Date

Sh. 5 7 OUT. PARKING BRAKE

B B

DISPLAY
2005-07-01

A6
X31
121
SERIE + 1 405 SERIE +

X31
122
SERIE - 2 406 SERIE -
RS 485
C X31 C
125
RX + 3 407 TX+
423260-

Service Manual
X31
126
RX - 4 408 TX-

27
Sh. 4 8

7FBRE
X36

1
X36
D 51 D
R2 502 INP. BRAKE REFERENCE VALUE

3
Valid from serial number

2
X36
28
Sh. 4 8

E E
T-code
689-692

201339
6/10 Prod A
F F
14Electrical System – 5000.2
Electrical diagram

1 2 3 4 5 6 7 8

26- 9
 1 2 3 4 5 6 7 8

26- 10
T-code
689-692
A A
Electrical diagram

TRANSITOR REGULATOR, LIFT

A2
160A
F3
8 5 119 119
Sh. 2 B+ 48VDC PWR. SUPPLY
OUT/IN: CAN H. J2-1 Sh. 2
B B

40 40 120 120
Sh. 6 9 B- GROUND OUT/IN CAN L J2-8 Sh. 2
423260-

PUMP MOTOR
D1 A2/E2 6
M3 M OUT. PUMP MOTOR

C C
14Electrical System – 5000.2

Service Manual
E1 22 22
INP: 48VDC, KEY SWITCH J2-16 Sh. 6 8
Valid from serial number

7FBRE
D D
Date
2005-07-01

E E
201004-040

201339
Order number

F 7/10 Prod A F

© TIEE SARL
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

A A

© TIEE SARL
201004-040
Order number

ELECTRONIC CARD
X32 X11
27 A5
Sh. 6

Ye
X11 X33
Date

B 82 B
R11 503 INP. JOYSTICK FORK

R
X32 X11

Gr
28
Sh. 6
2005-07-01

Ye
X11 X33
83
R12 504 INP. JOYSTICK REACH CARRIAGE

Gr
Ye
X11 X33
C 84 C
R13 505 INP. JOYSTICK TILT

R
423260-

Service Manual
Gr
Ye
X11 X33
85
R14 506 INP. JOYSTICK SPARE 1

Gr

7FBRE
D D
Valid from serial number

E E
T-code
689-692

201339
F 8/10 Prod A
F
14Electrical System – 5000.2
Electrical diagram

1 2 3 4 5 6 7 8

26- 11
 1 2 3 4 5 6 7 8

26- 12
T-code
689-692
A A

EMERGENCY MODE
100~E / 25W
X30 S132 R102
22 1 2 ELECTRONIC CARD
Sh. 8 10 A5
Electrical diagram

X14 X17 Y10 X17 X14

40 Bk1 3Wh 88
Sh. 7 10 803 OUT. FORK LOWER

B X17 X14
B
Bk1 2Gr 89
701 OUT. FORK LIFT
EMERGENCY MODE
S133
1 2
423260-

Y12 X17 X14

Bk1 2R 90
702 OUT. REACH CARRIAGE, IN

C Y13 C
X17 X14
14Electrical System – 5000.2

Bk1 91

Service Manual
2Bl
703 OUT REACH CARRIAGE, OUT

Y14 X17 X14

Bk1 2Or 92
704 OUT. TILT DOWN

Y15 X17 X15

Valid from serial number

7FBRE
Bk1 2Ye 93
705 OUT. TILT UP

X29 X50 Y16 X50 X29 X17 X15

D 1 2 94 D
706 OUT. SPARE 1A

Y17 X50 X29 X17 X15

1 2 95
707 OUT. SPARE 1B
Date
2005-07-01

E E
201004-040

201339
9/10 Prod A
Order number

F F

1 2 3 4 5 6 7 8

© TIEE SARL
 1 2 3 4 5 6 7 8

OPTIONS

© TIEE SARL
201004-040

A A
Order number

EXTERNAL EQUIPMENT
WORKING LIGHT
10A X42 X42
F63 X30 S99 E4 E3
1 26 1 1 26 1 5 191 192
Sh. 5

X30
Date

40 40 2 2 40
Sh. 9
B B
2005-07-01

SEAT HEATER
X30 X25 E10 X25
22
Sh. 9

C C
423260-

Service Manual
ELECTRONIC CARD
A5

X14 X43 S46 X43 X15

Br Bl 106
303 INP. REDUCED LIFT SPEED

7FBRE
202 OUT. DATA COLLECT, LIFT
D D
Valid from serial number

208 OUT. DATA COLLECT, DRIVE

X14 X16 S31 X52 X16 X14

79
206 INP. SPEED REDUCTION

X32 S33 X33

5 1 100
205 INP. OVERRIDE
E S32 E
X15 X16 X16 X15
T-code

98
689-692

301 INP. LIFT LIMIT SPECIAL HEIGHT

201339
F 10/10 Prod A F
14Electrical System – 5000.2
Electrical diagram

1 2 3 4 5 6 7 8

26- 13
 14Electrical System – 5000.2
Electrical diagram
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

26.3.1 Component List

Symbol Designation/function Picture

A1 Frequency converter, M1 5
A2 Frequency converter, M3 5
A5 Electronic card 5
A6 Display 1

B1 Thermoelectric sensor, M1 5

E10 Seat heater 4

E3, E4 Work spotlight 7

F1 Drive motor fuse, 125 A 5

F3 Pump motor fuse 160 A 5
F60 Operating fuse for A5 card, 10 A 5
F61 Steering motor fuse, 30 A 5
F62 Operating fuse for K10, 10 A 5
F63 Operating fuse for extra equipment, 5
10/16 A

G1 Battery, 48 V 8

H1 Horn 5

K10 Main contactor 5

M1 Drive motor 5
M3 Pump motor 5
M6 Steering motor 5
M10 Fan for pump motor 5
M12 Fan for electrical panel 5

26- 14 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Symbol Designation/function Picture

R1 Potentiometer, driving 5
R2 Potentiometer, braking 5
R11 Potentiometer, forks raised/lowered 2
R12 Potentiometer, reach carriage 2
R13 Potentiometer, tilt 2
R14 Potentiometer, extra hydraulic function 2
R15 Potentiometer, extra hydraulic function 2
R100 Resistor, service key 8
R102 Resistor, emergency lowered forks 5

S1 Microswitch, driver number/programming 1

S2 Microswitch, driver number/step up 1
S3 Microswitch, driver number/step down 1
S17 Key switch 1
S18 Microswitch, horn 2
S21 Emergency switch 1
S23 Safety switch, left foot-pedal 3
S26 Microswitch, direction of travel selector at 2
crawl speed
S27 Microswitch travel direction (foot), direc- 3
tion of forks
S29 Microswitch travel direction (foot), direc- 3
tion of steering wheel
S31 Microswitch, speed reduction 8
S32 Microswitch, max. lift height 8
S33 Microswitch, by-pass max. lift height 1
S46 Magnetic switch, lowering between free lift 7
and main lift
S56 Magnetic switch, retracting mast low
speed
S65 Pulse sensor, steering wheel centre 5
S66 Pulse sensor, steering wheel direction 5
S89 Microswitch, seat 4

© TIEE SARL Service Manual 7FBRE 26- 15

 14Electrical System – 5000.2
Electrical diagram
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Symbol Designation/function Picture

S99 Microswitch, work spotlight 1
S131 Microswitch, released parking brakes 5
S132 Microswitch, emergency lowered forks 5
S133 Microswitch, emergency retraction of mast 5

U1 Tachometer, steering 2
U11 Pulse sensor, drive motor 5

X1 Contact 8
X11 Contact 2
X14 Contact 5
X15 Contact 5
X16 Contact 6
X17 Contact 6
X18 Contact 5
X19 Contact 5
X20 Contact 5
X21 Contact 5
X22 Contact 6
X24 Contact 5
X25 Contact 4
X26 Contact 5
X27 Contact 5
X29 Contact 6
X30 Contact 5
X31 Contact 5
X32 Contact 5
X33 Contact 5
X34 Contact 5
X35 Contact 5
X36 Contact 5

26- 16 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Symbol Designation/function Picture

X37 Contact 5
X41 Contact 7
X42 Contact 5
X43 Contact 6
X45 Contact 1
X50 Contact 8
X52 Contact 6

Y1 Magnet, parking brakes 5

Y10 Solenoid valve, lift/lower 6
Y12 Solenoid valve, reach carriage in 6
Y13 Solenoid valve, reach carriage out 6
Y14 Solenoid valve, tilt down 6
Y15 Solenoid valve, tilt up 6
Y16 Solenoid valve, extra hydraulic function 1A 6
Y17 Solenoid valve, extra hydraulic function 1B 6

© TIEE SARL Service Manual 7FBRE 26- 17

 14Electrical System – 5000.2
Electrical diagram
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

26.3.2 Figure 1
S99
S33
A6

S1
S2
S3
S17
S21

X45

26.3.3 Figure 2
R14
R13
R12
R11
S18

U1

S26

X11

26- 18 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

26.3.4 Figure 3
S27
S29
S23

26.3.5 Figure 4

© TIEE SARL Service Manual 7FBRE 26- 19

 14Electrical System – 5000.2
Electrical diagram
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

26.3.6 Figure 5
X24
X21
X20
S133 S132 S131

X32
R102 X33
X22
X34
X37
X15
X30 X14
X42
X31

F63 F62 F61 F60

A5 M12 F1 A1 A2 F3

K10
R1
X19
R2
X36 H1

M10
X35

M3

X18 S66 S65 M6 M1 Y1

B1 X27 X26
U11

26- 20 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Electrical diagram
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

26.3.7 Figure 6

Y13
X52
X17 Y14

X16 Y17

X29

X43

X22 Y16 Y15 Y12 Y10

26.3.8 Figure 7

© TIEE SARL Service Manual 7FBRE 26- 21

 14Electrical System – 5000.2
Functional Description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

26.3.9 Figure 8

26.4 Functional Description

The electronic card for TOYOTA 7FBRE has a microprocessor that
monitors switch status, control voltages, etc., and provides instructions
for external electronics, contactors, valves, etc.
The module is equipped with an internal battery so that pre-set informa-
tion remains in the electronics module once battery power has been
switched off. Any errors registered by the micro-processor are shown
on the display. Error codes are explained in conjunction with the elec-
tronic card. The electronic card’s inputs and outputs are marked with
connection numbers and can be easily connected and disconnected
using connectors. The inputs and outputs, which have two fixed posi-
tion, have LEDs indicators: green is used for inputs, red for outputs
and yellow for others.

Signal Name Diode number

Designations for card inputs/out- Diode name indicating the
puts, in accordance with electri- card’s active input/output
cal diagrams.

26- 22 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Functional Description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

26.4.1 Key in Position 0

When the battery is connected to the truck via the charging plug, the
electronic cards A5 receives a +48 V voltage and the LEDs (shown in
the table) light. LEDs 209, 210, 211 and 301 light depending on whether
the respective sensor is actuated or not. A voltage of +7.35 V is sup-
plied by A5 to potentiometer R1 in the acceleration controller, the brak-
ing controller R2 and the hydraulic controllers R11–R15.

Signal Name Diode number

STEER WHEEL ANGLE 210, 211
HEIGHT COUNTER 301
HEIGHT COUNTER 302 (lights dimly)
+48 V 805
STEER PWR
POWER OK
+48 V STEER

26.4.2 Key in Position I

The truck is voltage fed through the driver turning the key to position I.
In order to use the travel direction selector and hydraulics the driver
must sit in the truck so that switch S89 makes. The voltage is fed
through the control fuse F60, ignition S17 and the emergency switch
S21 to the electronic card A5, frequency converters A1 and A2 and the
fan M 10, which starts. The A5 electronic card checks that the internal
safety function is functioning and closes the main contactor K10, which
provides power to the drive and pump motors. The electronic card A5
feeds +32 V to the fan M12, which then rotates at half speed.
A5 checks that the voltage from the potentiometers is +3.65 V and
sends control pulses to tachometer U1 and steering motor M6. If the
seat has built-in heating, a voltage of +48 V is also supplied to the ther-
mostat and the seat heater E10.
The display turns on and the computer software version number is
shown before the display enters the normal mode. The normal model
shows the time of day, operating time, battery status and any error
codes.
The length of time that the truck key is in the I position is monitored and
stored in the electronics module.
The LEDs in the following table will light:
• No. 706–711 light if the valves are not installed on the truck.
• No 110, 203 and 301 light if the switches are actuated.
The LEDs on the frequency converters light.

© TIEE SARL Service Manual 7FBRE 26- 23

 14Electrical System – 5000.2
Functional Description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Signal Name Diode number

LEFT FOOT SWITCH 110
SEAT SWITCH 203
SPARE 1A, 1B 706, 707
SUPPORT ARM BRAKE 801
FORK LOWER 803 (lights dimly)
MAIN CONTACTOR 804
+48 V KEY
+48 V ESO
+48 V_SR

26.4.3 Choice of travel direction

The travel direction can be selected in two ways.

On the control console

When the control S26 is pressed down voltage is fed from the switch to
A5. If the control is held down for at least three seconds, the truck runs
at crawl speed.

Signal Name Diode number

DRIVE FORK DIRECTION 104
DRIVE, STEER WHEEL 105
DIRECTION

On the accelerator
When the pedal is pressed down on the right-hand side (fork direction)
voltage is fed from the switch S27 to A5. The truck switches travel
direction by pressing down on the left-hand side. The pedal does not
offer the possibility of selecting the crawl speed function.

Signal Name Diode number

DRIVE FORK DIRECTION 106
DRIVE, STEER WHEEL 107
DIRECTION

The display shows the direction of travel.

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 14Electrical System – 5000.2
Functional Description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

26.4.4 Driving
When the accelerator R1 is manoeuvred, the drive motor brakes are
released. If the safety switch S23 is not actuated when the parking
brake is released, a signal sounds from the display.
If the driver presses the accelerator pedal as the key is turned to I, the
pedal must be returned to the neutral position before the truck can be
driven.
When the accelerator pedal is pressed down the potentiometer R1 is
actuated and the more the accelerator is pressed down the lower the
voltage that is fed from R1 to A5. The voltage drops from 3.7 V to 1.7 V,
which gives the speed 0-100% A1 controls the drive motor’ speed using
information from A5. Current passes through A1’s fuse F1 and is con-
verted to 3-phase AC, which goes to till M1.
If the switch for speed reduction S31 is actuated so that there is voltage
on A5’s input, the pre-programmed max speed will apply. Drive motor
speed is measured by sensor U11.
If the direction of travel selector on the control console is held down for
at least three seconds, the truck runs at crawl speed.
If the driver is unseated for more than three seconds, A5 cuts the cur-
rent to Y1, which applies the parking brakes.
The drive motor’s running time is monitored and stored in the electron-
ics module.

Signal Name Diode number

PARKING BRAKE 802

26.4.5 Steering
When the wheel is turned, voltage is supplied by tachometer U1 to A5,
which provides progressive power to steering motor M6. This means
that the faster the steering motion, the faster the steering motor runs.
Progression also entails that the higher the driving speed, the lower the
turning speed. Drive motor speed is measured by sensor U11.
When the wheel is moved the steering wheel sensor S65 is actuated
and voltage is fed to A5. The opposite driving direction is shown on the
display. The electronics automatically indicate the correct travel direc-
tion in that switch S65 transmits signals for 180° of the possible 360.
Sensor S65 must pass one of the reference points for the electronics to
determine the direction of the steering wheel and indicate the travel
direction. The function is initiated by a turn of the wheel. This must be
done at the initial start and after service.

© TIEE SARL Service Manual 7FBRE 26- 25

 14Electrical System – 5000.2
Functional Description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

LEDs 209, 210 and 211 light depending on whether the respective sen-
sors are actuated or not.

Signal Name Diode number

STEER WHEEL REF. 180° 209
STEER WHEEL ANGLE A 210
STEER WHEEL ANGLE B 211

26.4.6 Steering wheel indicator

When the wheel is turned, sensor S66 sends signals to A5, which indi-
cates the travel direction on the display. Sensor S65 must pass one of
the reference points for the electronics to determine the direction of the
steering wheel and indicate the travel direction. The function is initiated
by a turn of the wheel. This must be done at the initial start and after
service. When the travel direction is changed using the lever, the
arrows switch on the display.
LEDs 209, 210 and 211 light depending on whether the respective sen-
sors are actuated or not.

Signal Name Diode number

STEER WHEEL REF. 180° 209
STEER WHEEL ANGLE A 210
STEER WHEEL ANGLE B 211

26.4.7 Braking
The truck employs various braking systems:

Auto-brakes
When the driver releases the accelerator pedal, the drive motor auto-
matically brakes the truck to the desired speed. The auto-brake func-
tion and braking power can be set with parameters.

Motor brakes (electric)

When the driver changes directions using the lever, the drive motor
functions as a generator/brake and feeds current back to the battery.
Braking force is determined by the accelerator pedal. The A5 electronic
card receives information from A1 that motor braking is underway and
changes regulation of A1.

Foot brakes
When the driver depresses the brake pedal, potentiometer R2 is actu-
ated. The voltage rises from 1.7 V to 4.1 V, which gives a braking force
of 0-100%. When the pedal is pressed down fully this also activates the
parking brake.

26- 26 Service Manual 7FBRE © TIEE SARL

 14Electrical System – 5000.2
Functional Description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Parking brake
When the truck is standing still and the brake pedal is depressed, the
parking brakes are activated.
If the driver is unseated for more than three seconds, A5 cuts the cur-
rent to Y1, which applies the parking brakes.

26.4.8 Fork lifting

When the driver actuates the hydraulic control R11 a voltage of 3.7-
6.6 V is fed to the input on A5 and the direction valve Y10 opens and
sends a signal to the transistor regulator A2 The pump motor M3 starts
and pumps oil to the lifting cylinders.
If the battery monitor has detected 20% or lower battery capacity, lifting
speed is reduced.
The lifting speed is reduced with the transition from free lift to main lift.
The speed on M3 is measured by sensor U12.

Signal Name Diode number

FORKLIFT 701

26.4.9 Maximum Height

When the forks reach the height switch S32 and A5 receives a signal,
the fork lift will be stopped. If the forks are to be lifted above this height,
switch S33 must be depressed, which sends a signal to A5 and move-
ment continues. Start must occur within fifteen seconds.

Signal Name Diode number

LIFT LIMIT SPECIAL HEIGHT 301
OVERRIDE 205

26.4.10 Fork lowering

When then the driver actuates the hydraulic lever R11 a voltage of 3.7-
0.66 V is fed to A5, which opens the proportional valve Y10 and the
driver can lower the forks at a variable speed.
The lowering speed is reduced when switch S46 is actuated.

Signal Name Diode number

FORK LOWER 803

© TIEE SARL Service Manual 7FBRE 26- 27

 14Electrical System – 5000.2
Functional Description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

26.4.11 Mast out/in

When the driver actuates the hydraulic lever R12 a voltage (out = 3.7-
0.77 V or in =3.7-6.6 V) to A5 which opens the direction valves Y12/
Y13 and sends a signal to the transistor panel A2. The pump motor M3
starts and pumps oil to the reach cylinder. The oil flow in the cylinder is
reduced before the mast reaches the outer position. The reduction in
the inner position takes place when the switch S56 is activated.

Signal Name Diode number

REACH CARRIAGE IN 702
REACH CARRIAGE OUT 703

26.4.12 Fork tilt up/down

When the driver actuates the hydraulic lever R13 a voltage (up = 3.7-
6.6 V or in =3.7-0.66 V) to A5 which opens the direction valves Y14/
Y15 and sends a signal to the transistor panel A2. The pump motor M3
starts and pumps oil to the tilt cylinders.

Signal Name Diode number

TILT DOWN 704
TILT UP 705

26.4.13 Hydraulic function 4

When the driver actuates the hydraulic lever R14 a voltage (3.7-6.7 V
or 3.7-0.66 V) to A5 which opens the direction valves Y16/Y17 and
sends a signal to the transistor panel A2. The pump motor M3 starts
and pumps oil to the extra function.

Signal Name Diode number

SPARE 1A 706
SPARE 1B 707

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 14Electrical System – 5000.2
Functional Description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

26.4.14 Driver identification

Login can be performed in two different ways:

Without pin code

• Press one of the switches I, II, or III to select driver 1 to 3.

With pin code

• Press the switches I, II, and III the 4 digit combination, (e. g. I, II,
III and III) to select driver 1 to 10.
For programming of the driver combination, see C-code 5710.

Signal Name Diode number

SETUP SELECT 101
SETUP UP 102
SETUP DOWN 103

© TIEE SARL Service Manual 7FBRE 26- 29

 14Electrical System – 5000.2
Functional Description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

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26- 30 Service Manual 7FBRE © TIEE SARL

 Battery – 5110
Battery dimensions
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

27- Battery – 5110

27.1 Battery dimensions

Model Battery Min. Depth Width (1Height (1Drawing

size (Ah) weight (kg) (A) mm (B) mm (C) mm number
7FBRE12, 14 292-300 510 275 1040 778 148243
783 148573
7FBRE14 360-450 610 340 1040 778 148255
783 145069
7FBRE14 480-600 780 430 1040 778 148259
783 145070
7FBRE16 360-450 700 273 1208 778 148200
783 145066
7FBRE16, 20 480-600 865 344 1208 778 148204
783 145067
7FBRE20, 25 600-750 1075 419 1208 778 148216
783 145068
7FBRE25 876-900 1270 491 1208 778 148221
783 146987

(1
Lower measurement is the roller table battery.

© TIEE SARL Service Manual 7FBRE 27- 1

 Battery – 5110
Setting the battery parameters on 7FBRE trucks fitted with Hawker Evolution gel batteries
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

27.2 Setting the battery parameters on

7FBRE trucks fitted with Hawker
Evolution gel batteries

27.2.1 General
Following completed evaluation and testing, recommendations for the
setting of parameter 21 on 7FBREs fitted with Hawker Evolution gel
battery have been prepared. There are also instructions for verifying
and adjusting the set values.

27.2.2 Battery recommendation

Exide gel batteries (e.g. Sonnenschein)
In our tests of Exide gel batteries, we have not been able to make any
recommendations for setting the parameters on any of our products.
As a result, we do not recommend using this type of batteries.
Hawker Evolution batteries
For Hawker Evolution gel batteries, clear guidelines regarding their
use exist. This is why we are able to recommend these batteries.
- -The Evolution batteries have been designed for use in low-inten-
sity applications.
- -The recommended use is one shift per day (max. 8 hours).
- -Max. 6 days of use per week with an expected service life of
1,000 cycles.
- -Max. discharge level 70%
- -The ambient temperature should be from +5°C to +35°C
- -The battery must be charged using a Hawker battery charger
with an EZ controller. Charging must be done according to the in-
structions supplied with the Hawker battery.
- -Typical charging time 12 hours
- -Equalising charging is required after 6 charge cycles
- -Discharged batteries must not be stored away. The maximum al-
lowed storage time is 2 month, however, charging once a month
is required.

27.2.3 Battery installation

NOTE
Parameter 21 must always be checked and adapted to the battery,
which is installed in the truck. The parameter setting depends on the
battery type, machine type and battery size.

27- 2 Service Manual 7FBRE © TIEE SARL

 Battery – 5110
Setting the battery parameters on 7FBRE trucks fitted with Hawker Evolution gel batteries
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

27.2.4 Recommended parameter setting for

ventilation regulated batteries
When setting parameter 21 in a 7FBRE truck fitted with Hawker Evolu-
tion batteries, we advise that the recommended value for wet-type bat-
teries should be reduced by six (6) units
Example:
Parameter 21 with a 520 Ah wet battery: 14

Parameter 21 with a Hawker Evolution battery: 8

WARNING!
Battery service life will be reduced if the value of parameter 21 is set
too high. Please always check that the parameter setting is correct
by referring to the instructions below.

To verify the charging state of a discharged 48 V battery, meas-

ure the open circuit voltage (i.e. voltage at no load) following a
period of inactivity. 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.

27.2.5 Instructions for verifying the

parameter setting
• Charge the battery.
• Operate the truck in its normal application until the battery indicator
indicates a discharged battery (0% in the display).
• 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.
• Measure the voltage in the battery at room temperature. If the volt-
age is less than Uend, (see the table below), the parameter value
must be reduced. If the value considerably exceeds Uend, the risk
of causing damage to the battery is reduced. At the same time,
however, the operating time of the truck decreases. If an extended
operating time is desired, slightly increase the parameter value.
• Each change should be followed up by a new verification of the
parameter setting.
Battery type Battery voltage when idle, Uend
Hawker Evolution 48.48 V

© TIEE SARL Service Manual 7FBRE 27- 3

 Battery – 5110
Setting the battery parameters on 7FBRE trucks fitted with Hawker Evolution gel batteries
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

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27- 4 Service Manual 7FBRE © TIEE SARL

 Transistor panel – 5460
Frequency converter
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

28- Transistor panel – 5460

28.1 Frequency converter

28.1.1 General description

The frequency converter is equipped with a green LED that indicates
OK status.
Basic software to control the motor is stored in the frequency converter.
The frequency converter has internal monitoring of CAN communica-
tions DC voltage levels, intrinsic temperature and motor temperature.
Any detected function errors are registered by the frequency converter
and the information sent via CAN to the main card A5, which registers
the error code and presents the corresponding code on the instrument
panel display.
The frequency converter can be reprogrammed via CAN.

1 2 3 4 5 6 7

8 9 10 11 12 13

K1
B+ 15 Nm

U V W B-

© TIEE SARL Service Manual 7FBRE 28- 1

 Transistor panel – 5460
Frequency converter
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

28.1.2 Terminal connections and pole bolts

I = Input, O = Output

Term. Cable Description Active Input/

A1/A2 Output
1 22 Ignition Start/Stop +48 VDC I
2 No con-
nection
3 10/15 Sensor, + voltage +12 VDC, O
50mA
4 11/16 Sensor, - voltage 0V O
5 12/17 Pulse generator, phase 1 +12 V, 1kOhm I
6 13/18 Pulse generator, phase 2 +12 V, 1kOhm I
7 14/19 Motor temp. I
8 -/16 CAN ID0 1: Open I
(Not connected when used as A1) 0: Sensor, -
9 No con- I
nection
10 119 CAN H 0-5 V I/O
11 120 CAN L 0-5 V I/O
12 117 CAN + voltage, external +15 VDC I
13 118 CAN – voltage, external 0V I
B+ 8 Battery + +48 VDC I
B- 40 Battery - 0V I
U 2/5 Motor winding U 0-33 V O
V 3/6 Motor winding V 0-33 V O
W 4/7 Motor winding W 0-33 V O

28- 2 Service Manual 7FBRE © TIEE SARL

 Transistor panel – 5460
Frequency converter
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

28.1.3 Technical Data

Parameter Setting ACS Setting Unit Description
4808 ACS 4811
Operating voltage 48 48 Volt
Maximum voltage 65 65 Volt Over-voltage point
Minimum operating voltage 30 30 Volt Under-voltage point
Frequency 13 8/13 kHz
Contactor voltage 48 48 Volt
Ambient operating temperature -35 - +55 -35 - +55 °C
Current limit, down-regulation 85 85 °C 0 A at 125°C
with overheating of the heatsink
Current limit, down-regulation at -20 -20 °C 50% current limiting at
excessively low cooling block start
temperatures
Current limiting 250 350 Amp 2 minutes
Speed 100 100 % Modulation

28.1.4 Installation of New Frequency

Converter on Truck
Frequency converters from TOYOTA can be delivered in different con-
figurations:

1. Ready programmed with complete number

= part number for frequency converter including program.
2. Non-programmed at part number
= only part number for frequency converter.
When installing a new card, certain parameters must be reprogrammed
so that the truck can be safely operated.

28.1.5 Programming
For downloading new programs to the electronics card, the Truck Com
service program is used.
See the Truck Com user manual for a description of the procedure.

© TIEE SARL Service Manual 7FBRE 28- 3

 Transistor panel – 5460
Frequency converter
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

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28- 4 Service Manual 7FBRE © TIEE SARL

 Power electronics panel – 5660
General description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

29- Power electronics panel – 5660

29.1 General description

The regulator is equipped with a LED for error indication, this is located
on the top of the regulator and is marked STATUS. On one side of the
regulator there is also a socket for the connection of hand terminal
1307. See further under the chapter PARAMETERS.
Basic software to control the pump motor is stored in the regulator.
The regulator is equipped with internal monitoring of CAN communica-
tion and the DC voltage level.
Any detected function errors are registered by the regulator and the
information sent via CAN to the main card A5, which registers the error
code and presents the corresponding code on the instrument panel dis-
play.

© TIEE SARL Service Manual 7FBRE 29- 1

 Power electronics panel – 5660
General description
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

29.1.1 Terminal connections and pole bolts

I = Input, O = Output

Term. Cable Description Active I/O

J1-(1-4) Hand terminal
J2-1 22 CAN H 0-5 V I/O
J2-(3-7) Not con-
nected
J2-8 CAN L 0-5 V I/O
J2-(9-15) Not con-
nected
J2-16 10/15 Ignition Start/Stop +48 VDC I
B+ 8 Battery + +48 VDC I
B- 40 Battery - 0V I
M 4/7 Motor connection - U

The transistor panel has three connections for the motor and battery.
The cables for these are secured using M8 bolts that may be tightened
to max 16.3 Nm.

29- 2 Service Manual 7FBRE © TIEE SARL

 Power electronics panel – 5660
Parameter
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

29.1.2 Technical Data

Parameter Setting Unit Description
Operating voltage 48 Volt
Maximum voltage 61 Volt Over-voltage point
Minimum operating voltage 30 Volt Undervoltage point
Frequency 16 kHz
Ambient operating temperature -35 - +55 o
C
Current limit, down-regulation at 85 oC 0 A at 95o C
excessively high heatsink tem-
perature
Current limit, down-regulation at -25 o
C 50% current limiting at start
excessively low heatsink tem-
perature
Current limiting 250 Amp 2 minutes
Speed 100 % Modulation

29.1.3 Installing a new transistor panel

No programming/setting is required.

29.2 Parameter
Curtis 1243 has a number of parameters for setting the ID number and
communications. The parameters that can be modified by a service
technician using the hand terminal 1307 are shown in the table below.
How to access and modify the parameters is described in the chapter
“Using the hand terminal”.

No. Parameter type Unit Min./max. Std. value Comments

01 Module ID 1–31 4 Can bus module address
02 TX COB 0-128 1 CAN bus transmitting
03 RX COB 0-128 1 CAN bus receiving

© TIEE SARL Service Manual 7FBRE 29- 3

 Power electronics panel – 5660
Diagnostics and trouble shooting
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

29.3 Diagnostics and trouble shooting

29.3.1 Displaying error codes, logging errors

An internal microprocessor monitors regulator operations the whole
time. When an error is detected an error code is sent to the main card,
which displays and stores it. This error code can also be read off using
the hand terminal 1307 or by the combination of flashes produced by
the STATUS LED on top of the regulator. During normal conditions,
when no error code is detected, the LED flashes approximately once
per second.
The regulator logs the error in its internal memory. If an error occurs
several times this is logged as occurring once. You can use the hand
STATUS
MODEL VOLTAGE
terminal to read off the errors that are active and see a log of the errors
that have occurred. The STATUS LED only shows one error at a time
SERIAL CURRENT

and no errors are stored.

How you read off the error codes using the hand terminal is described
in the chapter “Using the hand terminal”.

29- 4 Service Manual 7FBRE © TIEE SARL

 Power electronics panel – 5660
Diagnostics and trouble shooting
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

29.3.2 Error codes, trouble shooting

The error codes that can be given via the STATUS LED or read off
using the hand terminal are shown in the table below. The table also
lists the probable cause of each error.

STATUS LED Hand termi- Explanation Probable cause/see error

nal display code in section 5710
LED Off No voltage or Burnt fuse, bad connection, not
faulty regulator connected, faulty regulator
LED On Faulty regulator Faulty regulator
1,2 ¤ ¤¤ 234

1,3 ¤ ¤¤¤ 221

1,4 ¤ ¤¤¤¤ 222

3,1 ¤¤¤ ¤
4,1 ¤¤¤¤ ¤ 48

4,2 ¤¤¤¤ ¤¤
4,3 ¤¤¤¤ ¤¤¤ 46

5,0 ¤¤¤¤¤
5,1 ¤¤¤¤¤ ¤
5,2 ¤¤¤¤¤ ¤¤
5,3 ¤¤¤¤¤ ¤¤¤
5,4 ¤¤¤¤¤ ¤¤¤¤

29.3.3 Resetting an error

To reset the error and remove the error code requires, in addition to rec-
tify the cause of the error, the ignition (S17) to be switched on and off.
Exceptions are these errors

Error Reset when

4,1 When the battery voltage rises above 30 V
4,2 The battery voltage falls under 61 V
4,3 The temperature is within permitted limits

© TIEE SARL Service Manual 7FBRE 29- 5

 Power electronics panel – 5660
Maintenance
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

29.4 Maintenance
There are no components in the transistor regulator that the user may
repair.
NOTE:
Do not attempt to open the transistor regulator.
OPENING THE REGULATOR WILL INVALIDATE THE WARRANTY!
It is recommended that the outside of the transistor regulator is cleaned
regularly. Cleaning the regulator provides the perfect opportunity to
check the regulator’s diagnostic file using the hand terminal, if one is
available.

29.4.1 Safety
The regulator is a high power component. All requisite safety regula-
tions must be observed when working on battery powered vehicles.
These comprise, among others, appropriate training, the use of protec-
tive glasses, avoiding wearing loose hanging clothes, watches and jew-
ellery. Always use insulated spanners.
WARNING
Risk of short-circuiting.
Remove all watches and jewellery and always use insulated tools.

29.4.2 Cleaning
Despite the transistor regulator not requiring any maintenance if cor-
rectly installed, the following minimum maintenance is recommended
at 500 hour intervals.
• Cut the voltage by disconnecting the battery.
• Discharge the capacitors in the transistor regulator by connecting a
load (for example a contactor coil or horn) across the regulator’s B+
and B- terminals, before any work is carried out on the transistor reg-
ulator.
• Remove all dirt and corrosion from the power connections. The reg-
ulator should be wiped clean with a damp cloth. Allow the regulator
to dry before the battery can be reconnected.
Check that the regulator’s power connections are well tightened. Use
two well-insulated spanners to perform this work to prevent uneven
loads on the power connections.

29- 6 Service Manual 7FBRE © TIEE SARL

 Power electronics panel – 5660
Hand terminal 1307
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

29.5 Hand terminal 1307

The hand terminal 1307 is used to program, test and trouble shooting
the transistor regulator 1243. The hand terminal is powered by the tran-
sistor regulator via a 4 pin Molex connector located on one side of the
regulator.

S1 S2

B- M- B+

© TIEE SARL Service Manual 7FBRE 29- 7

 Power electronics panel – 5660
Hand terminal 1307
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Function Comments
LCD display 4-row LCD Display
PROGRAM MODE button Select this function to display (and modify) the regulator’s parame-
ters.
TEST MODE button Select to show the status of the inputs and outputs, etc.
DIAGNOSTICS MODE Select to display the current active error discovered by the regulator
SCROLL DISPLAY buttons Scrolls the display text rows (up and down)
MORE INFO button Press to access more relevant information about the actual mode.
Key active LED Indicates whether the relevant CHANGE VALUE button is active
When it dims no more adjustments can be made.
CHANGE VALUE buttons Increase or decrease the value of the selected object
Operating mode LED Indicates which operating mode is active

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 Power electronics panel – 5660
Using the hand terminal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

29.6 Using the hand terminal

• Connect the hand terminal to the regulator’s programming socket.
• Ensure that the truck’s current is switched on.
When this is ready the terminal will display the regulator’s control
number, date of manufacture and the software’s revision code. After
this display the terminal will show a prompt for further instructions.
The terminal has three main functions: PROGRAM, TEST and DIAG-
NOSTICS.
• PROGRAM mode is used to show the terminal’s parameters. Dis-
S1 S2 played parameters can also be replaced in this mode.
• TEST mode shows real time information about the status of the input
B- M- B+
and output signals and the temperature of the regulator. In TEST
mode the current point does not have to be the first on the list; it only
needs to be among the first four displayed in the window. TEST
mode can be used when you wish to check the operation of the reg-
ulator during installation and for trouble shooting if problems occur.
• DIAGNOSTICS mode displays the active error found by the regula-
tor.
You also have access to two other functions: SPECIAL PROGRAM
MODE and SPECIAL DIAGNOSTIC MODE.
• The SPECIAL PROGRAM MODE is used for a number of functions,
for example, to select the language, save settings, adjust the con-
trast on the LCD display and to clear the DIAGNOSTIC HISTORY
FILE.
• SPECIAL DIAGNOSTIC MODE is used when you wish to see which
errors have been logged. The regulator logs all errors that have oc-
curred and save these in the DIAGNOSTIC HISTORY FILE, until
this file has been cleared.

© TIEE SARL Service Manual 7FBRE 29- 9

 Power electronics panel – 5660
Using the hand terminal
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

29.6.1 Check and adjust parameters

• Press the PROGRAM mode button. The program function mode
LED comes on.
The terminal now shows the first four parameters.
See the picture below.
PROGRAM

Parameters are shown four at a time. Each row represents one param-
eter. (A) indicates the name of the parameter. The arrow (B) indicates
the parameter selected for adjustment. (C) indicates the current param-
eter value.
Press one of the SCROLL DISPLAY buttons to display more parame-
ters.
To adjust a specific parameter scroll the display up or down so that the
arrow (B) points at it.
• Increase the value by pressing CHANGE VALUE – “up” button or
decrease the value using the CHANGE VALUE - “down” button.
NOTE!
The new value is transferred directly to the regulator, as soon as any
of the parameters on the display have be changed.

Use MORE INFO in PROGRAM MODE

If you press the MORE INFO button when in PROGRAM MODE the
current parameter is shown in more detail. The parameter is displayed
by means of a horizontal bar chart together with the minimum and max-
imum values for the selected parameter.

MODE 1 ACCELERATION
RATE; SECS

MIN 0.2
1.3
MAX 3.0

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 Power electronics panel – 5660
Using the hand terminal
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

29.6.2 Special program mode

SPECIAL PROGRAM MODE is used for a number of different functions
that are self-instructional. In SPECIAL PROGRAM MODE you can
select the language, save settings, return to the previous settings,
download settings to a regulator, adjust the contrast on the LCD display

*
MORE INFO PROGRAM
and clear the DIAGNOSTIC HISTORY FILE.
To enter SPECIAL PROGRAM MODE you must first press MORE
INFO and PROGRAM button simultaneously. The LED on the PRO-
GRAM button will come on, exactly as in PROGRAM mode. When in
SPECIAL PROGRAM MODE use the MORE INFO button to perform
the desired function.
Example: Select Contrast Adjustment by pressing one of the SCROLL
buttons until the Contrast Adjustment is shown uppermost on the dis-
play to adjust the contrast on the LCD display. When this is ready press
on MORE INFO to make the settings.

29.6.3 Using TEST mode

• Press the TEST mode button. The TEST mode LED comes on.
The terminal now shows the real time status for the various input and
output values. See the picture below.

TEST

Values are shown four rows at a time. Each row represents an input/
output signal or value. (A) is the name and (B) is the current value.
Press one of the SCROLL DISPLAY buttons to display more parame-
ters.

29.6.4 Using DIAGNOSTICS MODE

• Press the DIAGNOSTICS mode button. The DIAGNOSTICS func-
tion mode LED comes on.
The terminal now shows a list of the current active errors discovered by
the regulator. The picture below shows the display when no errors have
been discovered.
DIAGNOSTICS

© TIEE SARL Service Manual 7FBRE 29- 11

 Power electronics panel – 5660
Using the hand terminal
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

29.6.5 SPECIAL DIAGNOSTICS MODE

The regulator’s DIAGNOSTIC HISTORY FILE is shown in SPECIAL
DIAGNOSTICS MODE. This file contains all the errors logged by the

*
regulator since the file was last cleared. Each error is only logged once,
irrespective of how many times the error has occurred.
MORE INFO DIAGNOSTICS To enter SPECIAL DIAGNOSTICS MODE you must first press MORE
INFO and DIAGNOSTICS button simultaneously. The LED on the
DIAGNOSTICS button comes on.
You must go over to SPECIAL PROGRAM MODE and select Clear
Diag History and press MORE INFO for further instructions to clear the
DIAGNOSTICS HISTORY FILE.

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 Electronic card – 5710.1
General description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30- Electronic card – 5710.1

30.1 General description

This description is valid from electronic card 169937-001
The A5 electronic card is equipped with green LEDs on the inputs from
the microswitches and sensors, red LEDs on the outputs to the contac-
tors and valves, and yellow for voltages. This card is also equipped with
a potentiometer for adjusting the hydraulic control for fork lowering.
The truck’s programmable parameters settings are stored on the elec-
tronic card.
The main card monitors the truck’s steering, driving and hydraulic func-
tions. Any errors are registered and the corresponding error code is dis-
played on the instrument panel’s display.

© TIEE SARL Service Manual 7FBRE 30- 1

 Electronic card – 5710.1
Terminal connections and voltages on A5
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.2 Terminal connections and voltages

on A5
The LEDs on the connection terminals are designated in the tables as
follows:
I = Input, green light emitting diode (LED)
O = Output, red light emitting diode (LED)
Other = Yellow light emitting diode (LED)

30.2.1 10X

Term. Cable Description Active LED

(V)
101 34 Selection of driver/parameter settings +48 I
102 35 Selection of driver/step up +48 I
103 36 Selection of driver/step down +48 I
104 45 Travel direction selection for fork direction at crawl +48 I
speed
105 46 Travel direction selection for steering wheel direc- +48 I
tion at crawl speed
106 47 Travel direction selection for fork direction +48 I
107 48 Travel direction selection for steering wheel direc- +48 I
tion
108 - Reserve I
109 - Reserve I
110 43 Safety pedal (left foot-switch) +48 I
111 - Reserve I

30- 2 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Terminal connections and voltages on A5
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.2.2 20X

Term. Cable Description Active LED

(V)
201 - Reserve I
202 - Indication signal, lift +48 O
203 49 Seat switch +48 I
205 100 Lift height limitation, by-pass +48 I
206 79 Speed reduction, driving +48 I
207 - Reserve I
208 - Indication signal, driving +48 O
209 57 Steering wheel sensor, 180° +48 I
210 58 Steering wheel sensor, channel A +15 I
211 59 Steering wheel sensor, channel B +15 I

30.2.3 30X

Term. Cable Description Active LED

(V)
301 98 Lifting height limit/height meter, channel A 0 –(+)15 I
302 99 Height meter, channel B 0 –(+)15 I
303 106 Reference height sensor +48 I
307 107 Electronic fan +32/48

© TIEE SARL Service Manual 7FBRE 30- 3

 Electronic card – 5710.1
Terminal connections and voltages on A5
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.2.4 40X

Term. Cable Description Active LED

(V)
401 117 CAN – Serial (+) +15
402 118 CAN – Serial (-) 0
403 119 CAN H 0-5
404 120 CAN L 0-5
405 121 RS485 - Serial (+)
406 122 RS485 - Serial (-)
407 125 RS485 - TX (+), transmits data
408 126 RS485 - TX (-), transmits data
409 127 RS485 - RX (+), receives data
410 128 RS485 - RX (-), receives data
411 - Reserve

30.2.5 50X

Term. Cable Description Active LED

(V)
501 50 Potentiometer acceleration, set point +3,7–1,7
502 51 Potentiometer braking, set point +1,7–4,1
503 82 Potentiometer acceleration, set point +0,66–3,7–6,6
504 83 Potentiometer reach/retraction of the mast, +0,77–3,7–6,6
set point
505 84 Potentiometer tilting of forks, set point +0,66–3,7–6,6
506 85 Potentiometer extra (1) hydraulic function, set +0,66–3,7–6,6
point
507 27 Potentiometer feed +7,35
508 28 Minus to 501-506, 510 0
509 62 Steering tachometer (+) Max. ±3
510 86 Potentiometer extra (2) hydraulic function, set +0,66–3,7–6,6
point
511 129 Steering tachometer (-) 0

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 Electronic card – 5710.1
Terminal connections and voltages on A5
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.2.6 60X

Term. Cable Description Active LED

(V)
601 70 Battery monitor, voltage measurement (+) +48
602 71 Battery monitor, voltage/current measurement (-) 0
603 72 Battery monitor, current measurement (+)
604 - Reserve
605 - Reserve

30.2.7 70X

Term. Cable Description Active LED

(V)
701 89 Valve, lifting the forks +0,5–48 O
702 90 Valve, mast retraction +0,5–48 O
703 91 Valve, mast reach +0,5–48 O
704 92 Valve, downward tilting of forks +0,5–48 O
705 93 Valve, upward tilting of forks +0,5–48 O
706 94 Valve, extra hydraulic function 1 A +0,5–48 O
707 95 Valve, extra hydraulic function 1 B +0,5–48 O
708 96 Valve, extra hydraulic function 2 A +0,5–48 O
709 97 Valve, extra hydraulic function 2 B +0,5–48 O
710 101 Reserve O
711 102 Reserve O

© TIEE SARL Service Manual 7FBRE 30- 5

 Electronic card – 5710.1
Terminal connections and voltages on A5
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.2.8 80X
Term. Cable Description Active LED
(V)
801 63 Support arm brake, active 0,2 – O
(+)48
802 64 Motor brake, released 1,5– O
(+)48
803 88 Valve, lowering the forks 0,2– O
(+)24
804 31 Main contactor +48 O
805 21 Battery voltage, (+) 48 V +48 +48 V
806 Battery voltage, minus 0
807 24 Battery voltage, (+) 48 V after key on +48 +48 V KEY
808 23 Battery voltage, (+) 48 V after main contact on +48
809 22 Battery voltage, (+) 48 V after emergency stop +48 +48 V ESO
810 29 Potentiometer supply, (+) 15 V +15
811 30 Potentiometer supply, minus 0

30.2.9 90X
Term. Cable Description Active LED
(V)
901 25 Battery voltage, (+) 48 V +48
902 40 Battery voltage, minus 0
903 60 Steering motor, (+) +48
904 61 Steering motor, (-) +48

LED Colour Function

+48 V STEER Yellow Voltage at steering electronics
+ 48V_SR Yellow Steering OK
STEER PWR Yellow Steering OK
POWER OK Yellow Indicates all voltages available on
electronic card

Potentiometer Function
RV 1 Trimming of the proportional
valve’s opening position

30- 6 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Adjusting the lowering speed
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.3 Adjusting the lowering speed

To set the lowering speed, see C-code 6000.

30.4 Show
The show function allows you to view the driver/machine-specific regis-
ters, but does not permit reprogramming of the registers. The clock,
however, may be programmed.
To program the driver/truck parameters, see the chapter "Parameter
Settings".
To view the register:
• Turn the ignition key so that voltage is supplied to the electronic
card.
• State the driver number using the pushbuttons I–III.
• Press and hold switch I until the clock begins to flash (approximately
5 seconds.
• Press the switch I again to step up to the next function.
The display will present the various functions:
• Time of day (C)
• Warning codes and Error codes (D).
• Parameters (D).
• Operating time and service time (D).
For the functions “Warning codes and error codes“ and “Parameters“,
the address register number is shown to the left and the value to the
right.
.

© TIEE SARL Service Manual 7FBRE 30- 7

 Electronic card – 5710.1
Programming
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.5 Programming

30.5.1 Clock
When the clock is in programming mode, the text widow for hours flash-
es, and after pressing switch I, the window for minutes flashes.
• Make changes by stepping up with switch II and down with III.
• Store the programmed values and show function by pressing I.

Function Value
Hours 09 = 9 hours
Minutes 35 = 35 minutes

When error codes are shown in the text window D, text box G lights.
When parameters are presented in text window D, text box I lights.
Parameters, however, cannot be reprogrammed in this mode. To make
changes, see the chapter “Parameter Settings“.
Terminate programming by turning the ignition key off and on. Program-
ming is terminated automatically if no buttons are pressed for 20 sec-
onds.
NOTE:
Truck operating characteristics.
Changing the truck-specific parameters changes the truck’s operat-
ing characteristics.
Do not change any parameters unless you have the necessary com-
petence.

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 Electronic card – 5710.1
Warning Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.5.2 Driver parameters (1–7)

To reprogram driver parameters (when permitted):
• Turn the ignition key so that voltage is supplied to the electronic
card.
• Specify the applicable driver number with the switches
(I-III).
• Switch off the ignition key so that the voltage to the electronic card is
cut.
• Press switch I at the same time as you turn the ignition key. The driv-
er number will be shown in the text box E.
• Step using switch II to move up and switch III to move down to the
parameter you want to change.
• Press switch I, the parameter number will flash.
• Change the value using switches II and III.
• Press the switch I to select the value, the parameter number will
stop flashing.
If you want to change more parameters, step with switches II and III to
the parameter you want to change and repeat from “Press switch I, the
parameter number will flash“.
Terminate programming by turning the ignition key off and on.
The common truck parameters can only be reprogrammed using a
service key. See the chapter “Parameter Settings“.

30.6 Warning Codes

Character Error
Warning

When an error occurs a buzzer sounds and a code is displayed, for 10

seconds, in the right-hand section of the text window D. The error is
also displayed in the text box (G). If the error is still present after one
minute, the buzzer will sound again for two seconds.
This will be repeated until the error is corrected, however the truck can
be driven with all functions, as set out in the following table
WARNING
Ignoring error indication
Jeopardises truck safety.
Always check truck functions before operation.

© TIEE SARL Service Manual 7FBRE 30- 9

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.7 Error Codes

The last 50 errors are stored in the error log with the date and time.

30.7.1 Error mode

Error mode Explanations/corrective actions

Start error The truck starts, no driving or hydraulic func-
tions
Critical error Steering safety relay makes
Main contactor opens
Parking brakes are activated
General error Current function stops
Height error Fork lift at low speed
Emergency Main contactor opens
switch on Parking brakes are activated
Steering error Steering safety relay makes
Drive motor reverses to stop
Drive regula- Main contactor opens
tor error Lift regulator error
Steering enabled
Parking brake activated when braking
Lift regulator Hydraulics stop
error Valves closed

Warning codes 11–99 give a warning signal of 2 Hz.

Error codes 100– give a warning signal of 4 Hz.

30.7.2 Safety logic

This applies to the following functions:
X = Action -- = Function disabled

Action: K10 Y1 Reversing Steering Function at A2

Function opens activated with M1 disabled halted
Emergency switch X X -- --
Key X X -- X --
Steering error X X
Error at A1 X -- --
Error at A2 X (and el. valves off)
Error at A5 X X -- X --

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.7.3 Warning Codes without registration

Code 11
Description Overheating of cooling flange on electronic card
Error mode Maximum current to steering motor drops and the
driving speed is reduced to crawl speed.
Error cause 1. Seized steering/gear
Cool and check motor/gear
3. Seized steering bearings
4. Defective steering motor
Defective electronic card A5
Comments

Code 13
Description No/too few pulses from the height measurement
sensor when raising or lowering the forks
Error mode No corrective action
Error cause 1. Incorrectly adjusted RV1 potentiometer on A5
electronic card
2. Defective height sensor U10/cables.
3. Incorrect oil quality
4. Fork carriage too light (forks missing)
5. Defective electronic card A5
Comments

1. Turn the potentiometer RV1, on the A5 electronic card, anti-

clockwise and increase the flow on the valve until the correct
lowering speed is obtained.
2. Height sensor U10.

© TIEE SARL Service Manual 7FBRE 30- 11

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

- Check whether the LeDs LD301 and LD302 flash when the forks
are raised or lowered. Flashing is irregular, as the pulses are
phase displacement by 90 degrees.
- If LD301 and LD302 are switched off the entire time, check that
the +15 V supply voltage is on U10. The red cable is positive and
the black cable is 0 V. If there is no voltage: check that the cables
are intact and that there is no play or oxidisation on the connector
pins on terminals X28, X16 and X14.
- If flashing only occurs sporadically, check that the wire does not
slip on the height sensor's roller.
- If the mechanics are okay, check that the cables from U10, white
cable 98 to input 301 and black cable 99 to input 302 are not bro-
ken. Check that there is no play or oxidisation on the connector
pins on terminals X28, X16 and X15.
- If the cables and connector are okay, replace the height sensor
U10.
3. Is the oil too thick, standard oil in a coldstore truck. Is it espe-
cially fork lowering that runs too slowly?
4. Fork lowering will be too slow, if the forks are missing.
5. If nothing helps, replace the A5 card.

30- 12 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 14
Description Seat switch activated more than 20 minutes with-
out moving the truck
Error mode No corrective action
Error cause 1. Strapped switch
2. Faulty switch/wiring
3. Defective electronic card A5
Comments

Seat switch S89

ELECTRONIC CARD
A5
21
805 X +48VDC
24 807 X INP. KEY

43 110 X INP. LEFT FOOT SWITCH

22 809 +48VDC SUPPLY OUTPUTS

45 104 X INP. DRIVE, FORK DIR, CREEP

46 105 X INP. DRIVE, STEER WHEEL, DIR,

47 106 X INP. DRIVE,FORK DIR

48 107 X INP. DRIVE, STEER WHEEL DIR

S89
X25 X25 49 203 INP. SEAT SWITCH
1 3

1. If LD203 is on the entire time.

- Check that the seat switch has not been strapped.
- Remove cable 49 on switch S89, terminal 3. If LD203 goes out,
check the functionality of S89.
2. If LD203 does not go out, check the cable by also removing it
from terminal 203.
3. If LD203 does not go out, replace the A5 electronic card.

© TIEE SARL Service Manual 7FBRE 30- 13

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 15
Description Safety switch activated more than 20 minutes
without moving the truck
Error mode No corrective action
Error cause 1. Strapped switch
2. Faulty switch/wiring
3. Defective electronic card A5
Comments

Safety switch (left-foot switch), S23

ELECTRONIC CARD
A5
21
805 X +48VDC
24 807 X INP. KEY
S23
43
1 3
110 INP. LEFT FOOT SWITCH

22 809 +48VDC SUPPLY OUTPUTS

45 104 X INP. DRIVE, FORK DIR, CREEP

46 105 X INP. DRIVE, STEER WHEEL, DIR,

47 106 X INP. DRIVE,FORK DIR

48 107 X INP. DRIVE, STEER WHEEL DIR

49
203 INP. SEAT SWITCH

1. If LD110 is on the entire time.

- Check that the safety switch has not been strapped.
- Remove cable 43 on the switch S23, terminal 3. If LD110 goes
out, check the functionality of S23.
2. If LD110 does not go out, check the cable by also removing it
from terminal 110.
3. If LD110 does not go out, replace the A5 electronic card.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 16
Description Voltage from accelerator pedal’s potentiometer R1
is outside the calibrated value at start up. (+/-
0.2V).
Error mode Start up error
Error cause 1. Activated pedal at start up
2. Faulty potentiometer/bracket/wiring
3. Calibration error.
4. Defective electronic card A5
Comments Manoeuvre to neutral position

Accelerator, R1

1. Check that the accelerator has not stuck in the actuated posi-
tion.
2. Check that R1 is located in its bracket.
Check that there is no play or oxidisation on the connector
pins on terminal X19. The voltage on input 501 should be
3.7 +/- 0.2 VDC when R1 is correctly mechanically adjusted.
3. Calibration of the accelerator.
Check that both the accelerator and brake as well as the joy-
sticks for the hydraulic functions are in their neutral positions.
(Non actuated position).
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step through using II, to parameter 38.
- Press switch I the display will flash.
- Change the value to 1 using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
- Turn the ignition on and off once.
- Calibration of the accelerator and brake as well as the hydraulic
joystick potentiometers now takes place.
© TIEE SARL Service Manual 7FBRE 30- 15
 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

- Retract the reach carriage towards the inner stop, battery parti-
tion.
- Move the reach carriage out to the outer stop.
The reach distance has now been calibrated.
4. If the correct voltage is on input 501 and calibration does not
help, replace the A5 electronic card.

Code 17
Description Voltage from the brake pedal potentiometer R2 is
outside of the calibrated value at start up
(+/-0.2 V).
Error mode Start up error
Error cause 1. Activated brake pedal at start up
2. Faulty potentiometer/bracket/wiring
3. Calibration error.
4. Defective electronic card A5
Comments Manoeuvre to neutral position

Brakes, R2

1. Check that the brake pedal has not stuck in the actuated posi-
tion.
2. Check that R2 is located in its bracket.
Check that there is no play or oxidisation on the connector
pins on terminal X36. The voltage on input 502 should be 1.7 +/
- 0.2 VDC when R2 is correctly mechanically adjusted.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

3. Calibration of the brakes.

Check that both the accelerator and brake as well as the joy-
sticks for the hydraulic functions are in their neutral positions.
(Non actuated position).
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step through using II, to parameter 38.
- Press switch I the display will flash.
- Change the value to 1 using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
- Turn the ignition on and off once.
- Calibration of the accelerator and brake as well as the hydraulic
joystick potentiometers now takes place.
- Retract the reach carriage towards the inner stop, battery parti-
tion.
- Move the reach carriage out to the outer stop.
The reach distance has now been calibrated.
4. If the correct voltage is on input 502 and calibration does not
help, replace the A5 electronic card.

Code 18
Description Battery on the electronic card has reached the
lowest voltage
Error mode Internal clock stops
Error cause 1.Battery voltage too low
Comments

Code 19
Description Previously programmed values missing
Error mode Standard values have been loaded
Error cause Displaced A5 electronic card
1. Program A5 card
Comments

1. See chapter “Parameter Settings” in this manual.

© TIEE SARL Service Manual 7FBRE 30- 17

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 21
Description Potentiometer R11 for fork lift/lower gives incor-
rect voltage when ignition is switched on (+/-0.6
V).
Error mode Start up error
Error cause 1. Activated joystick at start up
2. Faulty potentiometer/wiring
3. Calibration error.
4. Defective electronic card A5
Comments Manoeuvre to neutral position

Fork control, joystick R11

27 X32 X11
Pg 6 4 Ye
X11
R11 R
X32
Pg 6 4 28 X11 Gr
ELECTRONIC CARD
A5
X33 82 503 INP. JOYSTICK FORK
83 504 INP. JOYSTICK REACH CARRIAGE

84 505 INP. JOYSTICK TILT

85 506 INP. JOYSTICK SPARE 1

86 510 INP. JOYSTICK SPARE 2

202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that the joystick for the fork operations has not stuck in
an actuated position.
2. Check that R11 is located in its bracket.
Check that there is no play or oxidisation on the connector
pins on terminal X11. The voltage on input 503 should be 3,7 +/
-0,6 VDC when R11 is correctly adjusted.
3. Calibration of fork joystick.
- Check that the joystick is not actuated and is in its neutral posi-
tion.
- Turn the ignition on and off once.
4. Calibration of the joystick takes place. If the correct voltage is
on input 503 and calibration does not help, replace the A5
electronic card.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 22
Description Potentiometer R13 for tilting gives incorrect volt-
age when ignition is switched on (+/-0.6 V).
Error mode Start up error
Error cause 1. Activated joystick at start up
2. Faulty potentiometer/wiring
3. Calibration error
4. Defective electronic card A5
Comments

Tilt control, joystick R13

27 X32 X11
Pg 6 4

Pg 6 4 28 X32 X11
ELECTRONIC CARD
A5
82 503 INP. JOYSTICK FORK
Ye
X11 83
R13 R
504 INP. JOYSTICK REACH CARRIAGE
Gr
X33 84
505 INP. JOYSTICK TILT
85 506 INP. JOYSTICK SPARE 1

86 510 INP. JOYSTICK SPARE 2

202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that the joystick for the tilt operation has not stuck in an
actuated position.
2. Check that R13 is located in its bracket.
Check that there is no play or oxidisation on the connector
pins on terminal X11. The voltage on input 505 should be 3.7 +/
-0.6 VDC when R13 is correctly adjusted.
3. Calibration of the tilt control.
- Check that the joystick is not actuated and is in its neutral posi-
tion.
- Turn the ignition on and off once.
4. Calibration of the joystick now takes place. If the correct volt-
age is on input 505 and calibration does not help, replace the
A5 electronic card.

© TIEE SARL Service Manual 7FBRE 30- 19

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 23
Description Potentiometer R12 for the mast reach in/out gives
incorrect voltage when ignition is switched on (+/-
0.6 V).
Error mode Start up error
Error cause 1. Activated joystick at start up
2. Faulty potentiometer/wiring
3. Calibration error
4. Defective electronic card A5
Comments

Mast reach/retraction control, joystick R12

27 X32 X11
Pg 6 4

Pg 6 4 28 X32 X11
ELECTRONIC CARD
A5
82 503 INP. JOYSTICK FORK

83 504 INP. JOYSTICK REACH CARRIAGE

84 505 INP. JOYSTICK TILT

Ye
X11
R14 R X33 85
506 INP. JOYSTICK SPARE 1
Gr

Ye X33 86 510 INP. JOYSTICK SPARE 2

R15 X11
R
Gr 202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that the joystick for the mast's reach/retraction opera-

tions has not stuck in an actuated position.
2. Check that R12 is located in its bracket.
Check that there is no play or oxidisation on the connector
pins on terminal X11. The voltage on input 504 should be 3,7 +/
-0,6 VDC when R12 is correctly adjusted.
3. Calibration of the mast's reach/retraction control.
- Check that the joystick is not actuated and is in its neutral posi-
tion.
- Turn the ignition on and off once.
4. Calibration of the joystick now takes place. If the correct volt-
age is on input 504 and calibration does not help, replace the
A5 electronic card.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 24
Description Potentiometer R14 or R15 for extra functions “1“
and “2“ give incorrect voltage when the ignition
key is switched on (+/-06 V).
Error mode Start up error
Error cause 1. Activated joystick at start up
2. Faulty potentiometer/wiring
3. Calibration error
4. Defective electronic card A5
Comments Manoeuvre to neutral position

Extra hydraulic functions, joystick R14 and joystick

R15
27 X32 X11
Pg 6 4

Pg 6 4 28 X32 X11
ELECTRONIC CARD
A5
82 503 INP. JOYSTICK FORK

83 504 INP. JOYSTICK REACH CARRIAGE

84 505 INP. JOYSTICK TILT

Ye
X11
R14 R X33 85
506 INP. JOYSTICK SPARE 1
Gr

Ye X33 86 510 INP. JOYSTICK SPARE 2

R15 X11
R
Gr 202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that both of the joysticks for the extra hydraulic func-
tions have not stuck in actuated positions.
2. Check that R14 and R15 are located in their brackets.
Check that there is no play or oxidisation on the connector
pins on terminal X11. The voltage on input 506 and 510 should
be 3.7 +/-0.6 VDC when R14 and R15 are correctly adjusted.
3. Calibration of the control for extra hydraulic functions
- Check that both the joysticks are not actuated and are in their
neutral positions.
- Turn the ignition on and off once.
4. Calibration of the joysticks now takes place. If the correct volt-
age is on inputs 506 and 510 and calibration does not help, re-
place the A5 electronic card.

© TIEE SARL Service Manual 7FBRE 30- 21

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 25
Description Output stage error
Error mode General error
Error cause 1. Emergency switch S133 for Y12
(retracted mast) activated
2. See codes 50-62 for more information
Comments

1. Check S133, which is located under the arm panel.

2. Proceed as follows when you wish to look in the register for
warning codes when registering:
- Turn the ignition key so that voltage is supplied to the electronic
card.
- State the driver number using the pushbuttons I–III.
- Press and hold switch I until the clock begins to flash (approxi-
mately 5 seconds.)
- Press the switch I again to step up to the next function.
The display will present the various functions:
• Time of day (C)
Warning codes and error codes (D)
• Parameters (D).
• Operating time and service time (D).
For the functions "Warning codes and error codes" and "Parameters",
the address register number is shown to the left and the value to the
right.

Code 26
Description Input stage error
Error mode General error
Error cause 1. See codes 90-94 for more information
Comments

1. Proceed as follows when you wish to look in the register for

warning codes when registering:
- Turn the ignition key so that voltage is supplied to the electronic
card.
- State the driver number using the pushbuttons I–III.
- Press and hold switch I until the clock begins to flash, approxi-
mately 5 seconds.
- Press the switch I again to step up to the next function.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

The display will present the various functions:

• Time of day (C)
• Warning codes and error codes (D)
• Parameters (D).
• Operating time and service time (D).
For the functions "Warning codes and error codes" and "Parameters",
the address register number is shown to the left and the value to the
right.

Code 27
Description Incorrect battery measurement
Error mode Battery display flashes
Error cause 1. No voltage to the battery indicator
2. Poor contact on battery measurement cables
3. Defective electronic card A5
4. Defective battery
Comments

Battery measurement

1. Check the voltage supply (+48 VDC) to the battery indicator,

cable 70 feeds positive to terminal 601 and cable 71 feeds ter-
minal 602 with negative.
2. Check that cable 72 and its connector are intact and make
good contact from the shunt to terminal 603. Also check that
cable 71 makes good contact with the shunt.

© TIEE SARL Service Manual 7FBRE 30- 23

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

3. If there is no error as set out in points 1 and 2, try a new A5

card.
4. Contact the battery manufacturer for assistance in determin-
ing whether the battery is OK.

Code 28
Description Emergency switch is activated
Error mode Emergency switch on
Error cause 1. Driver action
2. Faulty switch/wiring
3. Defective electronic card A5
Comments Reset S21 and turn S17 on/off

Emergency switch
ELECTRONIC CARD
10A A5

Pg. 1 5 1 F60 21 805 X +48VDC

X30 24 807 X INP. KEY

43 110 X INP. LEFT FOOT SWITCH

EMERGENCY SWITCH OFF

KEY
S17 S21
24 X30 22 809 X +48VDC SUPPLY OUTPUTS
15 61A

45 104 X INP. DRIVE, FORKS DIR, CREEP.

46 105 X INP. DRIVE, STEER WHEEL DIR, CREEP

47 106 X INP. DRIVE, FORK DIR

48
107 X INP. DRIVE, STEER WHEEL DIR

49 203 X INP. SEAT SWITC

1. Check that S21 is not actuated.

2. If LeD 809 does not come there is a break in the circuit.
If Led 809 comes on the error code could be due to a loose
connector in the circuit. Check cable 22 by removing it from
terminal 809 and measure using an ohmmeter to terminal 2 on
S21. Also check the connector pins for play and oxidisation. If
the cable is intact, continue to measure with the ohmmeter
through S21 to terminal 1. If S21 is not depressed there should
be no breakage. If everything is OK, check that the connection
between S17 and S21 is intact.
3. If S21 and its cables are okay, replace the A5 card.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 29
Description Service time (S) is zero
Error mode No corrective action
Error cause 1. Time for servicing
Comments Reset with parameter 25

1. Resetting parameter 25:

- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step through using II, to parameter 25.
- Press switch I the display will flash.
- To verify the old value, only press switch I once.
- To change the value, press switches II/III. New values are set by
pressing the switch I.
- When the required value is set the display stops flashing.
- Recommended service interval is 500.

© TIEE SARL Service Manual 7FBRE 30- 25

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 40
Description Warning temperature for drive motor
Error mode Maximum current reduced
Error cause 1. Overheated drive motor M1
2. Faulty temperature sensor/wiring
3 Defective drive regulator, A1
Comments

Temperature sensor B1 in drive motor M1

1. Check that the ventilation is okay, especially the fan M10 in the
motor compartment.
2. Check B1.
- Remove connection X26. Measure B1 in X26 with the ohmmeter,
approx. 570 ohm at 20oC.
- Check that cable 11 is intact between X26 and terminal 4 on A1.
- Check that cable 14 is intact between X26 and terminal 7 on A1.
- Also check the connector pins on the terminals for play and oxidi-
sation.
3. If B1 and its cables are okay, replace A1.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 41
Description Warning temperature on the drive regulator
Error mode Maximum current reduced
Error cause 1. Overheated drive regulator
2. Defective fan
3.Defective drive regulator, A1
Comments

1. Check that the ventilation is okay.

2. Check the fan M12, by the motor regulators.
3. If the ventilation okay, replace A1.

Code 42
Description Current calibration error on the drive regulator
Error mode No corrective action
Error cause 1. Defective drive regulator, A1
Comments

1. Replace the drive regulator, A1.

© TIEE SARL Service Manual 7FBRE 30- 27

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 43
Description Incorrect number of pulses from the drive
motor's pulse transducer bearing
Error mode General error
Error cause 1. Faulty sensor/wiring.
2. Defective drive regulator.
Comments

Drive motor's pulse transducer bearing, U11

1. Check the cables to U11.

- Remove connection X27.
- Check that cable 11 is intact between X27 and terminal 4 on A1.
- Check that cable 10 is intact between X27 and terminal 3 on A1.
- Check that cable 12 is intact between X27 and terminal 5 on A1.
- Check that cable 13 is intact between X27 and terminal 6 on A1.
- Also check the connector pins on the terminals for play and oxidi-
sation.
- If the cables are okay, replace the transducer bearing U11.
2. If the fault remains, replace A1

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 45
Description Warning temperature for pump motor
Error mode Maximum current reduced
Error cause 1. Overheated pump motor
2. Faulty temperature sensor/wiring
3. Defekta lyftregulatorer, A2
Comments

Temperature sensor B2 in the pump motor M3

1. Check that the ventilation is okay, especially the fan M10 in the
motor compartment.
2. Check B2.
- Remove connection X12. Measure B2 in X12 with the ohmmeter,
approx. 570 ohm at 20oC.
- Check that cable 16 is intact between X12 and terminal 4 on A1.
- Check that cable 19 is intact between X12 and terminal 7 on A1.
- Also check the connector pins on the terminals for play and oxidi-
sation.
3. If B2 and its cables are okay, replace A2.

© TIEE SARL Service Manual 7FBRE 30- 29

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 46
Description Warning temperature in the lift regulator
Error mode Maximum current reduced
Error cause 1.Overheated lift converter
2. Defective fan
3.Defective lift regulator, A2
Comments

1. Check that the ventilation is okay.

2. Check the fan M12, by the motor regulators.
3. If the ventilation okay, replace A2.

Code 47
Description Current calibration error in the lift regulator
Error mode No corrective action
Error cause 1. Defective frequency converter
Comments

1. Replace the lift regulator A2.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 48
Description Incorrect number of pulses from the pump
motor's pulse transducer bearing
Error mode General error
Error cause 1. Faulty sensor/wiring
2. Defective drive regulator
Comments

Pump motor's pulse transducer bearing, U12

1. Check the cables to U12.

- Remove connection X13.
- Check that cable 16 is intact between X13 and terminal 4 on A1.
- Check that cable 15 is intact between X13 and terminal 3 on A1.
- Check that cable 17 is intact between X13 and terminal 5 on A1.
- Check that cable 18 is intact between X13 and terminal 6 on A1.
- Also check the connector pins on the terminals for play and oxidi-
sation.
- If the cables are okay, replace the transducer bearing U12.
2. If the fault remains, replace A2.

© TIEE SARL Service Manual 7FBRE 30- 31

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.8 Warning codes with registration

When a warning code is registered, it is automatically displayed. Regis-
tration is made in the first of the 50 possible locations and moves previ-
ous errors one step down.
Warning codes 52–62 are either for valve, support arm brake or cable
breakage or short circuits.
Warning codes 90-94 are either for potentiometer or cable breakage.
Only the actual function is disabled; other functions are unaffected.

Code 52
Description Output 701 short circuit/breakage
Error mode General error
Error cause 1. Faulty wiring/valve Y10/2
2. Defective electronic card A5
Comments

Hydraulic valve Y10/2 engages fork lift

1. Disconnect the cable 89 from output 701.

- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 89 is intact between terminal 701 and the
terminals in X17 via X14.
- Measure the coil on Y10/2 between the grey and black cables in
X17 with an ohmmeter. Resistance approx. 105 ohm.

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 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

- Check that cable 40 is intact from X17, via X14 to the battery neg-
ative.
2. If the fault remains, replace A5.

Code 53
Description Output 705 short circuit/breakage
Error mode General error
Error cause 1. Faulty wiring/valve Y15
2. Defective electronic card A5
Comments

Hydraulic valve Y15 engages fork tilt up

1. Disconnect the cable 93 from output 705.

- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 93 is intact between terminal 705 and the
terminals in X17 via X15.
- Measure the coil on Y15 between the yellow and black cables in
X17 with an ohmmeter. Resistance approx. 90 ohm.
- Check that cable 40 is intact from X17, via X14 to the battery neg-
ative.
2. If the fault remains, replace A5.

© TIEE SARL Service Manual 7FBRE 30- 33

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 54
Description Output 704 short circuit/breakage
Error mode General error
Error cause 1. Faulty wiring/valve Y14
2. Defective electronic card A5
Comments

Hydraulic valve Y14 engages fork tilt down

1. Disconnect the cable 92 from output 704.

- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 92 is intact between terminal 704 and the
terminals in X17 via X14.
- Measure the coil on Y14 between the orange and black cables in
X17 with an ohmmeter. Resistance approx. 90 ohm.
- Check that cable 40 is intact from X17, via X14 to the battery neg-
ative.
2. If the fault remains, replace A5.

30- 34 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 55
Description Output 706 short circuit/breakage
Error mode General error
Error cause 1. Parameter 15 >0, no valve connected
2. Faulty wiring/valve Y16
3. Defective electronic card A5
Comments

Hydraulic valve Y16 engages a extra hydraulic func-

tion, e.g. side shift or fork spread

1. If no valve is connected, parameter 15 should be 0.

Check parameter 15 as follows:
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step using II up and III down to the parameter you wish to
change.
- Press switch I the display will flash.
- Change the value using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
2. Disconnect the cable 94 from output 706.
- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 94 is intact between terminal 706 and the
terminals in X50 via X15, X17 and X29.
- Measure the coil on Y16 between the green and black cables in

© TIEE SARL Service Manual 7FBRE 30- 35

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

X50 with an ohmmeter. Resistance approx. 150 ohm.

- Check that cable 40 is intact from X50, via X29, X17 and X14 to
the battery negative.
3. If the fault remains, replace A5.

Code 56
Description Output 707 short circuit/breakage
Error mode General error
Error cause 1. Parameter 15 >0, no valve connected
2. Faulty wiring/valve Y17
3. Defective electronic card A5
Comments

Hydraulic valve Y17 engages a extra hydraulic func-

tion, e.g. side shift or fork spread

1. If no valve is connected, parameter 15 should be 0. Check pa-

rameter 15 as follows:
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step using II up and III down to the parameter you wish to
change.
- Press switch I the display will flash.
- Change the value using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
2. Disconnect the cable 95 from output 707.
- Check that the connector pins make contact, no play and no oxi-
disation.

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 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

- Check that the cable 95 is intact between terminal 707 and the
terminals in X50 via X15, X17 and X29.
- Measure the coil on Y17 between the green and black cables in
X50 with an ohmmeter. Resistance approx. 150 ohm.
- Check that cable 40 is intact from X50, via X29, X17 and X14 to
the battery negative.
3. If the fault remains, replace A5.

Code 57
Description Output 708 short circuit/breakage
Error mode General error
Error cause 1. Parameter 16 >0, no valve connected
2. Defective electronic card A5
Comments

Hydraulic valve Y18 engages a extra hydraulic func-

tion, e.g. side shift or fork spread

1. If no valve is connected, parameter 16 should be 0.

Check parameter 16 as follows:
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step using II up and III down to the parameter you wish to
change.
- Press switch I the display will flash.
- Change the value using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
2. Disconnect the cable 96 from output 708.
- Check that the connector pins make contact, no play and no oxi-
disation.

© TIEE SARL Service Manual 7FBRE 30- 37

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

- Check that the cable 96 is intact between terminal 708 and the
terminals in X16 via X15.
- Measure the coil on Y18 between the cable in X16 and the cable
in X17 with an ohmmeter. Resistance approx. 150 ohm. (Not
standard)
- Check that cable 40 is intact from X17, via X14 to the battery neg-
ative.
3. If the fault remains, replace A5.

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 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 58
Description Output 709 short circuit/breakage
Error mode General error
Error cause 1. Parameter 16 >0, no valve connected
2. Faulty wiring/valve Y19
3. Defective electronic card A5
Comments Non standard, accessory

Hydraulic valve Y19 engages a extra hydraulic func-

tion, e.g. side shift or fork spread

1. If no valve is connected, parameter 16 should be 0. Check pa-

rameter 16 as follows:
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step using II up and III down to the parameter you wish to
change.
- Press switch I the display will flash.
- Change the value using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
2. Disconnect the cable 97 from output 709.
- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 97 is intact between terminal 709 and the
terminals in X16 via X15.
- Measure the coil on Y18 between the cable in X16 and the cable
in X17 with an ohmmeter. Resistance approx. 150 ohm. (Not
standard)
- Check that cable 40 is intact from X17, via X14 to the battery neg-
ative.
3. If the fault remains, replace A5.

© TIEE SARL Service Manual 7FBRE 30- 39

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 59
Description Output 702 short circuit/breakage
Error mode General error
Error cause 1. Emergency switch for Y12 activated
2. Faulty wiring/valve Y12
3. Defective electronic card A5
Comments

Hydraulic valve Y12 operates the retraction of the

fork carriage

1. Check that the switch S133 is open.

2. Disconnect the cable 90 from output 702.
- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 90 is intact between terminal 702 and the
terminals in X17 via X14.
- Measure the coil on Y12 between the red and black cables in X17
with an ohmmeter. Resistance approx. 90 ohm.
- Check that cable 40 is intact from X17 via X14 to the battery neg-
ative.
3. If the fault remains, replace A5.

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 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 60
Description Output 703 short circuit/breakage
Error mode General error
Error cause 1. Faulty wiring/valve Y13
2. Defective electronic card A5
Comments

Hydraulic valve Y13 operates the extension of the

fork carriage

1. Disconnect the cable 91 from output 703.

- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 91 is intact between terminal 703 and the
terminals in X17 via X14.
- Measure the coil on Y13 between the blue and black cables in
X17 with an ohmmeter. Resistance approx. 90 ohm.
- Check that cable 40 is intact from X17 via X14 to the battery neg-
ative.
2. If the fault remains, replace A5.

© TIEE SARL Service Manual 7FBRE 30- 41

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 61
Description Output 803 short circuit/breakage
Error mode General error
Error cause 1. Emergency switch Y10/3 activated
2. Faulty wiring/valve Y10/3
3. Defective electronic card A5
Comments

Hydraulic valve Y10/3 engages fork lowering

1. Check that the switch S132 is open.

2. Disconnect the cable 88 from output 803.
- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 88 is intact between terminal 803 and the
terminals in X17 via X14.
- Measure the coil on Y10/3 between the white and black cables in
X17 with an ohmmeter. Resistance approx. 27 ohm.
- Check that cable 40 is intact from X17, via X14 to the battery neg-
ative.
3. If the fault remains, replace A5.

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 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 62
Description Output 801 short circuit/breakage
Error mode Fault in both support arm brakes give a max
speed of 9 km
Error cause 1. Faulty wiring/valve Y5/Y6
2. Defective electronic card A5
Comments

Y5/Y6 are the coils in the support arm brakes

1. Disconnect the cable 63 from output 801.

- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 63 is intact between terminal 801 and the
terminals in X38.
- Check that the cable 63 is intact between terminal X38 and the
terminals in X39/X40.
- Disconnect connector X39. Measure the coil on Y5 using an ohm-
meter. Resistance approx. 50 ohm. If the coils are measured
when connected in parallel from X38, the resistance is approx. 25
ohm.
- Disconnect connector X40. Measure the coil on Y6 using an ohm-
meter
Resistance = 50 ohm.
- Check that the cable 40 is intact between terminals X39/40 and
the terminals in X38.
- Check that cable 40 is intact from X38 to the battery negative.
2. If the fault remains, replace A5.

© TIEE SARL Service Manual 7FBRE 30- 43

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 90
Description Potentiometer R11 for fork lift/fork lower gives
incorrect voltage (<0.3 or >7.0 V).
Error mode General error
Error cause 1. Faulty potentiometer/wiring or activated input
without connected potentiometer
2. Defective electronic card A5
Comments

Fork control, joystick R11

27 X32 X11
Pg 6 4 Ye
X11
R11 R
X32
Pg 6 4 28
X11 Gr
ELECTRONIC CARD
A5
X33 82 503 INP. JOYSTICK FORK
83 504 INP. JOYSTICK REACH CARRIAGE

84 505 INP. JOYSTICK TILT

85 506 INP. JOYSTICK SPARE 1

86 510 INP. JOYSTICK SPARE 2

202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that R11 is located in its bracket.

- Check that the voltage across R11 (yellow and grey cable) is 7-
7.5 VDC.
- Check that there is no play or oxidisation on the connector pins
on terminal X11.
- The voltage on input 503 should be 3.7 +/-0.6 VDC when R11 is
correctly adjusted.
2. If the correct voltage is on input 503 and the fault remains, re-
place the A5 electronic card.

30- 44 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 91
Description Potentiometer R13 for tilt gives incorrect voltage
(<0.3 or >7.0 V).
Error mode General error
Error cause 1. Faulty potentiometer/wiring or activated input
without connected potentiometer
2. Defective electronic card A5
Comments

Tilt control, joystick R13

27 X32 X11
Pg 6 4

Pg 6 4 28 X32 X11
ELECTRONIC CARD
A5
82 503 INP. JOYSTICK FORK
Ye
X11 83
R13 R
504 INP. JOYSTICK REACH CARRIAGE
Gr
X33 84
505 INP. JOYSTICK TILT
85 506 INP. JOYSTICK SPARE 1

86 510 INP. JOYSTICK SPARE 2

202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that R13 is located in its bracket.

- Check that the voltage across R13 (yellow and grey cable) is 7-
7.5 VDC.
- Check that there is no play or oxidisation on the connector pins
on terminal X11.
- The voltage on input 505 should be 3.7 +/-0.6 VDC when R11 is
correctly adjusted.
2. If the correct voltage is on input 505 and the fault remains, re-
place the A5 electronic card.

© TIEE SARL Service Manual 7FBRE 30- 45

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 92
Description Potentiometer R12 for mast reach in/out move-
ment gives incorrect voltage (<0.3 or >7.0 V)
Error mode General error
Error cause 1. Faulty potentiometer/wiring or activated input
without connected potentiometer
2. Defective electronic card A5
Comments

Mast reach/retraction control, joystick R12

Pg 6 4 27
X32 X11

Pg 6 4 28 X32 X11
ELECTRONIC CARD
Ye X11 A5
R12 R
Gr 82 503 INP. JOYSTICK FORK

X33 83 504 INP. JOYSTICK REACH CARRIAGE

84 505 INP. JOYSTICK TILT

85 506 INP. JOYSTICK SPARE 1

86 510 INP. JOYSTICK SPARE 2

202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. Check that R12 is located in its bracket.

- Check that the voltage across R12 (yellow and grey cable) is 7-
7.5 VDC.
- Check that there is no play or oxidisation on the connector pins
on terminal X11.
- The voltage on input 504 should be 3.7 +/-0.6 VDC when R11 is
correctly adjusted.
2. If the correct voltage is on input 504 and the fault remains, re-
place the A5 electronic card.

30- 46 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 93
Description Potentiometer R14 or R15 for extra function “1“
and “2“ gives incorrect voltage (<0.3 or >7.0 V).
Error mode General error
Error cause 1. Parameters 15/16 >0, no potentiometer con-
nected
2. Faulty potentiometer/wiring
3. Defective electronic card A5
Comments

Extra hydraulic functions, joystick R14 and R15

27 X32 X11
Pg 6 4

Pg 6 4 28 X32 X11
ELECTRONIC CARD
A5
82 503 INP. JOYSTICK FORK

83 504 INP. JOYSTICK REACH CARRIAGE

84 505 INP. JOYSTICK TILT

Ye
X11
R14 R X33 85
506 INP. JOYSTICK SPARE 1
Gr

Ye X33 86 510 INP. JOYSTICK SPARE 2

R15 X11
R
Gr 202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

98 301 X INP. LIFT LIMIT SPECIAL HEIGHT

100 205 X INP. OVERRIDE

1. If no valve is connected, parameters 15/16 should be 0.

Check parameter 16 as follows:
- Connect the service key to the truck.
- Press switch I at the same time as you turn the ignition key.
- Step using II up and III down to the parameter you wish to
change.
- Press switch I the display will flash.
- Change the value using the switches II/III.
- Press switch I to set the value, the display will stop flashing.
2. Check that both of the joysticks for the extra hydraulic func-
tions have not stuck in actuated positions.
3. Check that R14 and R15 are located in their brackets.
Check that there is no play or oxidisation on the connector
pins on terminal X11. The voltage on input 506 and 510 should
be 3.7 +/-0.6 VDC when R14 and R15 are correctly adjusted.
4. If the correct voltage is on inputs 506 and 510, replace the A5
electronic card.

© TIEE SARL Service Manual 7FBRE 30- 47

 Electronic card – 5710.1
Warning codes with registration
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 94
Description Potentiometer R1 for accelerator pedal gives
incorrect voltage (<0.4 or >4.6 V).
Error mode General error
Error cause 1. Faulty potentiometer/wiring
2. Defective electronic card A5
Comments

Accelerator R1

1. Check that R1 is located in its bracket.

Check that there is no play or oxidisation on the connector
pins on terminal X19. The voltage on input 501 should be 3,7 +/
- 0.2 VDC when R1 is correctly mechanically adjusted.
2. If the correct voltage is on input 501 and the fault remains, re-
place the A5 electronic card.

30- 48 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.9 Error Codes

Character Error
Error

When an error occurs, a buzzer is sounded at the same time as an error

code is shown in the right-hand section of the text window D. The error
is also indicated in text window G. The buzzer sounds until the ignition
is switched off, cutting power to the truck.
If the error remains when the truck is restarted, the code will be shown
again and the buzzer will sound.
The truck’s hydraulic functions shown in the table will be inoperable.
The code is automatically registered in the error register when it’s dis-
played, the significance of the code is evident from the table. Registra-
tion is made in the first of the 50 possible locations and moves previous
errors one step down.
When the registry is shown in the text window, the most recent error will
be shown first, along with the error code.
.

To see the date when the error occurred, press III once. To see the
time, press III a second time.
.

To view more registered errors, press II.

WARNING
Ignoring error indication
Jeopardises truck safety.
Always check truck functions before operation.

© TIEE SARL Service Manual 7FBRE 30- 49

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.9.1 Error codes with registration

Code 104
Description Output 802 short circuit/breakage
Error mode Critical error
Error cause 1. Emergency switch for Y1 activated
2. Faulty wiring/valve Y1
3. Defective electronic card A5
Comments

Parking brake Y1

1. Check that the switch S131 is open.

2. Disconnect the cable 64 from output 802.
- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that the cable 64 is intact between terminal 802 and the
terminals in X37.
- Measure the coil on Y1 between the terminals in X37 with an
ohmmeter. Resistance approx. 33 ohm.
- Check that cable 40 is intact from X37 to the battery negative.
3. If the fault remains, replace A5.

30- 50 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 106
Description Output 804 short circuit/breakage
Error mode Critical error
Error cause 1. Faulty wiring/contactor K10
2. Defective electronic card A5
Comments

Main contactor, K10, coil

1. Disconnect the cable 31 from output 804.

- Check that the connector pins make contact, no play and no oxi-
disation.
- Check that cable 31 is intact up until contactor K10:A2.
- Measure the coil on Y10 between A1 and A2.
Resistance approx. 150 ohm.
- Check that cable 40 is intact between contactor K10: A1 and the
battery negative and terminals in X38.
2. If the correct voltage is on input 501 and the fault remains, re-
place the A5 electronic card.

© TIEE SARL Service Manual 7FBRE 30- 51

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 107
Description Main contactor K10 does not close when the igni-
tion is on and the emergency switch is deacti-
vated.
Error mode Critical error
Error cause 1. Defective contactor K10
2. Defective electronic card A5
Comments

Main contactor, K10, contactor points

1. Check the voltage on terminal 808. Should be battery positive

nominal +48 VDC, with ignition (S17) on.
- If there is no voltage, check fuse F62 (10 A).
- If the fuse has not blown, check that cable 23 is intact.
- If cable 23 is okay, check the contactor points on K10.
- If the contactor points are okay, check that cable 1 is okay.
2. If there is a voltage of +48 VDC on the card's terminal 808 and
the fault remains, replace the A5 card.

30- 52 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 108
Description Main contactor does not open when the ignition is
off and the emergency switch is deactivated
Error mode Critical error
Error cause 1. Defective contactor K10
2. Defective electronic card A5
Comments

Main contactor, K10, contactor points

1. Check the voltage on terminal 808. Should be 0 VDC, with igni-

tion (S17) off.
- If there is voltage, check whether the contactor points on K10 are
welded together.
- If the contactor points are okay, check that cable 23 is not short-
circuited to any live parts.
2. If the voltage is 0 VDC on the card's terminal 808 and the fault
remains, replace the A5 card.

© TIEE SARL Service Manual 7FBRE 30- 53

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 111
Description Potentiometer R2 for brake pedal gives incorrect
voltage (<0.4 or >4.6 V)
Error mode Critical error
Error cause 1. Faulty potentiometer/wiring
2. Defective electronic card A5
Comments

Potentiometer R2, brake

1. Check that R2 is located in its bracket.

- Check that the voltage across R2 (1 and 2) is 7-7.5 VDC.
- Check that there is no play or oxidisation on the connector pins
on terminal X36.
- The voltage on input 502 should be 1.7 VDC when R2 is in the
neutral position and 4.1 VDC with the brake pedal is fully actuat-
ed.
- If the voltage is < 0.4 VDC the 7-7.5 V voltage is missing, if the
voltage is > 46 VDC, 0 V is missing. If the cables are intact, re-
place potentiometer R2.
2. If the correct voltage is on input 505 and the fault remains, re-
place the A5 electronic card.

30- 54 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 112
Description Error on brake input test
Error mode Critical error
Error cause 1. Defective electronic card A5
Comments The computer on the card has found a fault during
the internal test.

Code 120
Description Memory cell for steering set point value, incorrect
value
Error mode Steering error
Error cause 1. Displaced A5 electronic card
2. Defective electronic card A5
Comments Restart can reset error

1. A temporary disturbance can have affected the card.

Try to restart the truck.

Code 121
Description Steering safety relay deactivated due to incorrect
voltage in drive stage or communications error
with master processor
Error mode Steering error
Error cause 1. Displaced A5 electronic card
2. Defective electronic card A5
Comments Restart can reset error

1. A temporary disturbance can have affected the card.

Try to restart the truck.

© TIEE SARL Service Manual 7FBRE 30- 55

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 122
Description Warning temperature in steering servo
Error mode Steering error
Error cause 1. High ambient temperature
2. Steering jams
3. Faulty wiring to steering motor
4. Defective steering motor
5. Defective electronic card A5
Comments

Steering motor, M6

1. Check the ventilation by the A5 card.

2. Lift up the truck.
- Check that the steering does not jam mechanically.
- Check the current on the steering, approx. 5A.
3. Check the cables 60 and 61, terminal X24 and terminals 903
and 904.
4. Check the steering motor.
- Brushes and brush holders, see MSM 1730.
- Armature windings.
5. If the fault remains, replace the A5 card.

30- 56 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 123
Description Output voltage to steering motor differs from
requested steering
Error mode Steering error
Error cause 1. Faulty wiring to steering motor
2. Defective steering motor
3. Defective electronic card A5
Comments

Steering motor, M6

1. Check the cables 60 and 61, terminal X24 and terminals 903
and 904.
2. Check the steering motor.
- Brushes and brush holders, see tab S1730 “electric steering mo-
tor”.
- Armature windings.
3. If the fault remains, replace the A5 card.

© TIEE SARL Service Manual 7FBRE 30- 57

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 125
Description Steering generator error on test
Error mode Steering error
Error cause 1. Defective wiring
2. Faulty generator/carbon brushes
3. Defective electronic card A5
Comments

Steering generator, U1

1. Check the cables 62 and 129, terminals in X32 and X34 and the
terminals 509 and 511.
2. Check the steering generator.
- Brushes and commutator, see tab S 4100 “Mechanical steering
system”.
- Armature windings.
3. If the fault remains, replace the A5 card.

30- 58 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 126
Description Steering motor error on test
Error mode Steering error
Error cause 1. Defective fuse F61
2. Defective wiring
3. Faulty steering motor/carbon brushes
4. Defective electronic card A5
Comments

Steering motor, M6

1. Check the fuse F61, 30 A, and the cables 1 and 25 as well as

terminal 901.
2. Check the cables 60 and 61, terminals X24, 903 and 904.
3. Check the steering motor.
- Brushes and brush holders, see MSM 1730.
- Armature windings.
4. If the fault remains, replace the A5 card.

© TIEE SARL Service Manual 7FBRE 30- 59

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 127
Description Communications error between steering proces-
sor and master processor
Error mode Steering error
Error cause 1. External interference (static electricity)
2. Defective electronic card A5
Comments Restart can reset error

1. A temporary disturbance can have affected the card.

Try to restart the truck.

Code 128
Description Memory cell for steering set point value contains
incorrect value
Error mode Critical error
Error cause 1. External interference (static electricity)
2. Defective electronic card A5
Comments Restart can reset error

1. A temporary disturbance can have affected the card.

Try to restart the truck.

Code 130
Description Communications error between I/O processor and
master processor
Error mode Critical error
Error cause 1. External interference (static electricity)
2. Defective electronic card A5
Comments Restart can reset error

1. A temporary disturbance can have affected the card.

Try to restart the truck.

30- 60 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 131
Description Error testing safety relay (steering) at start-up
Error mode Steering error
Error cause 1. Defective fuse F61
2. Defective wiring for F61
3. Defective electronic card A5
Comments

Fuse F61, 30 A

1. Check the fuse F61, 30 A.

2. Check the cables 1 and 25 and terminal 901.
3. If the fault remains, replace the A5 card.

© TIEE SARL Service Manual 7FBRE 30- 61

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 133
Description Error testing safety relay (steering) at start-up
Error mode Steering error
Error cause 1. Temporary fault during test
2. Defective electronic card A5
Comments

1. A temporary disturbance can have affected the card.

Try to restart the truck.
2. If the fault remains, despite repeated attempts to start, replace
the A5 card.

Code 134
Description Safety relay (steering) has opened
Error mode Steering error
Error cause 1. Electronic card A5 displaced/jarred
2. Defective electronic card A5
Comments

1. The relay can have opened if the truck has driven on very une-
ven ground or driven on something that has heavily affected
the truck.
Try to restart the truck.
2. If the fault remains, despite repeated attempts to start, replace
the A5 card.

Code 135
Description Error testing safety relay (main circuit) at start-up
Error mode Critical error
Error cause 1. Temporary fault during test.
2. Defective electronic card A5
Comments

1. A temporary disturbance can have affected the card.

Try to restart the truck.
2. If the fault remains, despite repeated attempts to start, replace
the A5 card.

30- 62 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 136
Description Error testing safety relay (main circuit) at start-up
Error mode Critical error
Error cause 1. Temporary fault during test
2. Defective electronic card A5
Comments

1. A temporary disturbance can have affected the card.

Try to restart the truck.
2. If the fault remains, despite repeated attempts to start, replace
the A5 card.

Code 137
Description Safety relay (main circuit) has opened
Error mode Critical error
Error cause 1. Electronic card A5 displaced/jarred
2. Defective electronic card A5
Comments Restart can reset

1. The relay can have opened if the truck has driven on very une-
ven ground or driven on something that has heavily affected
the truck.
Try to restart the truck.
2. If the fault remains, despite repeated attempts to start, replace
the A5 card.

Code 140
Description Incorrect checksum in parameter memory on
start-up
Error mode Critical error
Error cause 1. Displaced A5 electronic card
2. Defective electronic card A5
Comments

1. A temporary disturbance can have affected the card.

- Try to restart the truck.
- Change a parameter and restart.
- Download new program.
2. If the fault remains, replace A5 card.

© TIEE SARL Service Manual 7FBRE 30- 63

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 141
Description Incorrect checksum for current program
Error mode Critical error
Error cause 1. Bad download of program from PC
2. Defective electronic card A5
Comments

1. A temporary disturbance can have affected the card.

Download new program.
2. If the fault remains, replace A5 card.

30- 64 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 150
Description No communication with the motor regulators on
start-up
Error mode Drive regulator error and lift regulator error
Error cause 1. Faulty CAN wiring/resistance
2. 15 no V
3. Defective drive regulator A1
4. Defective lift regulator A2
5. Defective electronic card A5
Comments

CAN communication

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistors R100 and
R101.
2. 2. Check that output 401 on the A5 card has +15 VDC.
3. 3. Try using a new drive regulator A1.
4. 4. Try using a new lift regulator A2.
5. Try using a new A5 card.

© TIEE SARL Service Manual 7FBRE 30- 65

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 151
Description No communication with the drive regulator on
start-up
Error mode Drive regulator error
Error cause 1. Faulty CAN wiring/resistance
2. Defekt körregulator
Comments

CAN – communication between A5 and A1

TRANSISTOR PANEL, DRIVE

A1
F1
8 125A/160A
B+

U
2
40 B-

V 3
14 7

W 4
11 4

ELECTRONIC CARD
10 A5
3

12
117 401 OUT CAN +15VDC
12 5

118
13 402 OUT CAN GND
13 6

10
119
403 OUT/IN CAN H

22 120
1 11 404 OUT/IN CAN L

120 OHM / 0.6W

R100

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistor R101.
2. Try using a new drive regulator A1.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 152
Description No communication with drive motor’s frequency
converter during operation
Error mode Drive regulator error
Error cause 1. Faulty CAN wiring/resistance
2. Defective drive regulator
Comments

CAN – communication between A5 and A1

TRANSISTOR PANEL, DRIVE
A1
F1
8 125A/160A
B+

U
2
40 B-

V 3
14 7

W 4
11 4

ELECTRONIC CARD
10 A5
3

12
117 401 OUT CAN +15VDC
12 5

118
13 402 OUT CAN GND
13 6

10
119
403 OUT/IN CAN H

22 120
1 11 404 OUT/IN CAN L

120 OHM / 0.6W

R100

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistor R101.
2. Try using a new drive regulator A1.

© TIEE SARL Service Manual 7FBRE 30- 67

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 153
Description No communication with the lift regulator on start-
up
Error mode Lift regulator error
Error cause 1. Faulty CAN wiring/resistance
2. Defective lift regulator
Comments

CAN – communication between A5 and A2

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistor R101.
2. Try using a new lift regulator A2.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 154
Description No communication with the lift regulator while run-
ning
Error mode Lift regulator error
Error cause 1. Faulty CAN wiring/resistance
2. Faulty lift regulator
Comments

CAN – communication between A5 and A2

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistor R101.
2. Try using a new lift regulator A2.

© TIEE SARL Service Manual 7FBRE 30- 69

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 155 - 163

Description General communications error
Error mode Drive regulator error
Error cause 1. Faulty CAN wiring/resistance
2. External CAN unit incorrectly connected
3. Displaced A5 electronic card
4. Defective electronic card A5
Comments

CAN communication

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistors R100 and
R101.
2. Check that the CAN bus is connected correctly to all units.
3. A temporary disturbance can have affected the card.
Try to restart the truck.
4. If the fault remains, despite repeated attempts to start, replace
the A5 card.

30- 70 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 203
Description CPU or memory fault on the drive regulator
Error mode Drive regulator error
Error cause 1. Defective drive regulator
Comments

1. Replace the drive regulator, A1.

Code 205
Description Overheated drive motor
Error mode Drive regulator error
Error cause 1. Motor heavily loaded
2. Faulty wiring/temperature sensor
Comments Restart possible

Temperature sensor B1 in drive motor M1

1. Check that the ventilation is okay, especially the fan M10 in the
motor compartment.
2. Check B1.
- Remove connection X26. Measure B1 in X26 with the ohmmeter,
approx. 570 ohm at 20oC.
- Check that cable 11 is intact between X26 and terminal 4 on A1.
- Check that cable 14 is intact between X26 and terminal 7 on A1.
- Also check the connector pins on the terminals for play and oxidi-
sation.

© TIEE SARL Service Manual 7FBRE 30- 71

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 206 - 207

Description Overheated drive regulator
Error mode Drive regulator error
Error cause 1. Defective cooling fan
2. Defective motor, M1
3. Defective drive regulator, A1
Comments Restart possible

1. Check the fan M12, by the frequency converters.

2. Check the drive motor and its cables.
3. If everything else is okay, replace A1.

Code 208
Description Too high current on drive regulator
Error mode Drive regulator error
Error cause 1. Motor cables incorrectly connected
2. Defective driving regulator, A1
Comments

Drive motor circuit

1. Check that the motor cables are intact and connected correct-
ly.
2. Replace the drive regulator, A1.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 209 - 210

Description Too high voltage on drive regulator
Error mode Drive regulator error
Error cause 1. Defective battery
2. Defective motor
3. Defective drive regulator, A1
Comments

1. Check that the battery is okay, sufficiently charged and of the

right model.
2. Check that the drive motor is okay.
3. If everything else is okay, replace A1.

© TIEE SARL Service Manual 7FBRE 30- 73

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 211 - 212

Description Too low voltage on drive regulator
Error mode Drive regulator error
Error cause 1. Charger plug removed with ignition key S17
switched on
2. External current load incorrectly connected
3. Faulty wiring/fuse F62
4. Defective drive regulator, A1
5. Defective electronic card, A5
Comments

Main contactor, K10

1. If you forget to switch off the truck and pull out the charging
plug an error code is given.
2. Check that no extra equipment overloads the electrical sys-
tem.
3. Check that there is 48 VDC on input 808,
cable 23 when K10 is activated. If not, check the fuse F62 (10
A), contactor points on K10 and the cables 1, 8 and 23.
4. If this does not help, replace A1.
5. Replace A5.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 213 - 214

Description CAN fault on the drive regulator
Error mode Drive regulator error
Error cause 1. Defective drive regulator, A1
Comments

Code 223
Description CPU or memory fault on the lift regulator
Error mode Lift regulator error
Error cause 1. Defective lift regulator, A2
Comments

Code 225
Description Overheated pump motor
Error mode Lift regulator error
Error cause 1. Motor heavily loaded
2. Faulty wiring/temperature sensor
Comments Restart possible

Temperature sensor B2 in the pump motor

1. Check that the ventilation is okay, especially the fan M10 in the
motor compartment.

© TIEE SARL Service Manual 7FBRE 30- 75

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

2. Check B2.
- Remove connection X12. Measure B2 in X12 with the ohmmeter,
approx. 570 ohm at 20oC.
- Check that cable 16 is intact between X12 and terminal 4 on A1.
- Check that cable 19 is intact between X12 and terminal 7 on A1.
- Also check the connector pins on the terminals for play and oxidi-
sation.

Code 226 - 227

Description Overheated lift regulator
Error mode Lift regulator error
Error cause 1. Defective cooling fan
2. Defective motor cable/motor
3. Defective lift regulator
Comments Restart possible

Pump motor circuits

1. Check the fan M12 by the regulators.

2. Check the motor cables 5, 6 and 7 and the pump motor M3.
3. If everything is okay, replace A2.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 228
Description Too high current on lift regulator
Error mode Lift regulator error
Error cause 1. Motor cables incorrectly connected
2. Defective lift regulator, A2
Comments

Pump motor, M3

1. Check that the motor cables 5, 6 and 7 are intact and connect-
ed correctly.
2. If the cables are okay, replace A2.

© TIEE SARL Service Manual 7FBRE 30- 77

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 229 - 230

Description Too high voltage on lift regulator
Error mode Lift regulator error
Error cause 1. Defective battery
2. Poor contact at K10’s contactor points
3. Defective lift regulator, A2
Comments

Battery circuit

1. Check that the battery is okay, sufficiently charged and of the

right model.
2. Check the contactor points on K10.
3. If everything is okay, replace A2.

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 Electronic card – 5710.1
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Code 231 - 232

Description Too low voltage on lift regulator
Error mode Lift regulator error
Error cause 1. Faulty wiring/fuse F62
2. External current load incorrectly connected
3. Charger plug removed with ignition key
switched on
4. Defective electronic card A5
5. Defective lift regulator, A2
Comments

Main contactor, K10

1. If you forget to switch off the truck and pull out the charging
plug an error code is given.
2. Check that no extra equipment overloads the electrical sys-
tem.
3. Check that there is 48 VDC on input 808, cable 23 when K10 is
activated. If not, check the fuse F62 (10 A), contactor points on
K10 and the cables 1, 8 and 23.
4. If this does not help, replace A2.
5. Replace A5.

© TIEE SARL Service Manual 7FBRE 30- 79

 Electronic card – 5710.1
Error Codes
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Code 233 - 234

Description CAN fault on the lift regulator
Error mode Lift regulator error
Error cause 1. Faulty CAN wiring/resistance
2. Defective lift regulator
Comments

CAN – communication between A5 and A2

1. Check that the cables 117, 118, 119 and 120 are not short-
circuited or are broken. Also check the resistor R101.
2. Try using a new lift regulator A2.

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 Electronic card – 5710.1
Operating Time
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.10 Operating Time

When the running meter setting is displayed, the text window E lights.
The time is show as follows:

Character Time
Ignition time

Total movement time

Drive motor time

Pump motor time

Service time

30.11 Parameter Settings

• Connect the service key to the truck.
• Press switch I at the same time as you turn the ignition key.
• Step using II to move up and III to move down to the parameter you
wish to change.
• Press switch I the display will flash.
• Change the value using the switches II/III.
• Press switch I to set the value, the display will stop flashing.
If you want to change more parameters, step with switches II/III to the
parameter you want to change and repeat from “Press switch I the dis-
play will flash“.
NOTE:
Truck operating characteristics.
Changing the truck-specific parameters changes the truck’s operat-
ing characteristics.
Do not change any parameters unless you have the necessary com-
petence.

© TIEE SARL Service Manual 7FBRE 30- 81

 Electronic card – 5710.1
Parameter Settings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

No Parameter type Unit Min./max. Std. Comments

. value
01 Steering sensitivity 1–6 3 1 = Several wheel turns
5 = Few wheel turns
6 = No progressivity
In steps of 1
02 Drive motor, max. % 10–100 100 Percentage of max. speed
speed In steps of 5
03 Drive motor, accel- % 10–100 100 Percentage of max. speed
eration In steps of 5
04 Drive motor, speed % 0–100 20 Percentage of speed retardation
retardation 50 > 0 = no retardation
Note 1: In steps of 5
05 Drive motor, retar- % 35–100 80 Percentage of max. retardation
dation when revers- In steps of 5
ing
10 PIN code for driver 0000–3333 0000 0000 = PIN code not used.
selection > 0 = PIN code used.
11 Drive motor, speed % 10–100 100 Percentage of max. speed
reduction In steps of 5
12 Masts out/in move- % 10–100 80 Percentage of max. speed
ment, speed In steps of 5
13 Extra function 1 % 10–100 10 B/N/E 1-6 mast with integrated side
speed shift
20 B/E7-B/E8
14 Extra function 2 % 10–100 20 In percent of max. oil flow in steps of
speed 5
15 Engaging hydraulic % 0–100 100 0 = not connected
extra function 1, > 0 = connected
current limit In steps of 5
16 Engaging extra % 0–100 0 0 = not connected
function 2, current > 0 = connected
limit In steps of 5
17 Lift height limitation m 0–13,5 13,5 0 = not connected
level 1 > 0 = connected
In steps of 0.05

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 Electronic card – 5710.1
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

No Parameter type Unit Min./max. Std. Comments

. value
18 Lift height limitation m 0–13,5 13,5 0 = not connected
level 2 > 0 = connected
In steps of 0.05. Set greater or equal
to L.h. limitation 1.
19 Forks’ free lift height m 1,0–4,5 2,2 Top side of fork to floor when inner
See guide is at top.
table In steps of 0.01
20 Time indication 1–5 2 1 = ignition time (A)
2 = total movement time (b)
3 = drive motor time (c)
4 = pump motor time (d)
5 = service time (S)
21 Battery size 1–20 12 See table
See
table
22 Type of Truck 1–5 2 1 = N/B/E1-3 with support arm brakes
2 = N/B/E1-3 without support arm
brakes
3 = B/E4-6 with support arm brakes
4 = B/E4-6 without support arm
brakes
5 = B/E7-8
23 Type of Mast 0/1 1 0 = Old mast
1 = With valve in fork yoke
24 Left foot-switch 1/0 0 0 = Activates buzzer
1 = Also cuts drive motor
25 Service interval h 0–2000 100 0 = No service counter
In steps of 50h
27 Lift priority 0/1 1 0 = Fork lift prioritised
1 = Fork lift not prioritised

© TIEE SARL Service Manual 7FBRE 30- 83

 Electronic card – 5710.1
Parameter Settings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

No Parameter type Unit Min./max. Std. Comments

. value
28 Indication signal 0/1 0 0: 202 Pump motor
208 Drive motor
1: 202 Driving in drive wheel direction
208 Driving in fork direction
29 Maximum lift height m 0-13,5 13,5 0 = not connected
> 0 = connected
In steps of 0.05
37 Not used
38 Calibration of accel- 1 0 Set to 1 for calibration
eration/brake pedal See instructions
and reach carriage
39 Driver access 1–4 1 1 = no PIN code, open
2 = no PIN code, locked
3 = PIN code, open
4 = PIN code, locked
40 Time, years Years 0–99 In steps of 1
41 Time, days Days 1–31 In steps of 1
42 Time, months Month 1–12 In steps of 1
s

30.11.1 Parameter 1
The higher the number you program, the less number of turns of the
steering wheel required to turn the drive wheel. With a value of 6, steer-
ing is non-progressive, less sensitive at higher speeds.

30.11.2 Parameter 2
With this parameter, you set the maximum permitted driving speed.

30.11.3 Parameter 3
The lower the number you program, the longer the truck will require to
come up to maximum speed.

30.11.4 Parameter 4
With this parameter, you determine the force at which the truck will stop
when you release the accelerator pedal.
Note 1: Driver 1 has 20%, drivers 2-10 have 50% as the default value.

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 Electronic card – 5710.1
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.11.5 Parameter 5
With this parameter, you determine the force at which the truck will stop
when you change directions and use the drive motor to stop the truck.

30.11.6 Parameter 10
Value 0000 means that three drivers are chosen. The table below
shows the combinations for the first six PIN codes. These values are
attained by stepping up and down with the switches I and II.

Value Driver number

0000 No PIN code. Max. three drivers used
1111 First PIN code when max. 10 drivers used
1112 Second PIN code when max. 10 drivers used
1113 Third PIN code when max. 10 drivers used
1121 Fourth PIN code when max. 10 drivers used
1122 Fifth PIN code when max. 10 drivers used
1123 Sixth PIN code when max. 10 drivers used
etc. etc.

30.11.7 Parameter 11
With this parameter you set the maximum permitted driving speed
when switch S31 is activated.

30.11.8 Parameter 12
With this parameter you can adjust the speed of the mast’s in and out
movement.

30.11.9 Parameters 13 to 14
With this parameter you can adjust the oil flow for the two extra func-
tions.

30.11.10 Parameters 15 and 16

When these parameters are set to the value > 0, control of potentiome-
ters and valves for the two extra functions are activated. You also
define the pressure you require for the functions by means of the val-
ue’s size.

© TIEE SARL Service Manual 7FBRE 30- 85

 Electronic card – 5710.1
Parameter Settings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.11.11 Parameters 17 and 18

Using these parameters you can set two different maximum lifting
heights when the truck is equipped with a height meter. The maximum
height number 2 must be equal to or higher than height number 1. The
last activated height is normally used as the maximum height before
the mast reaches the top.

30.11.12 Parameter 19

Lift Coarse setting Coarse setting

height 7FBRE16, 20 mast 7FBRE20, 25
with integrated side
shift
4400 1,42
4600 1,50
4800 1,56 1,65
5400 1,75 1,84
5700 1,85
6300 2,07 2,14
6750 2,22 2,38
7000 2,42 2,48
7500 2,56
8000 2,74 2,83
8500 2,93 3,01
9000 3,09 3,14
9500 3,19 3,27
10000 3,43
10500 3,58
10800 3,70

30.11.13 Parameter 20
With this parameter you specify the time A-d or S that will be displayed
when the driver uses the truck.

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 Electronic card – 5710.1
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.11.14 Parameter 21
With this parameter you specify the battery the truck is equipped with.
You may also compensate for different ways of driving.
For additional information about battery installation and setting the bat-
tery parameters, please see section 5110.
For setting the battery monitor’s break point, measure as set out below:
• Acid density for fully charged battery. To check battery quality.
• When battery indicator shows 80% discharge (min. acid density
1.14).
The acid density can vary depending on the battery type.

Value Function Battery (Ah)

1
2
3
4
5
6
7
8
9
10
11 Less discharge 900
12 730, 700, 580 CSM
13 More discharge 600
14
15 480, 450
16
17 360
18
19
20

WARNING
Correct parameter setting.
Battery can be destroyed.
If the parameters are set to values higher than those recommended,
battery discharge will be excessive and the batteries destroyed.

© TIEE SARL Service Manual 7FBRE 30- 87

 Electronic card – 5710.1
Parameter Settings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.11.15 Parameter 22
With this parameter the function and control of the brake coils and a
higher top speed for the truck are activated.
A change in the type of truck will result in new parameters being loaded
into the frequency converters the next time the ignition is switched on.
The ignition must be switched on again for the parameters to apply.

30.11.16 Parameter 23
When the parameter is set to 1 this defines that a valve is fitted to the
fork plank and is used as a switching valve between two functions.
Direction is handled by the valve in the large valve assembly.

30.11.17 Parameter 24
If you set the parameter to 1, you will be able to stop the truck with the
drive motor but not be able to drive it again if the safety pedal is not
depressed.

30.11.18 Parameter 25
With this parameter, you specify the truck’s service interval. The buzzer
sounds and C029 is shown on the display when the service counter is
at zero. The counter will show the time that has passed since the truck
was last serviced.
If the previous service time is to be used, only the parameter is activat-
ed the time is not changed.

30.11.19 Parameter 27
When the parameter is set to 1 this removes the lift function’s priority,
i.e. the hydraulic function being used will continue irrespective of
whether the lift is activated.

30.11.20 Parameter 28
This parameter allows information on the outputs 202 and 208 to be
switched between two different functions. 0 is for TLS and 1 is used to
start the warning light/buzzer when the truck is driven, an intermediate
relay must be used.

30.11.21 Parameter 29
When the truck is equipped with a height meter, you can use this
parameter to define the maximum lifting height. No bypass connections
are possible. For general information see parameters 17 and 18.

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 Electronic card – 5710.1
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.11.22 Parameter 37
Not used.

30.11.23 Parameter 38
• Set the parameter to 1.
• Turn the ignition on and off once.
The acceleration and braking potentiometers will now be calibrated.
NOTE:
Calibration error.
Incorrect calibration value.
Do not move the lever when calibration begins.
• Retract the reach carriage towards the inner stop, battery partition.
• Move the reach carriage out to the outer stop.
The reach cylinder’s end position and lowering distance are now cali-
brated. The reach carriage’s movement will run at a reduced speed dur-
ing calibration.

© TIEE SARL Service Manual 7FBRE 30- 89

 Electronic card – 5710.1
Parameter Settings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

30.11.24 Parameter 39
Set the parameter to 1 or 2 if only three drivers/truck profiles are to be
programmed. If up to ten drivers/truck profiles are to be programmed,
set the value to 3 or 4. With up to ten drivers, the value must be pro-
grammed for each driver. See parameter 10.
Show/programming choices with parameter 39.

Para- Key S17 switched on, Switch I and key S17

meter then switch I switched on simultaneously
P39- Clock Parameter Driver Clock Parameter Driver
-1 Reprgm. See See Not Reprgm. Selected
U. CAN selected reprgm. reprgm.
-1 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-2 Reprgm. See See Not Not reprgm. See
U. CAN selected reprgm. selected
-2 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-3 Reprgm. See See Not Reprgm. Selected
U. CAN selected reprgm. reprgm.
-3 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-4 Reprgm. See See Not Not reprgm. See
U. CAN selected reprgm. selected
-4 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.

30.11.25 Parameters 40 to 42
With these parameters, you can set the year, day and month for error
code logging.

30.11.26 Other parameters

Other parameters between 10 and 42 are shown on the display and can
be programmed, but the value does not modify the program. Others
has a fixed value and cannot be reprogrammed.

30- 90 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.1
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

30.11.27 Installing a new card in the truck

The A5 card from TOYOTA can be supplied in different configurations:

1. Ready programmed with complete numbers and default val-

ues entered.
= P/N for the card including program.
2. Not programmed at part number
= only P/N for the card.
When installing a new card, certain parameters must be reprogrammed
so that the truck can be safely operated.
For downloading new programs to the electronic card, the Truck Com
service program is used.
See the Truck Com user manual for a description of the procedure.
Potentiometer R1 on the electronic card should be adjusted according
to C-code 6000.

© TIEE SARL Service Manual 7FBRE 30- 91

 Electronic card – 5710.1
Parameter Settings
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

This page is intentionally left blank

30- 92 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
General description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31- Electronic card – 5710.2

31.1 General description

This description is valid from electronic card 169937-001.
The A5 electronic card is equipped with green LEDs on the inputs from
the microswitches and sensors, red LEDs on the outputs to the contac-
tors and valves, and yellow for voltages. This card is also equipped with
a potentiometer for adjusting the hydraulic control for fork lowering.
The truck’s programmable parameter settings are stored on the elec-
tronic card.
The main card monitors the truck’s steering, driving and hydraulic func-
tions. Any errors are registered and the corresponding error code is dis-
played on the instrument panel’s display.

© TIEE SARL Service Manual 7FBRE 31- 1

 Electronic card – 5710.2
Terminal connections and voltages on A5
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.2 Terminal connections and voltages

on A5
The LEDs on the connection terminals are designated in the tables as
follows:
I = Input, green light emitting diode (LED)
O = Output, red light emitting diode (LED)
Other = Yellow light emitting diode (LED)

31.2.1 10X

Term. Cable Description Active (V) LED

101 34 Selection of driver/parameter settings +48 I
102 35 Selection of driver/step up +48 I
103 36 Selection of driver/step down +48 I
104 45 Travel direction selection for fork direc- +48 I
tion at crawl speed
105 46 Travel direction selection for steering +48 I
wheel direction at crawl speed
106 47 Travel direction selection for fork direc- +48 I
tion
107 48 Travel direction selection for steering +48 I
wheel direction
108 - Reserve I
109 - Reserve I
110 43 Safety pedal (left foot-switch) +48 I
111 - Reserve I

31- 2 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Terminal connections and voltages on A5
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.2.2 20X

Term. Cable Description Active (V) LED

201 - Reserve I
202 - Indication signal, lift +48 O
203 49 Seat switch +48 I
204 - Reserve I
205 100 Lift height limitation, by-pass +48 I
206 79 Speed reduction, driving +48 I
207 56 Low, speed, retracted mast I
208 - Indication signal, driving +48 O
209 57 Steering wheel sensor, 180° +48 I
210 58 Steering wheel sensor, channel A +15 I
211 59 Steering wheel sensor, channel B +15 I

31.2.3 30X

Term. Cable Description Active (V) LED

301 98 Lift height limiter +15 I
302 - Reserve I
303 106 Speed reduction, lift/lower +48 I
304 - Reserve I
305 - Reserve I
306 - Reserve
307 107 Electronic fan +32/48

© TIEE SARL Service Manual 7FBRE 31- 3

 Electronic card – 5710.2
Terminal connections and voltages on A5
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.2.4 40X

Term. Cable Description Active (V) LED

401 117 CAN – Serial (+) +15
402 118 CAN – Serial (-) 0
403 119 CAN H 0-5
404 120 CAN L 0-5
405 121 RS485 - Serial (+)
406 122 RS485 - Serial (-)
407 125 RS485 - TX (+), transmits data
408 126 RS485 - TX (-), transmits data
409 - Reserve
410 - Reserve
411 - Reserve

31.2.5 50X

Term. Cable Description Active (V) LED

501 50 Potentiometer acceleration, set point +3,7–1,7
502 51 Potentiometer braking, set point +1,7–4,1
503 82 Potentiometer acceleration, set point +0,66–3,7–
6,6
504 83 Potentiometer reach/retraction of the +0,77–3,7–
mast, set point 6,6
505 84 Potentiometer tilting of forks, set point +0,66–3,7–
6,6
506 85 Potentiometer extra (1) hydraulic function, +0,66–3,7–
set point 6,6
507 27 Potentiometer feed +7,35
508 28 Minus to 501-506, 510 0
509 62 Steering tachometer (+) Max. ±3
510 Reserve
511 129 Steering tachometer (-) 0

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 Electronic card – 5710.2
Terminal connections and voltages on A5
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.2.6 60X

Term. Cable Description Active (V) LED

601 70 Battery monitor, voltage measurement (+) +48
602 71 Battery monitor, voltage/current measure- 0
ment (-)
603 72 Battery monitor, current measurement (+)
604 - Reserve
605 - Reserve

31.2.7 70X

Term. Cable Description Active (V) LED

701 89 Valve, lifting the forks +0,5–48 O
702 90 Valve, mast retraction +0,5–48 O
703 91 Valve, mast reach +0,5–48 O
704 92 Valve, downward tilting of forks +0,5–48 O
705 93 Valve, upward tilting of forks +0,5–48 O
706 94 Valve, extra hydraulic function 1 A +0,5–48 O
707 95 Valve, extra hydraulic function 1 B +0,5–48 O
708 Reserve O
709 Reserve O
710 - Reserve O
711 - Reserve O

© TIEE SARL Service Manual 7FBRE 31- 5

 Electronic card – 5710.2
Terminal connections and voltages on A5
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.2.8 80X

Term. Cable Description Active (V) LED

801 - Reserve O
802 64 Motor brake, released 1,5–(+)48 O
803 88 Valve, lowering the forks 0,2–(+)24 O
804 31 Main contactor +48 O
805 21 Battery voltage, (+) 48 V +48 +48 V
806 - Battery voltage, minus 0
807 24 Battery voltage, (+) 48 V after key on +48 +48 V
KEY
808 23 Battery voltage, (+) 48 V after main con- +48
tact on
809 22 Battery voltage, (+) 48 V after emergency +48 +48 V
switch off ESO
810 29 Potentiometer supply, (+) 15 V +15
811 30 Potentiometer supply, minus 0

31.2.9 90X

Term. Cable Description Active (V) LED

901 25 Battery voltage, (+) 48 V +48
902 40 Battery voltage, minus 0
903 60 Steering motor, (+) +48
904 61 Steering motor, (-) +48

LED Colour Function

+48 V STEER Yellow Voltage at steering electronics
+ 48V_SR Yellow Steering OK
STEER PWR Yellow Steering OK
POWER OK Yellow Indicates all voltages available on electronic card

Potentiometer Function
RV 1 Trimming of the proportional valve’s opening position

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 Electronic card – 5710.2
Adjusting the lowering speed
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.3 Adjusting the lowering speed

To set the lowering speed, see C-code 6000.

31.4 Show
The show function allows you to view the driver/machine-specific regis-
ters, but does not permit reprogramming of the registers. The clock,
however, may be programmed.
To program the driver/truck parameters, see the chapter “Parameter
Settings“.
To view the register:
• Turn the ignition key so that voltage is supplied to the electronic
card.
• State the driver number using the pushbuttons I–III.
• Press and hold switch I until the clock begins to flash (approximately
5 seconds.
• Press the switch I again to step up to the next function.
The display will present the various functions:
• Time of day (C).
• Warning codes and Error codes (D).
• Parameters (D).
• Operating time and service time (D).
For the functions “Warning codes and error codes“ and “Parameters“,
the address register number is shown to the left and the value to the
right.
.

© TIEE SARL Service Manual 7FBRE 31- 7

 Electronic card – 5710.2
Programming
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.5 Programming

31.5.1 Clock
When the clock is in programming mode, the text widow for hours flash-
es, and after pressing switch I, minutes are displayed.
• Make changes by stepping up with switch II and down with III.
• Store the programmed values and show function by pressing I.

Function Value
Hours 09 = 9 hours
Minutes 35 = 35 minutes

When error codes are shown in the text window D, text box G lights.
When parameters are presented in text window D, text box I lights.
Parameters, however, cannot be reprogrammed in this mode. To make
changes, see the chapter “Parameter Settings“.
Terminate programming by turning the ignition key off and on. Program-
ming is terminated automatically if no buttons are pressed for 20 sec-
onds.
NOTE:
Truck operating characteristics.
Changing the truck-specific parameters changes the truck’s operat-
ing characteristics.
Do not change any parameters unless you have the necessary com-
petence.

31.5.2 Driver parameters (1–7)

To reprogram driver parameters (when permitted):
• Turn the ignition key so that voltage is supplied to the electronic
card.
• Specify the applicable driver number with the switches I-III.
• Switch off the ignition key so that the voltage to the electronic card is
cut.
• Press switch I at the same time as you turn the ignition key. The driv-
er number will be shown in the text box E.
• Step using switch II to move up and switch IIIto move down to the
parameter you want to change.
• Press switch I, the parameter number will flash.
• Change the value using switches II and III.
• Press the switch I to select the value, the parameter number will
stop flashing.

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 Electronic card – 5710.2
Warning Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

If you want to change more parameters, step with switches II and III to
the parameter you want to change and repeat from “Press switch I, the
parameter numbers flash“.
Terminate programming by turning the ignition key off and on.
The common truck parameters can only be reprogrammed using a
service key. See the chapter “Parameter Settings“.

31.6 Warning Codes

Character Error
Warning

When an error occurs, a buzzer sounds and an error code is displayed

for 10 seconds in the right side of the text window D. The error is also
displayed in the text box G. If the error is still present after one minute,
the buzzer will sound again for two seconds.
This will be repeated until the error is corrected, however the truck can
be driven with all functions, as set out in the following table
WARNING
Ignoring error indication
Jeopardises truck safety.
Always check truck functions before operation.

© TIEE SARL Service Manual 7FBRE 31- 9

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.7 Error Codes

The last 50 errors are stored in the error log with the date and time.

31.7.1 Error mode

Error mode Explanations/corrective actions
Start up error The truck starts, no driving or hydraulic func-
tions
Critical error Steering safety relay releases
Main contactor opens
Parking brakes are activated
General error Current function stops
Height error Fork lift at low speed
Emergency Main contactor opens
switch on Parking brakes activated
Steering error Steering safety relay releases
Drive motor reverses to stop
Drive regula- Main contactor opens
tor error Lift regulator error
Steering enabled
Parking brake activated when braking
Lift regulator Hydraulics stop
error Valves closed

Warning codes 11-99 give a warning signal of 2 Hz.

Error codes 100– give a warning signal of 4 Hz.

31.7.2 Safety logic

This applies to the following functions:
X = Action-- = Function disabled

Action: K10 Y1 Reversing Steering Function at A2

Function: opens activates with M1 disabled halted
Emergency switch X X -- --
Key X X -- X --
Steering error X X
Error at A1 X -- --
Error at A2 X (and el. valves off)
Error at A5 X X -- X --

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 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.7.3 Warning Codes without registration

Code 11
Description Overheating of cooling flange on electronic card
Error mode Maximum current to steering motor drops and the
driving speed is reduced to crawl speed.
Error cause Seized steering/gear
Seized steering bearings
Defective steering motor
Defective electronic card A5
Comments Cool and check motor/gear

Code 14
Description Seat switch activated more than 20 minutes with-
out moving the truck
Error mode No corrective action
Error cause Strapped switch
Faulty switch/wiring
Defective electronic card A5
Comments

Code 15
Description Safety switch activated more than 20 minutes
without moving the truck
Error mode No corrective action
Error cause Strapped switch
Faulty switch/wiring
Defective electronic card A5
Comments

© TIEE SARL Service Manual 7FBRE 31- 11

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 16
Description Voltage from accelerator pedal’s potentiometer R1
is outside the calibrated value at start up.
(+/-0.2 V).
Error mode Start up error
Error cause Activated pedal at start up
Faulty potentiometer/bracket/wiring
Calibration error.
Defective electronic card A5
Comments Manoeuvre to neutral position

Code 17
Description Voltage from the brake pedal potentiometer R2 is
outside of the calibrated value at start up (+/-0.2
V).
Error mode Start up error
Error cause Activated pedal at start up
Faulty potentiometer/bracket/wiring
Calibration error.
Defective electronic card A5
Comments Manoeuvre to neutral position

Code 18
Description Battery on the electronic card has reached the
lowest voltage
Error mode Internal clock stops
Error cause Battery voltage too low
Comments

Code 19
Description Previously programmed values missing
Error mode Standard values have been loaded
Error cause Displaced A5 electronic card
Comments Program A5 card

31- 12 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 21
Description Potentiometer R11 for fork lift/lower gives incor-
rect voltage when ignition is switched on (+/-0.6
V).
Error mode Start up error
Error cause Activated joystick at start up
Faulty potentiometer/bracket/wiring
Defective electronic card A5
Comments Manoeuvre to neutral position

Code 22
Description Potentiometer R13 for tilting gives incorrect volt-
age when ignition is switched on (+/-0.6 V).
Error mode Start up error
Error cause Activated joystick at start up
Faulty potentiometer/bracket/wiring
Defective electronic card A5
Comments

Code 23
Description Potentiometer R12 for the mast reach in/out gives
incorrect voltage when ignition is switched on (+/-
0.6 V).
Error mode Start up error
Error cause Activated joystick at start up
Faulty potentiometer/bracket/wiring
Defective electronic card A5
Comments

© TIEE SARL Service Manual 7FBRE 31- 13

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 24
Description Potentiometer R14 for extra functions “1“ gives
incorrect voltage when the ignition is switched on
(+/-06 V).
Error mode Start up error
Error cause Activated joystick at start up
Faulty potentiometer/bracket/wiring
Defective electronic card A5
Comments Manoeuvre to neutral position

Code 25
Description Output stage error
Error mode General error
Error cause See codes 50-62 for more information
Emergency switch for Y1 activated
Comments

Code 26
Description Input stage error
Error mode General error
Error cause See codes 90-94 for more information
Comments

Code 27
Description Incorrect battery measurement
Error mode Battery display flashes
Error cause Poor contact on battery measurement cables
Defective electronic card A5
Defective battery
Comments

31- 14 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 28
Description Emergency switch is activated
Error mode Emergency switch on
Error cause Driver action
Faulty switch/wiring
Defective electronic card A5
Comments Reset S21 and turn S17 on/off

Code 29
Description Service time (S) is zero
Error mode No corrective action
Error cause
Comments Reset with parameter

Code 40
Description Warning temperature for the drive motor
Error mode Maximum current reduced
Error cause Overheated drive motor
Faulty temperature sensor/wiring
Defective frequency converter
Defective electronic card A5
Comments

Code 41
Description Warning temperature on drive motor’s frequency
converter
Error mode Maximum current reduced
Error cause Overheated frequency converter
Defective fan
Defective frequency converter
Defective electronic card A5
Comments

© TIEE SARL Service Manual 7FBRE 31- 15

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 42
Description Current calibration error on drive motor’s fre-
quency converter
Error mode No corrective action
Error cause Defective frequency converter
Comments

Code 46
Description Too high/low temperature in the pump motor tran-
sistor panel
Error mode Maximum current reduced
Error cause Ambient temperature extremely hot/cold
Defective cooling fan
Defective pump motor
Defective transistor panel
Comments

Code 48
Description Voltage too low in pump motor’s transistor panel
Error mode Maximum current reduced
Error cause Defective battery
Poor contact at K10’s contact points
Defective transistor panel
Comments

31- 16 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.8 Warning codes with registration

When a warning code is registered, it is automatically displayed. Regis-
tration is made in the first of the 50 possible locations and moves previ-
ous errors one step down.
Warning codes 52–62 are either for valve, support arm brake or cable
breakage or short circuits.
Warning codes 90-94 are either for potentiometer or cable breakage.
Only the actual function is disabled; other functions are unaffected.

Code 52
Description Output 701 short circuit/breakage
Error mode General error
Error cause Faulty wiring/valve Y10
Defective electronic card A5
Comments

Code 53
Description Output 705 short circuit/breakage
Error mode General error
Error cause Faulty wiring/valve Y15
Defective electronic card A5
Comments

Code 54
Description Output 704 short circuit/breakage
Error mode General error
Error cause Faulty wiring/valve Y14
Defective electronic card A5
Comments

© TIEE SARL Service Manual 7FBRE 31- 17

 Electronic card – 5710.2
Warning codes with registration
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 55
Description Output 706 short circuit/breakage
Error mode General error
Error cause Parameter 15 >0, no valve connected
Faulty wiring/valve Y16
Defective electronic card A5
Comments

Code 56
Description Output 707 short circuit/breakage
Error mode General error
Error cause Parameter 15 >0, no valve connected
Faulty wiring/valve Y17
Defective electronic card A5
Comments

Code 57
Description Output 708 short circuit/breakage
Error mode General error
Error cause Parameter 16 >0, no valve connected
Defective electronic card A5
Defective electronic card A5
Comments

Code 58
Description Output 709 short circuit/breakage
Error mode General error
Error cause Parameter 16 >0, no valve connected
Faulty wiring/valve Y19
Defective electronic card A5
Comments

31- 18 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Warning codes with registration
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 59
Description Output 702 short circuit/breakage
Error mode General error
Error cause Emergency switch for Y1 activated
Faulty wiring/valve Y12
Defective electronic card A5
Comments

Code 60
Description Output 703 short circuit/breakage
Error mode General error
Error cause Faulty wiring/valve Y13
Defective electronic card A5
Comments

Code 61
Description Output 803 short circuit/breakage
Error mode General error
Error cause Faulty wiring/valve Y10
Defective electronic card A5
Comments

Code 90
Description Potentiometer R11 for fork lift/fork lower gives
incorrect voltage (<0.3 or >7.0 V).
Error mode General error
Error cause Faulty potentiometer/wiring
Activated input without connected potentiometer
Defective electronic card A5
Comments

© TIEE SARL Service Manual 7FBRE 31- 19

 Electronic card – 5710.2
Warning codes with registration
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 91
Description Potentiometer R13 for tilt gives incorrect voltage
(<0.3 or >7.0 V).
Error mode General error
Error cause Faulty potentiometer/wiring
Activated input without connected potentiometer
Defective electronic card A5
Comments

Code 92
Description Potentiometer R12 for mast reach in/out move-
ment gives incorrect voltage (<0.3 or >7.0 V)
Error mode General error
Error cause Faulty potentiometer/wiring
Activated input without connected potentiometer
Defective electronic card A5
Comments

Code 93
Description Potentiometer R14 for extra function “1“ gives
incorrect voltage (<0.3 or >7.0 V).
Error mode General error
Error cause Parameters 15/16 >0, no potentiometer con-
nected
Faulty potentiometer/wiring
Defective electronic card A5
Comments

Code 94
Description Potentiometer R1 for accelerator pedal gives
incorrect voltage (<0.4 or >4.6 V).
Error mode General error
Error cause Faulty potentiometer/wiring
Defective electronic card A5
Comments

31- 20 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.9 Error Codes

Character Error
Error

When an error occurs, a buzzer sounds and an error code is displayed

for 10 seconds in the right side of the text window D. The error is also
indicated in text window G. The buzzer sounds until the ignition is
switched off, cutting power to the truck.
If the error remains when the truck is restarted, the code will be shown
again and the buzzer will sound.
The truck’s hydraulic functions shown in the table will be inoperable.
The code is automatically registered in the error register when it’s dis-
played, the significance of the code is evident from the table. Registra-
tion is made in the first of the 50 possible locations and moves previous
errors one step down.
When the registry is shown in the text window, the most recent error will
be shown first, along with the error code.
.

To see the date when the error occurred, press III once. To see the
time, press III a second time.
.

To view more registered errors, press II.

WARNING
Ignoring error indication
Jeopardises truck safety.
Always check truck functions before operation.

© TIEE SARL Service Manual 7FBRE 31- 21

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.9.1 Error codes with registration

Code 104
Description Output 802 short circuit/breakage
Error mode Critical error
Error cause Emergency switch for Y1 activated
Faulty wiring/valve Y1
Defective electronic card A5
Comments

Code 106
Description Output 804 short circuit/breakage
Error mode Critical error
Error cause Faulty wiring/contactor K10
Defective electronic card A5
Comments

Code 107
Description Main contactor K10 does not close when the igni-
tion is on and the emergency switch is deacti-
vated.
Error mode Critical error
Error cause Defective contactor K10
Defective electronic card A5
Comments

Code 108
Description Main contactor does not open when the ignition is
off and the emergency switch is deactivated
Error mode Critical error
Error cause Defective contactor K10
Defective electronic card A5
Comments

31- 22 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 111
Description Potentiometer R1 for brake pedal gives incorrect
voltage (<0.4 or >4.6 V)
Error mode Critical error
Error cause Faulty potentiometer/wiring
Defective electronic card A5
Comments

Code 112
Description Error on brake input test
Error mode Critical error
Error cause Defective electronic card A5
Comments

Code 120
Description Memory cell for steering set point value, incorrect
value
Error mode Steering error
Error cause Displaced A5 electronic card
Faulty A5 electronic card
Comments Restart can reset error

Code 121
Description Steering safety relay deactivated due to incorrect
voltage on drive stage or communications error
with master processor
Error mode Steering error
Error cause Displaced A5 electronic card
Defective electronic card A5
Comments Restart can reset error

© TIEE SARL Service Manual 7FBRE 31- 23

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 122
Description Warning temperature in steering servo
Error mode Steering error
Error cause High ambient temperature
Steering jams
Defective steering motor
Faulty wiring to steering motor
Defective electronic card A5
Comments

Code 123
Description Output voltage to steering motor differs from
requested steering
Error mode Steering error
Error cause Defective steering motor
Faulty wiring to steering motor
Defective electronic card A5
Comments

Code 125
Description Steering generator error on test
Error mode Steering error
Error cause Faulty generator/carbon brushes
Defective wiring
Defective electronic card A5
Comments

31- 24 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 126
Description Steering motor error on test
Error mode Steering error
Error cause Defective fuse F61
Faulty steering motor/carbon brushes
Defective wiring
Defective electronic card A5
Comments

Code 127
Description Communications error between steering proces-
sor and master processor
Error mode Steering error
Error cause External interference, static electricity
Defective electronic card A5
Comments Restart can reset error

Code 128
Description Memory cell for steering set point value contains
incorrect value
Error mode Critical error
Error cause External interference, static electricity
Defective electronic card A5
Comments Restart can reset error

Code 130
Description Communications error between I/O processor and
master processor
Error mode Critical error
Error cause External interference, static electricity
Defective electronic card A5
Comments Restart can reset error

© TIEE SARL Service Manual 7FBRE 31- 25

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 131
Description Error testing safety relay, steering, at start-up
Error mode Steering error
Error cause Defective fuse F61
Defective wiring for F61
Defective electronic card A5
Comments

Code 133
Description Error testing safety relay, steering, at start-up
Error mode Steering error
Error cause Defective electronic card A5
Comments

Code 134
Description Safety relay, steering, has opened
Error mode Steering error
Error cause Electronic card A5 displaced/jarred
Defective electronic card A5
Comments

Code 135
Description Error testing safety relay, main circuit, at start-up
Error mode Critical error
Error cause Defective electronic card A5
Comments

Code 136
Description Error testing safety relay, main circuit, at start-up
Error mode Critical error
Error cause Defective electronic card A5
Comments

31- 26 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 137
Description Safety relay, main circuit, has opened
Error mode Critical error
Error cause Electronic card A5 displaced/jarred
Defective electronic card A5
Comments Restart can reset

Code 140
Description Incorrect checksum in parameter memory on
start-up
Error mode Critical error
Error cause Displaced A5 electronic card
Defective electronic card A5
Comments Restart can reset error
Change a parameter and restart
Download new program

Code 141
Description Incorrect checksum for current program
Error mode Critical error
Error cause Bad download of program from PC
Defective electronic card A5
Comments

Code 150
Description No communication with frequency converter on
start-up
Error mode Drive regulator error and lift regulator error
Error cause Faulty CAN wiring/resistance
15 no V
Defective frequency converter
Defective electronic card A5
Comments

© TIEE SARL Service Manual 7FBRE 31- 27

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 151
Description No communication with drive motor’s frequency
converter on start-up
Error mode Drive regulator error
Error cause Faulty CAN wiring/resistance
Defective frequency converter
Comments

Code 152
Description No communication with drive motor’s frequency
converter during operation
Error mode Drive regulator error
Error cause Faulty CAN wiring/resistance
Defective frequency converter
Comments

Code 153
Description No communication with pump motor’s frequency
converter at start-up
Error mode Lift regulator error
Error cause Faulty CAN wiring/resistance
Defective frequency converter
Comments

Code 154
Description No communication with pump motor’s frequency
converter during operation
Error mode Lift regulator error
Error cause Faulty CAN wiring/resistance
Defective frequency converter
Comments

31- 28 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 155 - 163

Description General communications error
Error mode Drive regulator error
Error cause Faulty CAN wiring/resistance
External CAN unit incorrectly connected
Displaced A5 electronic card
Defective electronic card A5
Comments

Code 203
Description CPU or memory error on drive motor’s frequency
converter
Error mode Drive regulator error
Error cause Defective frequency converter
Comments

Code 205
Description Overheated drive motor
Error mode Drive regulator error
Error cause Motor heavily loaded
Faulty wiring/temperature sensor
Comments Restart possible

Code 206 - 207

Description Overheated drive motor frequency converter
Error mode Drive regulator error
Error cause Defective cooling fan
Defective motor
Defective frequency converter
Comments Restart possible

© TIEE SARL Service Manual 7FBRE 31- 29

 Electronic card – 5710.2
Error Codes
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Code 208
Description Excessive current on drive motor frequency con-
verter
Error mode Drive regulator error
Error cause Motor cables incorrectly connected
Defective frequency converter
Comments

Code 209 - 210

Description Excessive voltage on drive motor frequency con-
verter
Error mode Drive regulator error
Error cause Defective battery
Defective motor
Defective frequency converter
Comments

Code 211 - 212

Description Voltage too low on drive motor’s frequency con-
verter
Error mode Drive regulator error
Error cause Faulty wiring/fuse F62
External current load incorrectly connected
Charger plug removed with ignition switched on
Defective electronic card A5
Defective frequency converter
Comments

Code 213 - 214

Description CAN error on drive motor’s frequency converter
Error mode Drive regulator error
Error cause Defective frequency converter
Comments

31- 30 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Error Codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

Code 220
Description No communication with the electronic card
Error mode Pump regulator error
Error cause Faulty CAN wiring
Defective transistor panel
Comments

Code 221
Description Negative error
Error mode Pump regulator error
Error cause Pump motor or M short circuited to B
Defective transistor panel
Comments

Code 222
Description Power supply error
Error mode Pump regulator error
Error cause Defective transistor panel
Comments

Code 234
Description No communication with the electronic card
Error mode Pump regulator error
Error cause Faulty CAN wiring
Defective transistor panel
Comments

© TIEE SARL Service Manual 7FBRE 31- 31

 Electronic card – 5710.2
Running Time
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.10 Running Time

When the running meter setting is displayed, the text window E lights.
The time is shown as follows:

Character Time
Ignition time

Total movement time

Drive motor time

Pump motor time

Service time

31.11 Parameter Settings

• Connect the service key to the truck.
• The switch I is pressed at the same time as the ignition key is
switched on.
• Step using II, to move up and III, to move down to the parameter
you wish to change.
• Press switch I the display will flash.
• Change the value using the switches II/III.
• Press switch I to set the value, the display will stop flashing.
If you want to change more parameters, step with switches II/III to the
parameter to be changed and repeat from “Press switch I the display
will flash“.
NOTE:
Truck operating characteristics.
Changing the truck-specific parameters changes the truck’s operat-
ing characteristics.
Do not change any parameters unless you have the necessary com-
petence.

31- 32 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

No Parameter type Unit Min./max. Std. Comments

. value
01 Steering sensitivity 1–6 3 1 = Several wheel turns
5 = Few wheel turns
6 = No progressivity
In steps of 1
02 Drive motor, max. % 10–100 100 Percentage of max. speed
speed In steps of 5
03 Drive motor, acceler- % 10–100 100 Percentage of max. speed
ation In steps of 5
04 Drive motor, speed % 0–100 20 Percentage of speed retardation
retardation 50 > 0 = no retardation
Note 1: In steps of 5
05 Drive motor, % 35–100 80 Percentage of max. retardation
retardation when In steps of 5
reversing
10 PIN code for driver 0000–3333 0000 0000 = PIN code not used.
selection > 0 = PIN code used.
11 Drive motor, speed % 10–100 100 Percentage of max. speed
reduction In steps of 5
12 Masts out/in move- % 10–100 80 Percentage of max. speed
ment, speed In steps of 5
13 Extra function 1 % 10–100 10 7FBRE16, 20 mast with integrated
speed side shift
20 7FBRE25
14 Not used
15 Engaging hydraulic % 0–100 100 0 = not connected
extra function 1, cur- > 0 = connected
rent limit In steps of 5
16 Not used 0
20 Time indication 1–5 2 1 = ignition time (A)
2 = total movement time (b)
3 = drive motor time (c)
4 = pump motor time (d)
5 = service time (S)
21 Battery size 1–20 12 See table
See
table
23 Type of Mast 0/1 1 0 = Mast tilt
1 = fork tilt
24 Left foot-switch 1/0 0 0 = Activates buzzer
1 = Also cuts drive motor

© TIEE SARL Service Manual 7FBRE 31- 33

 Electronic card – 5710.2
Parameter Settings
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

No Parameter type Unit Min./max. Std. Comments

. value
25 Service interval h 0–2000 100 0 = No service counter
In steps of 50h
26 Tilt speed % 10-100 30 In steps of 5
27 Lift priority 0/1 1 0 = Fork lift prioritised
1 = Fork lift not prioritised
28 Indication signal 0/1 0 0:
202 Pump motor
208 Drive motor
1:
202 Driving in drive wheel direction
208 Driving in fork direction
38 Calibration of accel- 1 0 Set to 1 for calibration
eration/brake pedal See instructions
and reach carriage
39 Driver access 1–4 1 1 = no PIN code, open
2 = no PIN code, locked
3 = PIN code, open
4 = PIN code, locked
40 Time, years Years 0–99 In steps of 1
41 Time, days Days 1–31 In steps of 1
42 Time, months Month 1–12 In steps of 1
s

31.11.1 Parameter 1
The higher the number you program, the less number of turns of the
steering wheel required to turn the drive wheel. With a value of 6, steer-
ing is non-progressive, less sensitive at higher speeds.

31.11.2 Parameter 2
This parameter sets the maximum permitted driving speed.

31.11.3 Parameter 3
The lower the number you program, the longer the truck will require to
come up to maximum speed.

31.11.4 Parameter 4
This parameter determines the force at which the truck will stop when
you release the accelerator pedal.
Note 1: Driver 1 has 20%, drivers 2-10 have 50% as the default value.

31- 34 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.11.5 Parameter 5
With this parameter, you determine the force at which the truck will stop
when you change directions and use the drive motor to stop the truck.

31.11.6 Parameter 10
Value 0000 means that three drivers are chosen. The table below
shows the combinations for the first six PIN codes. These values are
attained by stepping up and down with the switches I and II.

Value Driver number

0000 No PIN code. Max. three drivers used
1111 First PIN code when max. 10 drivers used
1112 Second PIN code when max. 10 drivers used
1113 Third PIN code when max. 10 drivers used
1121 Fourth PIN code when max. 10 drivers used
1122 Fifth PIN code when max. 10 drivers used
1123 Sixth PIN code when max. 10 drivers used
etc. etc.

31.11.7 Parameter 11
This parameter sets the maximum permitted driving speed when switch
S31 is activated.

31.11.8 Parameter 12
With this parameter you can adjust the speed of the mast’s in and out
movement.

31.11.9 Parameters 13
With this parameter you can adjust the oil flow for the two extra func-
tions.

31.11.10 Parameters 15
When these parameters are set to the value> 0, control of potentiome-
ters and valves for the two extra functions are activated. Function
requirements are also stated by the size of the value.

31.11.11 Parameter 20
This parameter specifies the time A-d or S that will be displayed when
the driver uses the truck.

© TIEE SARL Service Manual 7FBRE 31- 35

 Electronic card – 5710.2
Parameter Settings
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

31.11.12 Parameter 21
With this parameter you specify the battery the truck is equipped with.
You may also compensate for different ways of driving.
For additional information about battery installation and setting the bat-
tery parameters, please see section 5110.
For setting the battery monitor’s break point, measure as set out below:
• Acid density for fully charged battery. To check battery quality.
• When battery indicator shows 80% discharge, min. acid density
1.14.
The acid density can vary depending on the battery type.

Value Function Battery (Ah)

1
2
3
4
5
6
7
8
9
10

11 Less discharge 900

12 730, 700, 580 CSM
13 More discharge 600
14

15 480, 450
16
17 360
18
19
20

WARNING
Correct parameter setting.
Battery can be destroyed.
If the parameters are set to values higher than those recommended,
battery discharge will be excessive and the batteries destroyed.

31- 36 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.11.13 Parameter 23
When the parameter is set to 1 this defines that a valve is fitted to the
fork plank and is used as a switching valve between two functions.
Direction is handled by the valve in the large valve assembly.

31.11.14 Parameter 24
Set the parameter to 1 and you can stop the truck with the drive motor
but you cannot continue to drive, if the safety pedal is not depressed.

31.11.15 Parameter 25
With this parameter, you specify the truck’s service interval. The buzzer
sounds and C029 is shown on the display when the service counter is
at zero. The counter will show the time that has passed since the truck
was last serviced.
If the previous service time is to be used, only the parameter is activat-
ed the time is not changed.

31.11.16 Parameter 26
Using this parameter you can set the speed at which the mast tilts.

31.11.17 Parameter 27
When the parameter is set to 1 this removes the lift function’s priority,
i.e. the hydraulic function being used will continue irrespective of
whether the lift is activated.

31.11.18 Parameter 28
This parameter allows information on the outputs 202 and 208 to be
switched between two different functions. 0 is for TLS and 1 is used to
start the warning light/buzzer when the truck is driven, an intermediate
relay must be used.

31.11.19 Parameter 38
• Set the parameter to 1.
• Turn the ignition on and off once.
The acceleration and braking potentiometers will now be calibrated.
NOTE:
Calibration error.
Incorrect calibration value.
Do not move the lever when calibration begins.
• Retract the reach carriage towards the inner stop, battery partition.
• Move the reach carriage out to the outer stop.

© TIEE SARL Service Manual 7FBRE 31- 37

 Electronic card – 5710.2
Parameter Settings
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

The reach cylinder’s end position and lowering distance are now cali-
brated. The reach carriage’s movement will run at a reduced speed dur-
ing calibration.

31.11.20 Parameter 39
Set the parameter to 1 or 2 if only three drivers/truck profiles are to be
programmed. If up to ten drivers/truck profiles are to be programmed,
set the value to 3 or 4. With up to ten drivers, the value must be pro-
grammed for each driver. See parameter 10.
Show/programming choices with parameter 39.

Param- Key S17 switched on, then Switch I and key S17 switched
eter switch I on simultaneously
P39- Clock Parameter Driver Clock Parameter Driver
-1 Reprgm. See See Not Reprgm. Selected
U. CAN selected reprgm. reprgm.
-1 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-2 Reprgm. See See Not Not reprgm. See
U. CAN selected reprgm. selected
-2 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-3 Reprgm. See See Not Reprgm. Selected
U. CAN selected reprgm. reprgm.
-3 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.
-4 Reprgm. See See Not Not reprgm. See
U. CAN selected reprgm. selected
-4 Reprgm. See See Not Reprgm. All reprgm.
M. CAN selected reprgm.

31.11.21 Parameters 40 to 42
With these parameters you can set the year, day and month for error
code logging.

31.11.22 Other parameters

Other parameters between 10 and 42 are shown on the display and can
be programmed, but the value does not modify the program. Others
have a fixed value and cannot be reprogrammed.

31- 38 Service Manual 7FBRE © TIEE SARL

 Electronic card – 5710.2
Parameter Settings
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

31.11.23 Installing a new card in the truck

The A5 card from TOYOTA can be supplied in different configurations:

1. Ready programmed with complete numbers and default val-

ues entered.
= P/N for the card including program.
2. Not programmed at part number
= only P/N for the card.
When installing a new card, certain parameters must be reprogrammed
so that the truck can be safely operated.
For downloading new programs to the electronic card, the Truck Com
service program is used.
See the Truck Com user manual for a description of the procedure.
Potentiometer R1 on the electronic card should be adjusted according
to C-code 6000.

© TIEE SARL Service Manual 7FBRE 31- 39

 Electronic card – 5710.2
Parameter Settings
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

31- 40 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

32- Hydraulic system – 6000.1

32.1 General
The hydraulics on the truck consist of a pump that sucks oil from the
tank and transports this on to the parking brake and the main valve
located in the reach carriage.
The main valve distributes oil to the reach carriage and the mast.
The return oil from the reach cylinder and mast is transported via the
main valve through the filter to the tank.
The return oil from the reach carriage goes directly through the filter to
the tank.

32.2 Symbols
The table explains the symbols used in the hydraulic chart.

Symbol Description Symbol Description

Single acting hydraulic cylin- Double acting hydraulic cylin-
der der

Directional valve 3/2, three Directional valve 4/3, four

ports, two distinct positions, ports, three distinct posi-
electromagnetically control- tions, electromagnetically
led controlled.
Proportional valve Valve, two ports, two distinct
positions, electromagneti-
cally controlled.

Counter pressure valve

© TIEE SARL Service Manual 7FBRE 32- 1

 Hydraulic system – 6000.1
Symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Symbol Description Symbol Description

Pressure limit valve Load holding valve

Non-return valve Non-return valve, spring-

loaded (hose rupture valve)

One way throttle valve (lower Metering socket

brake valve)

Filter Wiper

Tank Electric motor and pump

Pressure pipe Pressure pipe with coupling

Drainage pipe Pilot pipe

Limit for units containing two

or more functions

32- 2 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.1
Symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

32.2.1 Hydraulic chart 1 (2)

7FBRE16, 20, 25, 7FBRE16C, 20C, 25C

© TIEE SARL Service Manual 7FBRE 32- 3

 Hydraulic system – 6000.1
Symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

32.2.2 Hydraulic chart 2 (2)

7FBRE16, 20, 25, 7FBRE16C, 20C, 25C, Integrated
side shift

32- 4 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.1
List of symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

32.3 List of symbols

Symbol Description Function Comments

1-2 Cylinder Main lift, forks
3 Cylinder Free lift, forks
4 Cylinder Extension/retraction, reach carriage
5 Cylinder Tilting, forks
6 Cylinder Extra function 1
7 Cylinder Extra function 2
11-12 Valve Hose rupture valve, main cylinder
13 Valve Hose rupture valve, free lift cylinder
14 Valve Load holding valve 14a 7FBRE16, 20, 25
14b 7FBRE16, 20, 25
Int SS
15 Valve Throttle/non-return valve, reach cylinder
16 Valve Non-return valve
17 Valve Shock valve, reach cylinder
18 Valve Pressure limit valve, overflow pressure
24 Valve Throttle non-return valve, M3
25 Socket Socket for pressure metering
26 Dryer Silica Gel filter Only 16C, 20C, 25C

F Filter Oil filter for return flow

M Motor Pump motor

P Pump Hydraulic pump

Y10/2 Valve Lifting, forks

Y10/3 Valve Proportional valve lowering, forks
Y12 Valve Retraction, mast
Y13 Valve Extension, mast
Y14 Valve Tilting down, forks

© TIEE SARL Service Manual 7FBRE 32- 5

 Hydraulic system – 6000.1
List of symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

Symbol Description Function Comments

Y15 Valve Tilting up, forks
Y16 Valve Extra function 1
Y17 Valve Extra function 1
Y18 Valve Extra function 2
Y19 Valve Extra function 2
Y22 Valve Switching tilt/side shift
Y23 Valve Switching tilt/side shift

32- 6 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.1
List of symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

32.3.1 Component placement 1 (2)

B2 C2 C1 B1

Y18 A2 A1
Y19

C2 B1

B2 C1

Y17
Y18 Y14 Y13 15 30
16
17

Y16 Y15 Y12 18 Y10

Y19

© TIEE SARL Service Manual 7FBRE 32- 7

 Hydraulic system – 6000.1
List of symbols
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

32.3.2 Component placement 2 (2)

1,11
3,13
2,12
6
5

14a

C2 C1

B2 B1

14b
A2 A1

F C2 C1

B2 B1

26

M3

24, 25
P

32- 8 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.1
Adjusting fork lowering
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

32.4 Adjusting fork lowering

The hydraulic system must be run warm for approx. 10 minutes when
adjusting fork lowering so that the correct value is obtained.
• Lift the forks, without a load, to eye-level.
• Actuate the potentiometer for lowering 2-2.5 mm forwards. The LED
803 on the electronic card will come on slightly weaker than with full
potentiometer movement.
• Adjust using potentiometer RV 1 on the electronic card A5, so that
the forks start to lower, lower very slowly.
• Lift the forks without a load, to the maximum lifting height.
• Adjust the valve B so that the right lowering speed is attained.
• Check that lowering from the free lift to main lift functions.
• Seal the valve and potentiometer.
A = Flow regulation for fork lift.
B B = Flow regulation for fork lowering.
Lowering speed above the free lift without load (m/s).

Model Min. Nom Max.

7FBRE16 0,49 0,52 0,55
7FBRE20 0,49 0,52 0,55
A 7FBRE25 0,53 0,56 0,59

Error code 0 13
If error code 0 13 arises, turn the potentiometer Lower, on the electronic
card A5, anticlockwise and increase the flow on the valve until the cor-
rect lowering speed is achieved.
NOTE!
If error code 0 13 arises on a truck that does not have height indica-
tion.
Check that the parameter 11 is set to 0.
See 5710 parameter setting.

© TIEE SARL Service Manual 7FBRE 32- 9

 Hydraulic system – 6000.1
Setting the maximum lifting capacity
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

32.5 Setting the maximum lifting

capacity
The hydraulic system must be run warm for approx. 10 minutes when
adjusting the maximum lift capacity so that the correct value is
obtained.
• Extend the reach carriage.
• Lower the forks to floor level.
• Remove the seal on the adjuster screw (A).
• Load the forks with the maximum weight.

Model Min. (kg) Max. (kg)

7FBRE16 1600 1920
7FBRE16 1475 1770
7FBRE16 (Side-shift standard) 1475 1770
7FBRE20 2000 2400
7FBRE20 Side-shift 1875 2250
7FBRE25 (side shift standard) 2500 3000

B The right lift capacity is obtained when the inner guide stops just outside
the free lift, approx. 10 mm,
• Lower the forks to floor level.
Adjust the right lift capacity using adjuster screw (A) on the main valve.
A = Flow regulation for fork lift.
B = Flow regulation for fork lowering.
• Loosen the locking nut.
A
• Screw the adjuster screw (A) outwards to increase the flow.
• Screw the adjuster screw (A) inwards to reduce the flow.
• Lock the lock nut.
Seal the adjustment screw (A).

32- 10 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

33- Hydraulic system – 6000.2

33.1 General
The hydraulics on the truck consist of a pump that sucks oil from the
tank and transports this on to the parking brake and the main valve
located in the reach carriage.
The main valve distributes oil to the reach carriage and the mast.
The return oil from the reach carriage and mast is transported via the
min valve through the filter to the tank.
The return oil from the reach carriage goes directly through the filter to
the tank.

33.2 Symbols
The table explains the symbols used in the hydraulic chart.

Symbol Description Symbol Description

Single acting hydraulic cylin- Double acting hydraulic cylin-
der der

Single acting hydraulic cylin- Double acting hydraulic cylin-

der with throughput der with damping in the outer
position

Directional valve 3/2, three Directional valve 4/4, four

ports, two distinct positions, ports, three distinct posi-
electromagnetically control- tions, electromagnetically
led, spring return. controlled.
Directional valve 4/4, four Valve, two ports, two distinct
ports, two distinct positions, positions, electromagneti-
electromagnetically control- cally controlled, spring return
led, spring return.

© TIEE SARL Service Manual 7FBRE 33- 1

 Hydraulic system – 6000.2
Symbols
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

Symbol Description Symbol Description

Counter pressure valve Proportional valve

Pressure limit valve Load holding valve

Non-return valve Non-return valve, spring-

loaded (hose rupture valve)

One way throttle valve (lower Metering socket

brake valve)

Filter Wiper

Tank Electric motor and pump

Pressure pipe Pressure pipe with coupling

Drainage pipe Pilot pipe

Optional pipe Limit for unit containing two

or more functions

33- 2 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.2
Symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

33.2.1 Hydraulic chart 1 (3)

7FBRE12, 7FBRE12C

© TIEE SARL Service Manual 7FBRE 33- 3

 Hydraulic system – 6000.2
Symbols
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

33.2.2 Hydraulic chart 2 (3)

7FBRE14, 7FBRE14C, Integrated side shift
6

A1

Y16
A2
C2

B2

A1
14

B1

B1
C1

Y17
5

Y15
Y14

26
B
15

16

17
A
4

Y13

Y12
Y10/3

F
2

12

30

R
18
H

25
13

P
P
Y10/2
3

M3
24
11
1

33- 4 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.2
Symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

33.2.3 Hydraulic chart 3 (3)

7FBRE14, 7FBRE14C

A2
B2
6

Y16
Y17
A1
B2
C2

14
B1
C1

B1
5

Y15
Y14

26
B
15

16

17
A
4

Y13

Y12
Y10/3

F
2

12

30

R
18
H

25
13

P
P
Y10/2
3

M3
24
11
1

© TIEE SARL Service Manual 7FBRE 33- 5

 Hydraulic system – 6000.2
List of symbols
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

33.3 List of symbols

Symbol Description Function Comments

1-2 Cylinder Main lift, forks
3 Cylinder Free lift, forks
4 Cylinder Extension/retraction, reach carriage
5 Cylinder Tilting, forks
6 Cylinder Extra function 1
11-12 Valve Hose rupture valve, main cylinder
13 Valve Hose rupture valve, free lift cylinder
14 Valve Load holding valve 14 7FBRE12
14a 7FBRE14
14b 7FBRE14,Int SS
15 Valve Throttle/non-return valve, reach cylinder
16 Valve Non-return valve
17 Valve Shock valve, reach cylinder
18 Valve Pressure limit valve, overflow pressure
24 Valve Throttle non-return valve, M3
25 Socket Socket for pressure metering
26 Dryer Silica Gel filter Only 12C-14C
30 Valve Lowering speed

F Filter Oil filter for return flow

M Motor Pump motor

P Pump Hydraulic pump

Y10/2 Valve Lifting, forks

Y10/3 Valve Proportional valve lowering forks
Y12 Valve Retraction mast
Y13 Valve Extension, mast
Y14 Valve Tilting down, forks
Y15 Valve Tilting up, forks
Y16 Valve Extra function 1 (Switching tilt/side shift)
Y17 Valve Extra function 1 (Switching tilt/side shift)

33- 6 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.2
List of symbols
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

33.3.1 Component placement 1 (2)

7FBRE12, 7FBRE12C

© TIEE SARL Service Manual 7FBRE 33- 7

 Hydraulic system – 6000.2
List of symbols
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

33.3.2 Component placement 2 (2)

7FBRE14, 7FBRE14C
Y17 Y14 Y13 15 30
16
17

Y16 Y15 Y12 18 Y10

1,11

2,12
3,13
6
5

14a
F
C2 C1

B2 B1

26

M3
14b
A2 A1
24
25
C2 C1
Y16 Y17
P B2 B1

33- 8 Service Manual 7FBRE © TIEE SARL

 Hydraulic system – 6000.2
Adjusting fork lowering
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

33.4 Adjusting fork lowering

The hydraulic system must be run warm for approx. 10 minutes when
adjusting fork lowering so that the correct value is obtained.
• Lift the forks, without a load, to eye-level.
• Actuate the potentiometer for lowering 2-2.5 mm forwards. The LED
803 on the electronic card will come on slightly weaker than with full
potentiometer movement.
• Adjust using potentiometer RV 1 on the electronic card A5, so that
the forks start to lower, lower very slowly.
• Lift the forks without a load, to the maximum lifting height.
• Adjust the valve B so that the right lowering speed is attained.
• Check that lowering from the free lift to main lift functions.
• Seal the valve and potentiometer.
A = Flow regulation for fork lift.
B B = Flow regulation for fork lowering.

Lowering speed above the free lift without load (m/s).

Model Min. Nom Max.

7FBRE
7FBRE
A 7FBRE
7FBRE

© TIEE SARL Service Manual 7FBRE 33- 9

 Hydraulic system – 6000.2
Setting the max lifting capacity
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

33.5 Setting the max lifting capacity

The hydraulic system must be run warm for approx. 10 minutes when
adjusting the max lift capacity so that the correct value is obtained.
• Extend the reach carriage.
• Lower the forks to floor level.
• Remove the seal on the adjuster screw (A).
• Load the forks with the max. weight.

Model Min. (kg) Max. (kg)

7FBRE12 1350 1620
7FBRE12, Side-shift 1225 1470
7FBRE
7FBRE Side-shift
7FBRE (Side-shift standard)
7FBRE
7FBRE Side-shift
7FBRE (side shift standard)

The right lift capacity is obtained when the inner guide stops just outside
B the free lift, approx. 10 mm,
• Lower the forks to floor level.
• Adjust the right lift capacity using adjuster screw (A) on the main
valve.
A = Flow regulation for fork lift.
B = Flow regulation for fork lowering.
• Loosen the locking nut.
A
Screw the adjuster screw (A) outwards to increase the flow.
Screw the adjuster screw (A) inwards to reduce the flow.
• Lock the lock nut.
Seal the adjustment screw (A).

33- 10 Service Manual 7FBRE © TIEE SARL

 Hydraulic pump – 6140.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

34- Hydraulic pump – 6140.1

34.1 General
There is one pump size in the truck that has a max flow of 60 litres per
minute.
The pump motor is available in two sizes on the trucks.
P150 is used on 7FBRE16, 7FBRE20.
P195 is used on 7FBRE25.
These service instructions contain a description on how to replace the
hydraulic pump.

34.2 Replacing the hydraulic pump

To open and close the motor compartment, see section P1 in this manual.

34.2.1 Dismantling
3
• Disconnect the battery plug.
6
• Drop the forks to the lowest position to reduce pressure in the hoses
7 and pump.
• Pump the oil out of the hydraulic tank 3 with filter pump V10-15191.
12
4 • Remove the support (4) so that the bolts (5) for the pump mounting
(12) are accessible.
• Remove the temperature/speed measuring contacts (6) and power
cables (7) from the pump motor (8).
• Remove the hydraulic hose (9) and loosen the hose clamp for the
hydraulic hose (10) attached to the tank.

• Fasten a lifting eye in the motor axle.

• Remove the bolts (5) holding the pump mounting (12) to the chassis.
• Lift out the hydraulic pump and place it on a clean surface.
• Remove both mountings (12) from the pump motor (8).
• Remove the hose coupling from the pump unit (13).
• Remove the screws and dismount the pump (13).
• Remove the carrier.

© TIEE SARL Service Manual 7FBRE 34- 1

 Hydraulic pump – 6140.1
Replacing the hydraulic pump
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

34.2.2 Assembling
• Fit the hose coupling on the pump unit (13).
• Replace the carrier between the pump and the pump motor (8).
• Replace the pump unit (13) on the pump motor (8).
• Replace both mounting (12) attachments on the pump motor (8).
8 • Screw a lifting eye into the end of the motor axle and connect it to an
overhead crane.
• Lift the hydraulic pump into the truck while at the same time refitting
the hydraulic hose (10) on the tank (3).

13 • Tighten the hose clamp.

• Fasten the two pump mountings (12) to the chassis using the bolts
(5).
• Unscrew the lifting eye.
• Refit the hydraulic hose (9) and the temperature/speed measuring
contacts (6) and power cables (7).
• Fill the hydraulic tank (3) with 48 litres of new oil.

34- 2 Service Manual 7FBRE © TIEE SARL

 Hydraulic pump – 6140.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-692

35- Hydraulic pump – 6140.2

35.1 General
There is one pump size in the truck that has a max flow of 60 litres per
minute.
These service instructions contain a description on how to replace the
hydraulic pump.

35.2 Replacing the hydraulic pump

• Loosen the handle beside the driver seat and swing the door out-
wards.

35.2.1 Dismantling
• Disconnect the battery plug.
• Drop the forks to the lowest position to reduce pressure in the hoses
and pump.
• Pump the oil out of the hydraulic tank, 3, with filter pump V10-15191.
3
6
7

12
4

• Remove the support (4) so that the bolts (5) for the pump mounting
(12) are accessible.
• Remove the temperature/speed measuring contacts (6) and power
cables (7) from the pump motor (8).
• Remove the hydraulic hose (9) and loosen the hose clamp for the
hydraulic hose (10) attached to the tank.
• Fasten a lifting eye in the motor axle.
• Remove the bolts (5) holding the pump mounting (12) to the chassis.
• Lift out the hydraulic pump and place it on a clean surface.
• Remove both mountings (12) from the pump motor (8).
• Remove the hose coupling from the pump unit (13).
• Remove the screws and dismount the pump (13).
• Remove the carrier.

© TIEE SARL Service Manual 7FBRE 35- 1

 Hydraulic pump – 6140.2
Replacing the hydraulic pump
T-code Valid from serial number Date Order number
689-692 423260- 2005-07-01 201004-040

35.2.2 Assembling
• Fit the hose coupling on the pump unit (13).
• Replace the carrier between the pump and the pump motor (8).
• Replace the pump unit (13) on the pump motor (8).
• Replace both mounting (12) attachments on the pump motor (8).
3
8
6
7

12
13 4

• Screw a lifting eye into the end of the motor axle and connect it to an
overhead crane.
• Lift the hydraulic pump into the truck while at the same time refitting
the hydraulic hose (10) on the tank (3).
• Tighten the hose clamp.
• Fasten the two pump mountings (12) to the chassis using the bolts
(5).
• Unscrew the lifting eye.
• Refit the hydraulic hose (9) and the temperature/speed measuring
contacts (6) and power cables (7).

• Fill the hydraulic tank (3) with 48 litres of new oil.

• Close the door and tighten the handle.

35- 2 Service Manual 7FBRE © TIEE SARL

 Mast mounted hose reel – 6370
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

36- Mast mounted hose reel – 6370

36.1 General
These assembly instructions contain requisite information to give trou-
ble-free installation and operation. The enclosed operating instructions
contain besides instructions also information regarding inspection and
maintenance.

36.2 Assembling
Assemble the hose reel or spring according to the drawing.
Turn the hose drum, with a fully wound hose, in the direction of extrac-
tion to preload the spring.
Preloading the hose drum:
• Right extraction clockwise.
• Left extraction anti-clockwise.
WARNING
Loaded spring.
The hose can cause injury.
Always exercise caution when working with the hose reel.
The number of turns depends on the hose length and hose diameter,
see the table. The stated values apply as guideline values.
Spring preload (turns)

Hose diameter Hose length (m)

(mm) 2.7 3 3.3 5 6 7 8.5
6.3 - - 4 3 3 3 1.5-2
8 4 4 - 3 3 - -

The hose is pulled out from the drum once the correct preloading value
has been reached.

© TIEE SARL Service Manual 7FBRE 36- 1

 Mast mounted hose reel – 6370
Check after assembly
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

36.3 Check after assembly

When the hose reel is first used lift the forks to the maximum lift height.
Check that the hose and hose drum work correctly and count the
number of turns that the hose drum rotates.
The total of the number of turns made by hand when preloading and the
number of turns for maximum extract must be 10 at most.
Turns with preloading + operating turns = max 10
NOTE:
The hose must not be fully unwound from the hose drum at maximum
lifting height. At least ¼ turn of hose must remain on the hose drum.
Make sure that the hose drum can still be turned by hand with the hose
fully extracted. The hose drum must not lock up.
Check that the hose rewinds correctly when the forks are lowered. The
hose must always be loaded otherwise there is a risk of the hose sliding
over the side plates. If this is the case adjust the preloading tension.
NOTE:
The spring-loaded eye must face the hose’s direction of unwinding.

Spare parts must correspond with the manufacturer’s defined technical

specifications. This demand is always met when using original spare
parts.

36- 2 Service Manual 7FBRE © TIEE SARL

 Hydraulic cylinder – 6600
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

37- Hydraulic cylinder – 6600

37.1 General
There are two lifting cylinders on each mast. Each free lift cylinder is fit-
ted with a lowering brake valve as a safety feature in the event of hose
rupture or a pipe failure. Mast lifting cylinders contain a number of
seals, support rings and scraper rings. These are wear parts and
should be changed when oil leakage occurs.
We recommend that all masts, irrespective of the lifting height are
raised before the cylinders are dismantled.
NOTE!
The greatest possible care should be exercised when assembling the
cylinders and its seals, support rings and scraper rings. Use special
assembly tools whenever possible.

37.2 Duplex mast

37.2.1 Dismantling the lift cylinders from the

mast
• Loosen the lift chain from the top on the lift cylinder to be dismantled
and place it on the floor over the reach carriage.
• Remove the lifting chain sprocket.
• Block both inner runners approximately 50 cm above the floor with
blocks.
• Lower the free lift cylinder to the bottom.
• Loosen the connection pipe in the lift cylinder and manifold.
• Plug the manifold connections.
• Check that the lift chain is not damaged or that it damages hoses,
pipes, rollers and cables while operating the mast to the top.
• Loosen the cylinder from the bottom stud.
• Loosen the cylinder support at the top.
• Remove the cylinder from the mast.

© TIEE SARL Service Manual 7FBRE 37- 1

 Hydraulic cylinder – 6600
Duplex mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

37.2.2 Dismantling the cylinder

• Dismantle the cylinder from the mast.

• Place the bottom stud (9) in a vice and let the top section rest against
e.g. a pipe stand so that the cylinder lies in the horizontal position.
• Carefully knock the top sleeve and the cylinder with a rubber mallet.
Carefully heat a little, if necessary.
• Loosen the top sleeve (1) using tool 08-15393.
• Carefully pull the rod out of the cylinder so that the threads do not
damage the collar (7). Place the rod on a soft and clean surface so
that it is not damaged.
• Knock off the top sleeve (1) using a rubber mallet.

37.2.3 Dismantling the rod seal, guide ring,

guide ring holder and locking ring in lift
cylinder
• Remove the clamping ring (8).
• Remove the collar (7).
• Dismantle the guide ring holder (5).
• Remove the guide ring (6) from the guide ring holder (5).
• Remove the retainer rings (4).

37- 2 Service Manual 7FBRE © TIEE SARL

 Hydraulic cylinder – 6600
Duplex mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

37.2.4 Assembling the locking ring, rod seal,

guide ring and guide ring holder in the lift
cylinder
• Fit the locking ring (4) on the rod using tools
08-15368, 08-15369 and 08-15370.
• Assemble the guide ring (6) on guide ring holder (5).
• Assemble the guide ring holder (5) on the rod.
• Place the assembly tool 08-15367 on the rod.
• Place the collar (7) on the assembly tool 08-15366.
• Assemble the collar (7) on the rod.
• Fit the clamping ring (8).

37.2.5 Dismantling and assembling the lower

brake valve
• Both dismantling and assembling of the lower brake valve (10) takes
place using tool 08-15400.

37.2.6 Assembling the cylinder

• Use assembly tool 08-15364 when inserting the rod in the cylinder.
• Remove the assembly sleeve 08-15364.
• Assemble the top sleeve (1) on the rod using a rubber mallet.
• Screw the top sleeve (1) in the cylinder a few turns.
• Apply flange sealant FD 1042 on the thread.
• Tighten using tool 08-15391.
• On triplex lift cylinders the venting hole and the hole for the lower
brake valve should be placed on either side of the cylinder.
• Assemble the cylinder on the mast.
NOTE!
The curing time for the flange sealant is 4 hours. The cylinders must
not be used before this.

© TIEE SARL Service Manual 7FBRE 37- 3

 Hydraulic cylinder – 6600
Duplex mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

37.2.7 Assembling the cylinder in the mast

• Lift the cylinder in the mast.
• Bolt the cylinder on the bottom stud.
• Assemble the cylinder support.
• Block up the inner runner approximately 50 cm above the floor using
blocks.
• Lower the mast.
• Remove the plugs from the manifold.
• Assemble the connection pipe in the cylinder and manifold.
• Lift up the forks until the lift cylinder rests against the top beam.
• Bolt the cylinder on top beam.
• Lower the forks fully.
• Assemble the chain sprocket and lift chain.
• Adjust the chain so that the mast does not pull to one side at the top.

37- 4 Service Manual 7FBRE © TIEE SARL

 Hydraulic cylinder – 6600
Triplex mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

37.3 Triplex mast

37.3.1 Dismantling the free lift cylinder from

the mast
• Remove the lift chain from the fork carriage.
• Lift the inner runner using an overhead crane so that the bottom
beam comes above the fork carriage (the fork carriage remains on
the support arm).
• Remove the lift chain from the inner runner.
• Dismantle the chain sprocket.
• Dismantle the bracket from the cylinder.
• Loosen the hydraulic pipe from the cylinder and the bracket for the
feeder hose, plug connections.
• Lift out the cylinder.

37.3.2 Dismantling the mast lift cylinders

from the mast
• Only replace one cylinder at a time if possible.
• Loosen the mast lifting chains.
• Loosen upper mounting bolt.
• Loosen the lower mounting bolt.
• Lift up the intermediate runner approx. 100 mm using an overhead
crane or plug the remaining pipes and lift using the other cylinder.
• Plug all connections.
• Lift out the cylinder.

37.4 Cylinder seals

Mast lifting cylinders contain a number of seals, support rings and
scraper rings. These are wear parts and should be changed when oil
leakage occurs.
NOTE!
The greatest possible care shall be exercised when assembling seals,
support rings and scrape rings.
Use special assembly tools whenever possible.

© TIEE SARL Service Manual 7FBRE 37- 5

 Hydraulic cylinder – 6600
Replacing wear parts in the cylinder
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

37.5 Replacing wear parts in the

cylinder

37.5.1 Securing
• Grip the cylinder by the bottom stud ( I ) and with a support below the
cylinder pipe.
Note! Under no circumstances may the cylinder be gripped by the pipe
as this can become misshaped.

B C E F
A D

H I

37.5.2 Dismantling the cylinder

• Loosen the top sleeve ( H ), using a hook spanner, by turning anti-
clockwise.
• Pull out the rod ( G ) from the cylinder with the top sleeve on the rod.
• Place the rod ( G ) on a clean surface.
• Pull off the top sleeve ( H ) by pulling it upwards on the rod ( G ).
• Cover all openings on the cylinder pipe.

37.5.3 Replacing the lower support ring

Note! Ensure that not scratches are made during dismantling or assem-
bly.
• Dismantle the rod's lower support ring ( F ) by pulling it over the
edge.
• Before a new support ring can be fitted the bearing should be care-
fully cleaned and lightly lubricated.
• Then push the support ring over the edge.

37- 6 Service Manual 7FBRE © TIEE SARL

 Hydraulic cylinder – 6600
Replacing wear parts in the cylinder
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

37.5.4 Replacing the O-ring on the top sleeve

Note! Ensure that not scratches are made during dismantling or assem-
bly.
• Dismantle the O-ring ( D ) and its support ring ( B ).
• Clean the O-ring's seating and thread.
• Lubricate lightly.
• Assemble the support ring ( B ) and then the O-ring ( D ).
B C E F
A D

H I

37.5.5 Replacing the internal wear parts in the

top sleeve
Note! Ensure that not scratches are made during dismantling or assem-
bly.
• Remove the scraper ( A ) by pulling it straight out.
• Remove the support ring ( B ) next to the joint by prying up a small
part of it using a sharp object.
• Grip the tab that has been lifted up with a pair of pliers and pull it out
of the sleeve.
• Remove the collar ( C ) by bending it to one side so that it can be
pulled up .
• Clean any dirt from the top sleeve ( H ) and makes sure no scratches
have been made.
• Lubricate lightly, and assemble the collar ( C ) using the appropriate
tool.
• Assemble the support ring ( B ) and make sure it really enters its
seating.
• Assemble the scraper ( A ) using the appropriate tool.

© TIEE SARL Service Manual 7FBRE 37- 7

 Hydraulic cylinder – 6600
Replacing wear parts in the cylinder
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

37.5.6 Assembling the cylinder

• Clean the rod and check that the locking ring ( E ) is in position.
• Lubricate the support ring ( B ) internally and push it over the rod.
• Lubricate the lower support ring ( F ) on the rod and push the assem-
bly into the cylinder pipe.
• Lubricate the O-ring ( C ) on the top sleeve and screw in as far as
possible by hand.
• Tighten using a hook spanner.
• Assemble the cylinder in the truck.

B C E F
A D

H I

37.5.7 Assembling the free lift cylinder in the

mast
• Lift the cylinder in the mast.
• Loosen the plugs in the cylinder.
• Assemble the hydraulic pipe in the cylinder and the bracket for the
feeder hose.
• Assemble the bracket on the cylinder.
• Assemble the chain sprocket.
• Place the lift chain on the inner runner.
• Lower the inner runner using an overhead crane.
• Assemble the lift chain on the fork carriage.

37- 8 Service Manual 7FBRE © TIEE SARL

 Hydraulic cylinder – 6600
Replacing wear parts in the cylinder
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

37.5.8 Assembling the mast lift cylinder

• Lift in the cylinder.
• Open all plugged connections.
• Lift up the intermediate runner approx. 100 mm using an overhead
crane, or plug the remaining pipes and lift with the help of the other
cylinder.
• Assemble and tighten the lower mounting bolts.
• Assemble and tighten the upper mounting bolts.
• Assemble the chain sprocket.
• Assemble the mast lifting chain.

© TIEE SARL Service Manual 7FBRE 37- 9

 Hydraulic cylinder – 6600
Replacing wear parts in the cylinder
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

This page is intentionally left blank

37- 10 Service Manual 7FBRE © TIEE SARL

 Main lift cylinder – 6610
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

38- Main lift cylinder – 6610

38.1 General
This instruction describes the main lift cylinders in the Newton mast.
There are two lifting cylinders on each mast. A hose rupture valve is
located on each cylinder that prevents the forks from falling in the event
of a hose rupturing.
We recommend that all masts, irrespective of the lifting height, are
raised before the cylinders are dismantled. Applies to 1600 and 2000
kg masts.

38.2 Tools
For lift cylinders on the mast and valve in the fork yoke.
(1600 and 2000 kg masts).

Tool Comments
number
08-15364 To protect the rod seals from damage against the
cylinder threads.
08-15366 Assembling the rod seal on 08-15367
08-15367 Assembling the rod seal on the ram
08-15368 Assembling the stop ring on 08-15369
08-15369 Assembling the stop ring on 08-15370
08-15370 Assembling the stop ring on the rod
08-15391 Hook spanner 60-90 with 5 mm pin
08-15393 Pipe wrench
08-15400 Assembling the hose rupture valve

© TIEE SARL Service Manual 7FBRE 38- 1

 Main lift cylinder – 6610
Dismantling the lift cylinders from the mast
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

38.3 Dismantling the lift cylinders from

the mast
• Loosen the lift chain from the top on the lift cylinder to be dismantled
and place it on the floor over the reach carriage.
• Remove the lifting chain sprocket.
• Block both inner runners approximately 50 cm above the floor with
blocks.
• Lower the free liftcylinder to the bottom.
• Loosen the connection pipe in the lift cylinder and manifold. The cyl-
inder can now be removed.
• Plug the manifold connections.
• Check that the remaining lift chains are not damaged.
• Check that the lift chains are not damaged or damage anything while
you raise the mast to the top.
• Loosen the lift cylinder by the bottom stud.
• Loosen the cylinder support at the top.
• Remove the cylinder from the mast.

38.4 Dismantling the cylinder

• Dismantle the cylinder from the mast.

• Place the bottom stud (9) in a vice and let the top section rest against
e.g. a pipe stand so that the cylinder lies in the horizontal position.
• Carefully knock the top sleeve and the cylinder with a rubber mallet,
carefully heat if necessary.
• Loosen the top sleeve (1) using tool 08-15393.
• Carefully pull the rod out of the cylinder so that the threads are not
damaged. Place the rod on a soft and clean surface so that it is not
damaged.
• Knock off the top sleeve (1) using a rubber mallet.
38- 2 Service Manual 7FBRE © TIEE SARL
 Main lift cylinder – 6610
Dismantling the cylinder
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

38.4.1 Dismantling the rod seal, guide ring,

guide ring holder and locking ring in lift
cylinder
• Remove the clamping ring (8).
• Remove the rod seal (7).
• Dismantle the guide ring holder (5).
• Remove the guide ring (6) from the guide ring holder (5).
• Remove the retainer rings (4).

38.4.2 Fit the locking ring, rod

seal, guide ring and guide ring holder in the
lift cylinder
• Fit the locking ring (4) on the rod using tool
08-15368, 08-15369 and 08-15370.
• Assemble the guide ring (6) on guide ring holder (5).
• Assemble the guide ring holder (5) on the rod.
• Place the assembly tool 08-15367 on the rod.
• Place the rod seal (7) on the assembly tool
08-15366.
• Assemble the rod seal (7) on the rod.
• Fit the clamping ring (8).

38.4.3 Dismantling and assembling the hose

rupture valve
• Dismantling and assembling of the hose rupture valve (10) takes
place using tool 08-15400.

© TIEE SARL Service Manual 7FBRE 38- 3

 Main lift cylinder – 6610
Assembling the cylinder
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

38.5 Assembling the cylinder

• Use assembly tool 08-15364 when inserting the rod in the cylinder.
• Remove the assembly sleeve 08-15364.
• Assemble the top sleeve (1) on the rod using a rubber mallet.
• Screw the top sleeve (1) in the cylinder a few turns.
• Apply flange sealant FD 1042 on the thread.
• Tighten using tool 08-15391.
• On 1350 -2.000 kg lift cylinders the venting hole and the hole for the
lower brake valve should be placed on either side.
• Assemble the cylinder on the mast.
NOTE!
The curing time for the flange sealant is 4 hours and the cylinders
must not be used before this.

38.5.1 Assembling the cylinder in the mast

• Lift the cylinder in the mast.
• Bolt the cylinder on the bottom stud.
• Assemble the cylinder support.
• Block up the inner runner approximately 50 cm above the floor using
blocks.
• Lower the mast.
• Remove the plugs from the manifold.
• Assemble the connection pipe in the cylinder and manifold.
• Lift up the forks until the lift cylinder rests against the top beam.
• Bolt the cylinder on top beam.
• Lower the forks fully.
• Assemble the chain sprocket and lift chain.
• Adjust the chain so that the mast does not pull to one side at the top.

38- 4 Service Manual 7FBRE © TIEE SARL

 Free lift cylinder – 6620
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

39- Free lift cylinder – 6620

39.1 General
The free lift cylinder is the cylinder located in the centre of the cylinders
in the mast.
There is a hose rupture valve fitted in the free lift cylinder that prevents
the load from falling in the event of a ruptured hose.

39.2 Tools
For free lift cylinders on the mast and valve in the fork yoke.
(1600 and 2000 kg masts).

Tool Comments
number
08-15365 To protect the rod seals from damage against the
cylinder threads.
08-15418 The assembly punch is used together with tool 08-
15419
08-15419 Assembling the rod seal on the ram
08-15391 Hook spanner 60-90 with 5 mm pin
08-15393 Pipe wrench
08-15417 Assembling the hose rupture valve

© TIEE SARL Service Manual 7FBRE 39- 1

 Free lift cylinder – 6620
Dismantling
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

39.3 Dismantling
• Remove the feeder pipe on the free lift cylinder.
• Plug the free lift cylinder.
• Remove the venting hose.
• Loosen the mounting bolts on the top side of the free lift cylinder.
• Lift up the intermediate runner using an overhead crane so that the
twin/triplet hoses become loose.
• Remove the twin/triplet hoses from the hose reels on the free lift cyl-
inder.
• Block up under the fork yoke.
• Lower the overhead crane so that the fork yoke rests on the block
and the free lift chains slacken off.
• Strap together the chains so that they do not slide out of the upper
chain sprockets.
• If there is a chain guard, this should be removed from the bracket.
• Remove the inner split pin on the free lift chain pin.
• Remove the free lift chain pin.
• Lift off the free lift chain from the free lift cylinder.
• Remove the chain adjuster from the free lift cylinder.
• Secure a lifting strap around the free lift chain bracket by the end of
the free lift ram and a lifting strap around the free lift cylinder (see di-
agram).
• Secure the lifting strap in an overhead crane.
• Remove the mounting bolts on the top side of the free lift cylinder.
• Lower the free lift cylinder.

39- 2 Service Manual 7FBRE © TIEE SARL

 Free lift cylinder – 6620
Dismantle the rod seal and the support ring.
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

39.3.1 Dismantling the cylinder

• Place the bottom stud (6) in a vice and let the top section of the cyl-
inder rest against e.g. a pipe stand so that the cylinder lies in the hor-
izontal position.
• Carefully knock the top sleeve (2) with a rubber mallet. Carefully
heat a little, if necessary.
• Loosen the top sleeve (2) using pipe wrench 08-15393.
• Carefully pull the rod out of the cylinder so that the threads are not
damaged. Place the rod on a soft and clean surface to prevent dam-
aged.
• Knock off the top sleeve (2) using a rubber mallet.

39.4 Dismantle the rod seal and the

support ring.
• Carefully knock a screwdriver in the rod seal (5) without making any
marks whatsoever on the ram (3).
NOTE!
If a ram is scratched it must be replaced to prevent leakage from oc-
curring.
• Very carefully lift up the rod seal (5).
• Carefully cut off the rod seal (5) using a knife so that not damage is
caused to the ram (3).
• Remove the support ring (4).

39.4.1 Assembling the rod seal and the

support ring.
• Fit the support ring (4) on the ram (3).
• Fit the rod seal (5) on the ram (3) using assembly tools 08-15418
and 08-15419.

© TIEE SARL Service Manual 7FBRE 39- 3

 Free lift cylinder – 6620
Dismantling the ram
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

39.5 Dismantling the ram

• Remove the rod seal (5) and the support ring (4).
• Knock and heat the ram a little (3) if necessary.
• Unscrew the ram (3) using pipe wrench 08-15393.
• Brush off any old flange sealant.

39.5.1 Assembling the ram in the free lift

cylinder
• Apply OMNI 230 on the thread
• Screw in the ram (3) using assembly tool 08-15390.
• Take care to wipe off all surplus sealant.

39.6 Dismantling and assembling the

hose rupture valve
• Dismantle the lowering brake valve (7) using tool 08-15417
• Assemble the lowering brake valve (7) using tool 08-15417

39- 4 Service Manual 7FBRE © TIEE SARL

 Free lift cylinder – 6620
Assembling the cylinder
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

39.7 Assembling the cylinder

• Position the assembly sleeve 08-15365 on the cylinder.
• Insert the rod in the cylinder.
• Remove the assembly sleeve.
• Knock the top sleeve (2) in position on the rod using a rubber
mallet.
• Screw the top sleeve (2) in the cylinder a few turns.
• Apply flange sealant FD 1042 on the thread.
• Tighten using hook spanner 08-15391.
NOTE!
The curing time for the flange sealant is 4 hours and the cylinders
must not be used before this.

39.8 Assembling
• Secure a lifting strap around the free lift chain bracket by the end of
the free lift ram and a lifting strap around the free lift cylinder (see di-
agram).
• Lift up the free lift cylinder into its correct position.
• Fit the free lift cylinder using its mounting bolts.
• Take away the overhead crane.
• Fit the chain adjuster.
• Fit the free lift chain with its pin.
• Fit the split pin.
• Fit chain guard, if there is one.
• Remove the straps from around the free lift chain
• Lift up the inner guide using an overhead crane.
• Place the twin/triplet hoses on the free lift cylinder’s hose reels.
• Take away the overhead crane.
• Remove the plugs on the free lift cylinder.
• Fit the feeder pipe on the free lift cylinder.
• Fit the venting hose

© TIEE SARL Service Manual 7FBRE 39- 5

 Free lift cylinder – 6620
Assembling
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

39- 6 Service Manual 7FBRE © TIEE SARL

 Reach cylinder – 6650.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

40- Reach cylinder – 6650.1

40.1 General
The reach cylinder is located in the reach carriage.
The reach cylinder is a double acting cylinder.
The direction of the cylinder is governed by the main valve.

40.2 Assembling and dismantling the

reach cylinder

40.2.1 Dismantling

• Loosen the handle beside the driver seat and swing the door out-
wards.
• Loosen the footboard from the footboard cylinder.
• Unscrew the return hose from the tank.
• Plug the return hose by the tank.
• Unscrew the hoses from the reach cylinder.
• Unscrew the upper left bolt on the protective plate.
• Unscrew the mounting bolts for the pins.

© TIEE SARL Service Manual 7FBRE 40- 1

 Reach cylinder – 6650.1
Assembling and dismantling the reach cylinder
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Screw in a lifting eye of the like in the pins.

• Pull out the pins.
• Lift out the reach cylinder

40.2.2 Dismantling the cylinder

• Place the bottom stud in a vice and let the top section rest against
e.g. a pipe stand so that the cylinder lies in the horizontal position.
• Carefully knock the rod housing with a rubber mallet.
• Unscrew the rod housing using a pipe wrench.
• Carefully pull the rod out of the cylinder so that the threads are not
damaged. Place the rod on a soft and clean surface to prevent dam-
aged.
• Knock off the top sleeve using a rubber mallet.

40.2.3 Dismantle the rod seal and the support

ring.
• Knock a screwdriver in the rod seal without making any marks what-
soever on the ram.
NOTE!
If a ram is scratched it must be replaced to prevent leakage from oc-
curring.
• Very carefully lift up the rod seal.
• Carefully cut off the rod seal using a knife so that not damage is
caused to the ram.
• Remove the support ring.

40.2.4 Assembling the rod seal and the

support ring.
• Assemble the support ring and rod seal on the piston.

40.2.5 Dismantling the ram

• Remove the rod seal and the support ring.
• Knock and heat the ram a little, if necessary.
• Unscrew the ram using a pipe wrench.
• Brush off any old flange sealant.

40- 2 Service Manual 7FBRE © TIEE SARL

 Reach cylinder – 6650.1
Assembling
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

40.2.6 Assembling the ram

• Apply OMNI 230 on the thread.
• Screw in the ram using a hook spanner.
• Take care to wipe off all surplus sealant.

40.2.7 Assembling the cylinder

• Insert the rod in the cylinder.
• Knock the top sleeve in position on the rod using a rubber
mallet.
• Screw the top sleeve in the cylinder a few turns.
• Apply flange sealant FD 1042 on the thread.
• Tighten using a hook spanner.
• Assemble the cylinder in the truck.
NOTE!
The curing time for the flange sealant is 4 hours and the cylinders
must not be used before this.

40.3 Assembling
• Fit the reach cylinder.
• Knock in the pins.
• Screw in the mounting bolts for the pins.
• Bolt the protective plate in position.
• Fit the connectors X18 and X19 in the connector plate.
• Assemble the hoses on the cylinder.
• Fit the return hose on the tank.
• Bolt on the footboard.
• Close the door and tighten the handle.

© TIEE SARL Service Manual 7FBRE 40- 3

 Reach cylinder – 6650.1
Assembling
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

This page is intentionally left blank

40- 4 Service Manual 7FBRE © TIEE SARL

 Reach cylinder – 6650.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

41- Reach cylinder – 6650.2

41.1 General
The reach cylinder is located in the reach carriage.
The reach cylinder is a double acting cylinder.
The direction of the cylinder is governed by the main valve.

41.2 Assembling and dismantling the

reach cylinder

• Loosen the handle beside the driver seat and swing the door out-
wards.
• Unbolt the footboard.
• Unscrew the return hose from the tank.
• Plug the return hose by the tank.
• Unscrew the hoses from the reach cylinder.
• Unscrew the mounting bolts for the pins.
• Screw in a lifting eye of the like in the pins.
• Pull out the pins.
• Lift out the reach cylinder

© TIEE SARL Service Manual 7FBRE 41- 1

 Reach cylinder – 6650.2
Assembling and dismantling the reach cylinder
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

41.2.1 Dismantling the cylinder

• Place the bottom stud (2) in a vice and let the top section rest against
e.g. a pipe stand so that the cylinder lies in the horizontal position.
• Remove the circlip (13) using the circlip pliers 19-60 mm.
• Carefully knock the top sleeve (9) in the cylinder tube approx. 50-60
mm using a rubber mallet.
NOTE!
If a cylinder is scratched it must be replaced to prevent leakage from
occurring.
• Use a rounded screwdriver to press in one end of the wire locking
ring (12) so that it folds. Slide another screwdriver under the wire
locking ring and pry out the ring using the rounded screwedriver.
NOTE!
Bear in mind that there can still be oil in the cylinder that can come
into contact with the skin or cause environmental problems.
• Carefully pull the rod (6) out of the cylinder so that the threads are
not damaged. Place the rod on a soft and clean surface to prevent
damaged.
• Place the rod on a soft and clean surface.

41- 2 Service Manual 7FBRE © TIEE SARL

 Reach cylinder – 6650.2
Assembling and dismantling the reach cylinder
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

41.2.2 Dismantling the rod

• Secure the rod (6) on the self-aligning bearing bracket (15).
• Dismantle the ram seal (4) from the ram using a rounded screwdriv-
er. Dismantle the guide ring first and then the support ring.
NOTE!
If a ram is scratched it must be replaced to prevent leakage from oc-
curring.
• Heat the ram (3) to over 150 degrees and unscrew it using an adjust-
able hook spanner.
NOTE!
Exercise care. Parts are hot and Loctite can drip on the skin.
• Pull off the top sleeve (9).
• Brush off the threads on the ram and rod.

41.2.3 Dismantle the to sleeve seals

• Knock a screwdriver behind the wiper (14) and lift out.
• Use a screwdriver to dismantle the rod seal (11) from the top sleeve.
• Remove the O-rings (8, 10) and support rings (8,10) from the top
sleeve using a screwdriver.

41.2.4 Assembling the top sleeve

• Fit the rod seal (11).
• Fit the O-rings (8, 10) and the support rings (8, 10).
• Knock down the wiper (14) using a punch (D=37.7x2mm).

41.2.5 Fit the ram seal

• Fit the ram seal (4) using the rounded screwdriver.

41.2.6 Dismantling the rod

• Clamp the rod in a vice by the self-aligning bearing bracket (15).
• Press on the top sleeve (9)
• Fit the damping sleeve (5).
• Place a bead of LOCTITE 270 on the rod thread (6).
• Screw in the ram (3) using the adjustable hook spanner.

© TIEE SARL Service Manual 7FBRE 41- 3

 Reach cylinder – 6650.2
Assembling
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

41.2.7 Assembling the cylinder

• Clamp the cylinder tube in a vice by the self-aligning bearing bracket
(1).
• Lubricate the ram seal (4) and insert in the cylinder tube.
• Knock the top flange in the tube approx. 50-60 mm and fit the wire
locking ring (12).
• Pull out the rod so that the top sleeve (9) is in its outer position.
• Fit the locking ring (13) with the circlip pliers.

41.3 Assembling
• Fit the reach cylinder.
• Knock in the pins.
• Screw in the mounting bolts for the pins.
• Assemble the hoses on the cylinder.
• Fit the return hose on the tank.
• Bolt the protective plate in position.
• Bolt on the footboard.
• Close the door and tighten the handle.

41- 4 Service Manual 7FBRE © TIEE SARL

 Tilt cylinder – 6660.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

42- Tilt cylinder – 6660.1

42.1 General
The fork tilt cylinder is located on the mast behind the lower edge of
the fork yoke.
The cylinder is double acting, which means it is the oil pressure that
moves the ram backwards and forwards in the cylinder. When the ram
is pressed out, the lower edge of the fork yoke is moved outwards and
in doing so the forks are tilted upwards.
This document is divided into two chapters:
• Mast with valve on the fork carriage.
• Mast without valve on the fork carriage.

© TIEE SARL Service Manual 7FBRE 42- 1

 Tilt cylinder – 6660.1
Mast with valve on the fork carriage
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

42.2 Mast with valve on the fork carriage

42.2.1 Dismantling the fork carriage

• Lift up the fork carriage to the right working height.

• Remove the forks.
• Remove the clamping ring to dismantle the side shift (2) or the stay
(1).
• Loosen the bolts (11) and remove the stop lugs (12).
• Secure a lifting strap around the fork yoke (3) and lift out using an
overhead crane.
• Unscrew the bolts (4) and remove the plate (5) and the sliding block
(6).
• Loosen the nut/bolt (15) and unbolt the bolts (10) from the fork car-
riage (13).
• Remove the tilt cylinder.
• Knock out the spiral pin (8) and remove the plate (7).

42- 2 Service Manual 7FBRE © TIEE SARL

 Tilt cylinder – 6660.1
Mast with valve on the fork carriage
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

42.2.2 Dismantling the cylinder

• Unscrew the bolts (16).
• Carefully pull the rod out of the cylinder so that the threads are not
damaged. Place the rod on a soft and clean surface to prevent dam-
aged.
.

42.2.3 Dismantling the rod seal

• Knock a screwdriver in the rod seal without making any marks what-
soever on the ram.
NOTE!
If a ram is scratched it must be replaced to
prevent leakage from occurring.
• Very carefully lift up the rod seal.
• Carefully cut off the rod seal using a knife so that not damage is
caused to the ram.

42.2.4 Dismantling the ram

• Remove the rod seal.
• Knock and heat the ram a little, if necessary.
• Unscrew the ram (3) using pipe wrench 08-15393.
• Brush off any old flange sealant.

42.2.5 Assembling the ram

• Apply OMNI 230 on the thread.
• Screw in the ram using a hook spanner.
• Take care to wipe off all surplus sealant.

© TIEE SARL Service Manual 7FBRE 42- 3

 Tilt cylinder – 6660.1
Mast with valve on the fork carriage
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

42.2.6 Assembling the rod seal

• Press on the rod seal carefully.

42.2.7 Assembling the cylinder

• Insert the rod in the cylinder.
• Tighten with the 8 bolts.

42.2.8 Assembling the fork carriage

• Fit plate (7) and lock in position with the spiral pin (8).
• Fit the tilt cylinder using bolts (10).
• Fit the sliding block (6) and the plate (5) using the bolts (4).
• Lock the sliding block with the bolt/nut (15) so tight that the insert
(14) rotates with difficulty.
• Lift the fork yoke (3) in position using an overhead crane.
• Fit the stop lugs(12) using bolts (11).
• Fit the side-shift (2).
• Fit the forks.

42- 4 Service Manual 7FBRE © TIEE SARL

 Tilt cylinder – 6660.1
Mast without valve on the fork carriage
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

42.3 Mast without valve on the fork

carriage

42.3.1 Dismantling the fork carriage

• Lift up the fork carriage to the right working height.
• Remove the forks.
• Lift up the fork yoke in an overhead crane.
• Unscrew the bolts (4) and washers (3).
• Knock out the axles (5).
• Remove the fork yoke.
• Unscrew the bolts (6) and remove the tilt cylinder.

© TIEE SARL Service Manual 7FBRE 42- 5

 Tilt cylinder – 6660.1
Mast without valve on the fork carriage
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

42.3.2 Dismantling the cylinder

• Unscrew the eight bolts (7).
• Carefully pull the rod out of the cylinder so that the threads are not
damaged. Place the rod on a soft and clean surface so that it is not
damaged.

42.3.3 Dismantling the rod seal

• Knock a screwdriver in the rod seal without making any marks what-
soever on the ram.
NOTE!
If a ram is scratched it must be replaced to
prevent leakage from occurring.
• Very carefully lift up the rod seal.
• Carefully cut off the rod seal using a knife so that not damage is
caused to the ram.

42.3.4 Dismantling the ram

• Remove the rod seal.
• Knock and heat the ram a little, if necessary.
• Unscrew the ram using pipe wrench 08-15393.
• Brush off any old flange sealant.

42.3.5 Assembling the ram

• Apply OMNI 230 on the thread.
• Screw in the ram using a hook spanner.
• Take care to wipe off all surplus sealant.

42- 6 Service Manual 7FBRE © TIEE SARL

 Tilt cylinder – 6660.1
Mast without valve on the fork carriage
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

42.3.6 Assembling the rod seal

• Press on the rod seal carefully.

42.3.7 Assembling the cylinder

• Insert the rod in the cylinder.
• Tighten with the 8 bolts.

42.3.8 Assembling the fork carriage

• Fit the tilt cylinder using bolts (6).
• Lift the fork yoke in position.
• Knock the axles (5) in position.
• Bolt the axles in position using the bolts (4) and washers (3).
• Fit the forks.

© TIEE SARL Service Manual 7FBRE 42- 7

 Tilt cylinder – 6660.1
Mast without valve on the fork carriage
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

42- 8 Service Manual 7FBRE © TIEE SARL

 Tilt cylinder – 6660.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

43- Tilt cylinder – 6660.2

43.1 General
The mast tilt cylinder is located in the reach carriage.
The cylinder is double acting, which means it is the oil pressure that
move the ram backwards and forwards in the cylinder. When the ram is
pressed out, it moves the fork yoke’s mast outwards and in doing so the
forks are tilted upwards.

43.2 Assembling and dismantling the

tilt cylinder

• Move the mast out to its outer position.

• Lift the mast so that the front bracket on the tilt cylinder can be ac-
cessed.
• Dismantle the cover plate on the reach carriage.
• Unscrew the return hose from the tank.
• Plug the return hose by the tank.

© TIEE SARL Service Manual 7FBRE 43- 1

 Tilt cylinder – 6660.2
Assembling and dismantling the tilt cylinder
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

• Unscrew the hoses from the tilt cylinder.

• Fit the protective plugs on the hoses.
• Secure the mast so that it cannot fall backwards when the cylinder
is removed.
• Unscrew the mounting bolts for the pins.
• Screw an extractor in the pins.
• Pull out the pins.
• Remove the tilt cylinder.

43.2.1 Dismantling the cylinder

• Place the cylinder, by the self-aligning bracket (1), in a vice and let
the other section rest against e.g. a pipe stand so that the cylinder
lies in the horizontal position.
• Unscrew the top sleeve (10) using a hook spanner.
(68-75 mm).
• Pull the rod (6) out of the cylinder tube (2).
NOTE!
Bear in mind that there can still be oil in the cylinder that can come
into contact with the skin or cause environmental problems.
• Place the rod on a soft and clean surface so that it is not damaged.

43- 2 Service Manual 7FBRE © TIEE SARL

 Tilt cylinder – 6660.2
Assembling and dismantling the tilt cylinder
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

43.2.2 Dismantling the rod

• Secure the rod (6) on the self-aligning bearing bracket (11).
• Dismantle the ram seal (4) from the ram using a rounded screwdriver.
NOTE!
If a ram is scratched it must be replaced to prevent leakage from oc-
curring.
• Heat the ram (3) to over 150 degrees and unscrew it using an adjust-
able hook spanner.
NOTE!
Exercise care.
Parts are hot and Loctite can drip on the skin.
• Pull off the top sleeve (8).
• Brush off the threads on the ram and rod.

43.2.3 Dismantling the ram seals

• When the ram has cooled remove the O-ring and support ring (5)
from the ram using a screwdriver.

43.2.4 Dismantle the top sleeve seals

• Knock a screwdriver behind the wiper (10) and lift out.
• Use a screwdriver to dismantle the rod seal (9) from the top sleeve.
• Remove the O-ring and support ring (7) from the top sleeve using a
screwdriver.

43.2.5 Assembling the top sleeve

• Assembling the rod seal (9).
• Fit the O-ring and support ring (7).
• Knock down the wiper (10) with a punch (D=44.7 x 3.5 mm).

43.2.6 Assembling the ram seal

• Fit the ram seal (4) using the rounded screwdriver.
• Fit the 0-ring and support rings (5).

43.2.7 Dismantling the rod

• Clamp the rod in a vice by the self-aligning bearing bracket (11).
• Press on the top sleeve (8)
• Place a bead of LOCTITE 270 on the rod thread (6).
• Screw in the ram (3) using the adjustable hook spanner.

© TIEE SARL Service Manual 7FBRE 43- 3

 Tilt cylinder – 6660.2
Assembling
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

43.2.8 Assembling the cylinder

• Clamp the cylinder tube in a vice by the self-aligning bearing bracket
(1).
• Lubricate the ram seal (4) and insert the ram seal in the cylinder
tube.
• Screw in the top sleeve (8) and tighten using a hook spanner.

43.3 Assembling
• Fit the tilt clinder.
• Knock in the pins.
• Screw in the mounting bolts for the pins.
• Assemble the hoses on the cylinder.
• Fit the return on the tank.
• Bolt on the cover plate in the reach carriage.

43- 4 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

44- Main mast – 7100.1

44.1 General
This is an assembly and dismantling instruction for the mast. The docu-
ment also contains a list of tools and instructions how to transport the
truck without the battery installed.
This instruction also describes how to rectify mast play.
There are three runners in a mast the inner, intermediate and outer run-
ners. On the inner and intermediate runners there are four rollers on
each runner. The fork carriage also has four rollers.
It is these rollers that are shimmed so that the play is as little as possi-
ble.

44.2 List of tools

• Overhead crane with a capacity of at least 2500 kg.
• 1/2" ratchet wrench
• 13 mm socket
• 24 mm socket
• 30 mm socket
• 4 mm allen key
• 5 mm allen key
• 1/2" torque wrench 0 - 270 Nm.
• 3/4" torque wrench 0 -500 Nm.
• Crow bar.
• Large screwdriver
• 17 mm combination spanner
• 19 mm combination spanner
• 27 mm combination spanner
• 32 mm combination spanner
• 36 mm combination spanner
• Cloth
• Absorbent
• Cable ties

© TIEE SARL Service Manual 7FBRE 44- 1

 Main mast – 7100.1
Transporting the truck
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

44.3 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 lifting capacity.

Load 7FBRE16 7FBRE20 7FBRE25

Load centre spacing (Tp) 950 1000 1000
Weight without battery 1800 2250 2850

• Insert the forks under the support arms and lift as illustrated in the di-
agram.
Method 2:
To move the truck over short distances you can use an extension cable
from an adjacent battery.

44- 2 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

44.4 Assembling the mast

• Transport the truck to an assembly area with an overhead crane.
• Cut off the steel band around the support legs.
• Lift off the forks.
• Connect 48 V DC to the truck.
• Extend the reach carriage approximately 200 mm.
• Lift off the load support.
• Extend the reach carriage fully.
• Switch off the current using the ignition and disconnect the 48 V DC.
• Remove the protective plate on the reach carriage.
• Loosen the four M16 bolts and remove the upper part of the pin
bracket (see diagram).

© TIEE SARL Service Manual 7FBRE 44- 3

 Main mast – 7100.1
Assembling the mast
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Use the Mast assembly kit that contains the following:

- 2 bolts and 2 washers to secure the mast in the reach carriage on

the bottom mast.
- 2 socket head cap screws that secure the two halves of the pro-
tective plate on the reach carriage.
- 6 bolts for securing the load support.
- 0 – 6 shims for aligning the mast angle forwards and backwards.
The mast should be 90° ± 6’.
- 1 two-part hose clip for the feeder hose in the mast.
• Cut off the steel band on the mast, except the top band.

44- 4 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

• Lift up the mast using an overhead crane and tool

11-1091 för 7FBRE16, 7FBRE20 och
11-1133 för 7FBRE25.

• Guide the mast slowly to the reach carriage (1).

• Stop approximately 100 mm from the reach carriage (1).
• Insert the feeder hose (2) in the reach carriage.
• Guide in the mast fully and lower it so it rests on the pins (3).
• Position the top section of the pin holder and secure loosely with the
four bolts (4).
• Screw in the bolts (5) that hold the mast in the bottom of the reach
carriage, not far so that the shims still have space.
• Position the shims (6) and move the overhead crane in the direction
of the forks so that they fasten with the mast.
• Tighten the bolts (4 and 5) with the following torque

7FBRE16, 20, 25
Pin bracket bolt (4) 222 Nm
Bottom bolt (5) 434 Nm

© TIEE SARL Service Manual 7FBRE 44- 5

 Main mast – 7100.1
Assembling the mast
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Bolt the manifold block on the reach carriage wall.

• Fit the mast feeder hose with the twin hose clip on the reach carriage
wall (7).
• Remove the plugs on the feeder hose (2) and on the main valve (8).
• Fit the feeder hose (2) on the valve (8).
• Connect the side-shift cable in the terminal connection (9) on the
reach carriage.
• Connect the height indication cable in the terminal connection (9) on
the reach carriage.

44- 6 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

10

• Remove the plugs on the tilt hoses.

• Fit the tilt hoses on the side of the mast (10).
• Cut off the upper steel band on the mast.
• Connect 48 V DC to the truck and lift the forks approx. 1000 mm.
• Fit the forks on the fork yoke.
• Place the load support on the forks and secure the lower bolts (11).
• Fold up the load support (12) and secure the remaining bolts (13).
• Tighten the load support to a torque of 45 Nm.
• Bolt on the protective plate (14) above the main valve on reach car-
riage.
• Gather together the cables and hoses so they are not damaged.
• Dry or wipe off any oil spillage on the truck.

© TIEE SARL Service Manual 7FBRE 44- 7

 Main mast – 7100.1
Dismantling the mast
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

44.5 Dismantling the mast

For illustrated references, see section Assembling the mast.
• Always use a collection tray for escaping hydraulic oil and have
cloths at hand when the couplings on the hydraulic hoses are dis-
connected.
• Extend the reach carriage fully.
• Set all hydraulic functions on the mast in the offload position, fork
carriage fully lowered, tilt and side-shift in the
centre positions.
WARNING
Risk of spurting oil
Some parts of the hydraulic system may still hold a residual pressure
despite the system being offloaded.
Make sure there are no other persons in the vicinity of the truck and
that you are standing to the side of the coupling you are about to dis-
connect.
Loosen the hydraulic couplings carefully so that any residual pres-
sure can trickle out.
• Switch off the current and disconnect the battery by pulling out the
battery plug.
• Dismantle, if judged to be necessary, the load support and the forks.
• Dismantle the protective plate above the main valve on the reach
carriage.
• Secure the mast using an overhead crane and tools
11-1091 for 7FBRE16, 7FBRE20 and
11-1133 for 7FBRE25.
• Dismantle the tilt hoses (10) from the mast.
• Fit protective plugs to the tilt hoses and nipples on the mast.
• Disconnect the height indication cable (connector X16) and the side-
shift cable (connector X29) in the terminal connection (9).
• Dismantle the feeder hose (2) from the main valve (8).
• Fit protection plugs on the main valve and feeder hose.
• Dismantle the feeder hose’s hose clip from the reach carriage wall
(7) and loosen the manifold block.
• If the truck is fitted with extra hydraulic functions, loosen the hydrau-
lic hoses from the valve block on the reach carriage. Fit protective
plugs on the hoses and valve block.
• Loosen the mast bolts (5) on the reach carriage and on the cap to
the pin holders (4) a little. Remove the mast shims (6).
NOTE!
Mark the shims from right respective left sides so that the correct
mast angle is obtained when reassembling.

44- 8 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
Adjust the play
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

• Carefully lift the mast out of the pin holder, at the same time as the
feeder hose (2) is eased out of the reach carriage.
• Carefully lower the mast to the floor.
• Place the mast on a pallet on the floor or for a more comfortable
working height on a pair of trestles.
CAUTION!
Unexpected/uncontrolled movement
When the mast is laid down a shifting of the centre of gravity can
mean that the mast slides to the ground.
Ensure no one is within the area in which the mast can move: mast
length + 2 metres safety distance. Always stand to the side of the
mast at a safe distance, as far away as the controls of the overhead
crane will allow.
• Dry or wipe off any oil spillage on the truck.

44.6 Adjust the play

• Dismantle the mast from the truck
NOTE!
Oil leakage.
Risk of valve or cylinder failure if dirt enters the hydraulic connec-
tions.
Plug all hydraulic connections.
• Place the mast horizontally on a number of pallets or the like.

© TIEE SARL Service Manual 7FBRE 44- 9

 Main mast – 7100.1
Adjust the play
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Dismantle the twin hose and connector X5 (1) from the fork carriage.
• Dismantle the twin hose reel (2) from the free lift cylinder.
• Dismantle the twin hose (3) from the mast, but let it remain in the out-
er runner.
• Dismantling the manifold block with the feeder hose (4) from the
feeder pipe to the main lift cylinders.
• Dismantle the feeder hose bracket (5) and the feeder hose (6) from
inner runner.
• Dismantel any chain guard from the bracket

44- 10 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
Adjust the play
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

• Dismantle the free lift chain (7) from the fork carriage and the free lift
cylinder.
• Dismantle the main lift cylinders (8).
• Dismantle the main lift chains (9) but allow them to remain in the out-
er runners.
• Dismantle the main chain sprockets (10) and the twin hose reel (11)
in the bottom of mast.

© TIEE SARL Service Manual 7FBRE 44- 11

 Main mast – 7100.1
Adjust the play
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

• Dismantle the fork carriage (12) from the mast.

• Dismantle the inner runner (13) from the mast with the following lift-
ing yoke:
1600 kg mast use lifting yoke 11-1020
2000 kg mast use lifting yoke 011-1021
Pull out the inner runner, full stroke length and lift out the runner.
• Clean the mast’s component runners and rollers as well as the fork
carriage rollers.

44.6.1 Adjusting the mast play

The mast’s rollers are mounted on angled pins. When the mast is
adjusted with regard to play, adjust as follows:

Lateral play
By shimming the mast rollers the lateral mast play can be adjusted.
- Use an indicator gauge and a crowbar to measure the play.
- Measure the retracted and extended mast.
NOTE!
Max. play on the lower edge is 1 mm.
Max. play on the upper edge is 0.4 mm.
- Dismantle the runners from the mast.
- Dismantle the rollers that need to be shimmed.
- Fit the shims to the roller pins.
- Assemble the rollers.
- Fit the runners in the mast.
- Control measure.
• Secure the intermediate and outer runners next to each other
• Fit the inner runners in the mast.
• Measure and shim as set out in the instructions above.
• Fit the fork carriage in the mast.
• Measure and shim as set out in the instructions above.

44- 12 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.1
Assembling
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

44.6.2 Radial play

• The play between the rollers and the contact surfaces on respective
beams must not exceed 0.4 mm. Check using feeler gauges. If the
play is greater the rollers must be replaced with oversized rollers.
Oversized rollers (classified) are available in increments of 0.4 mm.
• When fitting oversized rollers the play may be <0, under the condi-
tion that the mast can be pushed together/drawn apart by hand,
even if difficult. After a short period of use, the rollers will give an im-
print of the contact surface as play > 0.

44.7 Assembling
• Assemble the free lift chain
• Assemble any chain guard.
• Assemble the main lift cylinders.
• Assemble the main lift chain sprockets.
• Assemble the main lift chains.
• Fit the twin hose and connector X50 in the fork carriage.
• Fit the twin hose roller on the free lift cylinder.
• Fit the manifold block with the feeder hose on the feeder pipe on the
main lift cylinders.
• Fit the feeder hose bracket on the inner runner.
NOTE!
The twin hose can separate.
Risk that the twin hose can break.
Make sure the twin hose rollers are in line.
• Fit the mast in the truck.

© TIEE SARL Service Manual 7FBRE 44- 13

 Main mast – 7100.1
Assembling
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

This page is intentionally left blank

44- 14 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45- Main mast – 7100.2

45.1 General
This is an assembly and dismantling instruction for the mast. The docu-
ment also contains a list of tools and instructions how to transport the
truck without the battery installed.
This instruction also describes how to rectify mast play.
There are two/three runners in a mast the inner, intermediate and outer
runners. On the inner and intermediate runners there are four rollers on
each runner. The fork carriage also has four rollers.
It is these rollers that are shimmed so that the play is as little as possi-
ble.

45.2 List of tools

• Overhead crane with a capacity of at least 2500 kg.
• 1/2" ratchet handle
• 13 mm socket
• 24 mm socket
• 30 mm socket
• 4 mm allen key
• 5 mm allen key
• 1/2" torque wrench 0 - 270 Nm.
• 3/4" torque wrench 0 -500 Nm.
• Crow bar.
• Large screwdriver
• 17 mm combination spanner
• 19 mm combination spanner
• 27 mm combination spanner
• 32 mm combination spanner
• 36 mm combination spanner
• Cloth
• Absorbent
• Cable ties

© TIEE SARL Service Manual 7FBRE 45- 1

 Main mast – 7100.2
Transporting the truck
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

45.3 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 lifting capacity.

Load 7FBRE12
Load centre spacing (Tp) 950
Weight without battery 1700

• Insert the forks under the support arms and lift as illustrated in the di-
agram.
Method 2:
To move the truck over short distances you can use an extension cable
from an adjacent battery.

45- 2 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45.4 Assembling the mast

• Transport the truck to an assembly area with an overhead crane.
• Cut off the steel band around the support legs.
• Connect 48 V DC to the truck.
• Extend the reach carriage approximately 200 mm.
• Lift off the load support.
• Extend the reach carriage fully.
• Switch off the current using the ignition and disconnect the 48 V DC.
• Remove the protective plate on the reach carriage.
• Loosen the four M16 bolts and remove the upper part of the pin
bracket (see diagram).

© TIEE SARL Service Manual 7FBRE 45- 3

 Main mast – 7100.2
Assembling the mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

• Use the Mast assembly kit that contains the following:

1. 2 bearings for the mast pins.

2. Pin and bolt for the tilt cylinder.
3. 2 bolts for securing the load support.
• Cut off the steel band on the mast, except the top band.
• Lift up the mast using an overhead crane and lifting straps.

• Fit the two bushings on the mast pins with the slots facing upwards.

45- 4 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

• Guide in the mast fully and lower it so it rests on the pins (3).
• Position the top section of the pin holder and secure with the four
bolts (4).
• Secure the tilt cylinder temporarily using a 16 mm nut and bolt.
• Fit the stop on the new intermediate runner on the Triplex mast or on
the inner runner on the Duplex mast.
• Lift so that the tilt cylinder bracket becomes free.
• Fit the pin and secure with the bolt.

7FBRE12
Pin bracket bolt (4) 222 Nm

• Remove the plugs on the feeder hose (2) and on the main valve (8).
• Fit the feeder hose (2) on the valve (8).
• Connect the cable for lowering.

© TIEE SARL Service Manual 7FBRE 45- 5

 Main mast – 7100.2
Assembling the mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

• Fit the side-shift hoses to the hose winder on the side of the mast
(10). These are strapped together using the lowering cable.

10

• Lower the mast slowly.

• Connect 48 V DC to the truck and lift the forks approx. 1000 mm.
• Place the load support on the forks and secure the lower bolt (11).
• Fold up the load support (12) and secure the upper bolt (13).
• Tighten the load support to a torque of 45 Nm.
• Bolt on the protective plate (14) above the main valve on reach car-
riage.
• Fit the battery wedges.
• Gather together the cables and hoses so they are not damaged.
• Dry or wipe off any oil spillage on the truck.

45- 6 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Dismantling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45.5 Dismantling the mast

For illustrated references, see section Assembling the mast.
• Always use a collection tray for escaping hydraulic oil and have
cloths at hand when the couplings on the hydraulic hoses are dis-
connected.
• Extend the reach carriage fully.
• Set all hydraulic functions on the mast in the offload position, fork
carriage fully lowered, tilt and side-shift in the
centre positions.
WARNING
Risk of spurting oil
Some parts of the hydraulic system may still hold a residual pressure
despite the system being offloaded.
Make sure there are no other persons in the vicinity of the truck and
that you are standing to the side of the coupling you are about to dis-
connect.
Loosen the hydraulic couplings carefully so that any residual pres-
sure can trickle out.
• Switch off the current and disconnect the battery by pulling out the
battery plug.
• Dismantle the load support if this is judged to be necessary.
• Dismantle the battery wedges and the protective plate above the
main valve on the reach carriage.
• Secure the lifting straps around the mast frame's top beam (A).
• Check that the lifting straps are well secured to the mast.
• Tension the lifting straps by using a lifting device (overhead crane,
crane or truck).
• Loosen the bolts on the mast mounting pins. Note the position of the
shims, the number and size.
• Remove the bolts to the tilt cylinder’s axle and dismantle the axle.
• Disconnect the lowering cable.
• Dismantle the feeder hose (2) from the main valve (8).
• Fit protection plugs on the main valve and feeder hose.
• If the truck is fitted with extra hydraulic functions, loosen the hydrau-
lic hoses from the valve block on the reach carriage. Fit protective
plugs on the hoses and valve block.
NOTE!
Mark the shims from right respective left sides so that the correct
mast angle is obtained when reassembling.
• Carefully lower the mast to the floor.
• Carefully lift out the mast and place it horizontally on a few pallets or
the like. Place the forks upwards, position a support between the
ground and the mast so that it does not rest on the cylinders.

© TIEE SARL Service Manual 7FBRE 45- 7

 Main mast – 7100.2
Dismantling the mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

• Secure the fork carriage in the overhead crane or the like, loosen the
chain on the fork carriage. Pull out the fork carriage downwards.
• Turn the mast so that the cylinders face upwards.
CAUTION!
Unexpected/uncontrolled movement
When the mast is laid down a shifting of the centre of gravity can
mean that the mast slides to the ground.
Ensure no one is within the area in which the mast can move: mast
length + 2 metres safety distance. Always stand to the side of the
mast at a safe distance, as far away as the controls of the overhead
crane will allow.
• Dry or wipe off any oil spillage on the truck.

45.5.1 Chains, cylinders and hoses

• Loosen the mast lifting chain (B).
• Pull the mast a part little.
• Dismantle:
- Sprocket (C) from the bracket (if necessary).
- Couplings and pipe from the mast lifting cylinders (couplings only
if necessary).
- The mast cylinders from the runner.
- Couplings and bracket for the return hose (D) on the free lift cylin-
ders (couplings if necessary).
- The bracket (E) from the free lift cylinder (if necessary).
- Free lift cylinder's lower mounting together with the chain bolt for
the free lift chain.
- Free lift chain and its chain sprocket (F) (if necessary).
- The free lift cylinder (G).

45- 8 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Dismantling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45.5.2 Dismantling the runner

• Remove the runner.
• Dismantle:
- The return hoses from the T-piece at the bottom of the mast.
- The cable tie (I) and return hoses (D).
- Split pin (J), chains (B) and chain sprockets (C) on the top beam
(if necessary).
- The support strip between the top beam and the cylinders.
- The nipples (K) for the return hose (if necessary).
- Hydraulic pipe.
- Pipes and manifold (L).
- The lowering brake valve (M) and couplings from the manifold (L)
(only if necessary).
- The bracket (N) for the manifold on the mast frame.
- The mast lift cylinders
- Couplings and hydraulic pipe from the mast lifting cylinders (cou-
plings only if necessary).
• Remove the runner half way, secure lifting straps in the centre of the
runner. Remove the runner with lifting support from the lifting straps.
• Dismantle:
- Rollers (O).
- Dashpots (P) on the mast frame (only if necessary).

B P
A
C
E G

© TIEE SARL Service Manual 7FBRE 45- 9

 Main mast – 7100.2
Dismantling the mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

45.5.3 Inner guide

• Loosen the mast lifting chains.
• Loosen the bracket for the feeder hose.
• Remove the inner runner.

N
L

M
D I

45- 10 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Dismantling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

Q S

© TIEE SARL Service Manual 7FBRE 45- 11

 Main mast – 7100.2
Dismantling the mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

45- 12 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Assembling Duplex mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45.6 Assembling Duplex mast

45.6.1 Assembly-shimming the side play

• Check the shimming and make any corrective measures so that the
intermediate runner lies 2 mm outside of mast frame.
• Clean any dirt from the mast mounting pins.
• Assemble - shimming the side play
• Initially shim the roller pins approx. 0.5 mm.
• Try the roller class on the beams by running a roller in the beam
opening , use the largest possible roller.
• Assemble the rollers (O).
• Assemble the runner so that the roller spacing is approx. 500 mm,
using an overhead crane.
• Check the play on the rollers by using an indicator gauge on a mag-
netic base. Check how many shims are required to set the least pos-
sible play, maximum 0.4 mm.
• Dismantle the runners if necessary. Reshim the rollers and refit the
runners.
• Check the play on the rollers in the same way as above.
• Slide the runner in its bottom position. Check the play in the bottom
position, maximum play 1 mm in retracted position. At the same time
check that the runner does not jam in any position.
• Attempt to get 0 mm play in the retracted position.
• Remove the runner to lubricate the flanges that the rollers run on
with grease.
• Slide in the runner.
• Assemble:
- Couplings and hydraulic pipes on the mast lifting cylinders.
- The mast lifting cylinders, tighten to a torque of 86.9 Nm.
- The bracket (N) for the manifold (L) on the mast frame.
• Place the manifold (L) in a vice, assemble the lowering brake valve
(M) and couplings.

© TIEE SARL Service Manual 7FBRE 45- 13

 Main mast – 7100.2
Assembling Duplex mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

• Assemble:
- Pipes with the manifold (L).
- The packet on the mast and tighten the hydraulic pipes.
- Nipples (K) for the return hose (D).
- The support strip between the top beam and the cylinders.
- Chains with split pin (Q) and chain sprockets (C) on the top beam
(A).
- Return hoses (D) and attach them to the cylinders using the cable
tie (I).
- Return hoses (D) in the T-piece at the bottom of the mast.
• Slide the runner down to its bottom position. Check the play in the
bottom position, the max play should be 1 mm in the retracted posi-
tion. At the same time check that the runner does not jam in any po-
sition.
• Remove the runner to lubricate the flanges the rollers run on with
grease.
• Slide in the runner.

45.6.2 Inner guide

• Shim according to the instructions under "Assembly - shimming the
side play" for the inner runner.

45.6.3 Chains, cylinders and hoses

Assemble and bolt fast lifting cylinders in position
• Guide in the cylinder in the cylinder clamp (R) and in the lower brack-
et and secure by screwing in the chain bolt (S) for the free lift chain.
• Assemble:
- The bracket (E) on the free lift cylinders (G).
- The chain sprockets (F) on the bracket (E).
• Secure the chains in the chain bolt (S).
• Assemble the couplings and pipes on the mast lifting cylinders.
• Place the mast lifting cylinders on the runner.
• Bolt the mast lifting cylinders in position.
• Assemble:
- Pipe and feeder hose bracket.
- Feeder hose.
- Chain sprockets (C).
- The mast lifting chains (B).

45- 14 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Assembling the Triplex mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45.6.4 Fork carriage

• Turn the mast and do not forget the supports so that the mast does
not rest on the cylinders.
• Repeat the points under "Assembly - shimming the side play" to
shim the fork carriage.
• Secure the chain in the fork carriage.
• Grease the tracks for the rollers.

45.6.5 Docking the mast in the truck

• Follow “Assembling the mast”.

45.7 Assembling the Triplex mast

45.7.1 Assembly-shimming the side play
• Clean the pins.
• Clean the tracks for the rollers.
• Initially shim the roller pins approx. 0.5 mm.
• Try the roller class on the beams by running a roller in the beam
opening. Use the largest possible roller.
• Assemble the rollers.
• Assembling the runners using an overhead crane. Roller spacing
should be approx. 500 mm
• Check the play on the rollers by using an indicator gauge on a mag-
netic base. Check how many shims are required to set the least pos-
sible play, maximum 0.4 mm.
• If necessary dismantle the runner, reshim rollers and reassemble
the runner. Check the play on the rollers in the same way as above.
• Slide the runner in its bottom position. Check the play in the bottom
position, maximum 1mm in the retracted position. At the same time
check that the runner does not jam in any position. Attempt to
get 0 mm of play in the retracted position.
• Remove the runner to lubricate the flanges that the rollers run on
with grease. Slide in the runner.
• Check, and if necessary, shim the dashpot on the mast top beam so
that the intermediate runner lies 2 mm outside of the mast frame.
• Assemble:
- Couplings and the hydraulic pipes on the mast cylinders if they
have been dismantled.
- The mast lifting cylinders, tighten to a torque of 87 Nm.
- The bracket (N) for the manifold (L) on the mast frame.
• Place the manifold (L) in a vice, assemble the lowering brake valve
(M) and couplings.
© TIEE SARL Service Manual 7FBRE 45- 15
 Main mast – 7100.2
Assembling the Triplex mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

• Assemble:
- The packet in the mast and adjust the switch according to the
same drawing and route the hydraulic pipes.
- Nipples (K) for the return hose (D).
- The support strip between the top beam and the cylinders.
- Chains (B) using the split pin (Q) and the chain sprockets (C) on
the top beam (A).
- Return hoses (D) and attach them to the cylinders using the cable
tie (I).
- Return hoses (D) in the T-piece at the bottom of the mast.
• Slide in the runner to its bottom position. Check the play in the bot-
tom position, maximum play must be 1mm in the retracted position.
At the same time check that the runner does not jam in any position.
• Remove the runner to lubricate the flanges the rollers run on with
grease.
• Slide in the runner.

45.7.2 Inner guide

• Shim according to the instructions under "Assembly - shimming the
side play" for the inner runner.
• Place the free lift chain in the inner runner's top beam and assemble
its chain sprocket (F).

45.7.3 Chains, cylinders and hoses

Assemble and bolt fast the lifting cylinders in position
• Guide in the cylinder in the cylinder clamp (R) and in the lower brack-
et and secure by screwing in the chain bolt (S) for the free lift chain.
• Assemble:
- The bracket (E) on the free lift cylinder and tighten to a torque of
152 Nm.
- Couplings (K) and the bracket for the return hose (D) on the free
lift cylinder.
- The chain sprocket (F) in the bracket (E).
• Bolt the mast lifting cylinders in position.
• Turn the mast and do not forget the supports so that the mast does
not rest on the cylinders.
• Assemble:
- Pipe and feeder hose bracket.
- Feeder hose.
- Chain sprockets (C).
- The mast lifting chains (B).

45- 16 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.2
Assembling the Triplex mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 689-690

45.7.4 Fork carriage

• Shim according to the instructions under "Assembly – shimming the
side play" to adjust the lateral fork carriage play.
• Secure the chains in the chain bolt (S).
• Secure the chains in the fork carriage.
• Now dock the mast in truck according to point "Assembling the
mast".

© TIEE SARL Service Manual 7FBRE 45- 17

 Main mast – 7100.2
Assembling the Triplex mast
T-code Valid from serial number Date Order number
689-690 423260- 2005-07-01 201004-040

This page is intentionally left blank

45- 18 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.3
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 691-692

46- Main mast – 7100.3

46.1 General
This is an assembly and dismantling instruction for the mast. The docu-
ment also contains a list of tools and instructions how to transport the
truck without the battery installed.
This instruction also describes how to rectify mast play.
There are three runners in a mast the inner, intermediate and outer run-
ners. On the inner and intermediate runners there are four rollers on
each runner. The fork carriage also has four rollers.
It is these rollers that are shimmed so that the play is as little as possi-
ble.

46.2 List of tools

• Overhead crane with a capacity of at least 2500 kg.
• 1/2" ratchet handle
• 13 mm socket
• 24 mm socket
• 30 mm socket
• 4 mm allen key
• 5 mm allen key
• 1/2" torque wrench 0 - 270 Nm.
• 3/4" torque wrench 0 -500 Nm.
• Crow bar.
• Large screwdriver
• 17 mm combination spanner
• 19 mm combination spanner
• 27 mm combination spanner
• 32 mm combination spanner
• 36 mm combination spanner
• Cloth
• Absorbent
• Cable ties

© TIEE SARL Service Manual 7FBRE 46- 1

 Main mast – 7100.3
Transporting the truck
T-code Valid from serial number Date Order number
691-692 423260- 2005-07-01 201004-040

46.3 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 lifting capacity.

Load 7FBRE14
Load centre spacing (Tp) 950
Weight without battery 1800

• Insert the forks under the support arms and lift as illustrated in the di-
agram.
Method 2:
To move the truck over short distances you can use an extension cable
from an adjacent battery.

46- 2 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.3
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 691-692

46.4 Assembling the mast

• Transport the truck to an assembly area with an overhead crane.
• Cut off the steel band around the support legs.
• Lift off the forks.
• Connect 48 V DC to the truck.
• Extend the reach carriage approximately 200 mm.
• Lift off the load support.
• Extend the reach carriage fully.
• Switch off the current using the ignition and disconnect the 48 V DC.
• Remove the protective plate on the reach carriage.
• Loosen the four M16 bolts and remove the upper part of the pin
bracket (see diagram).

© TIEE SARL Service Manual 7FBRE 46- 3

 Main mast – 7100.3
Assembling the mast
T-code Valid from serial number Date Order number
691-692 423260- 2005-07-01 201004-040

• Use the Mast assembly kit that contains the following:

1
4

1. 2 bolts and 2 washers to secure the mast in the reach carriage

on the bottom mast.
2. 6 bolts for securing the load support.
3. 0 – 6 shims for aligning the mast angle forwards and back-
wards. The mast should be 90° ± 6’.
4. 1 two-part hose clip for the feeder hose in the mast.
• Cut off the steel band on the mast, except the top band.
• Lift up the mast using an overhead crane and tool
11-1091.

• Guide the mast slowly to the reach carriage (1).

• Stop approximately 100 mm from the reach carriage (1).
46- 4 Service Manual 7FBRE © TIEE SARL
 Main mast – 7100.3
Assembling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 691-692

• Insert the feeder hose (2) in the reach carriage.

• Guide in the mast fully and lower it so it rests on the pins (3).
• Position the top section of the pin holder and secure loosely with the
four bolts (4).
• Screw in the bolts (5) that hold the mast in the bottom of the reach
carriage, not far so that the shims still have space.
• Position the shims (6) and move the overhead crane in the direction
of the forks so that they fasten with the mast.
• Tighten the bolts (4 and 5) with the following torque:

7FBRE14
Pin bracket bolt (4) 222 Nm
Bottom bolt (5) 434 Nm

• Bolt the manifold block on the reach carriage wall.

• Fit the mast feeder hose with the hose clip on the reach carriage
wall.
• Remove the plugs on the feeder hose (2) and on the main valve (8).
• Fit the feeder hose (2) on the valve (8).
• Connect the side-shift cable in the terminal connection (9) on the
reach carriage.
• Connect the cable for the lowering switch.

© TIEE SARL Service Manual 7FBRE 46- 5

 Main mast – 7100.3
Assembling the mast
T-code Valid from serial number Date Order number
691-692 423260- 2005-07-01 201004-040

10

• Remove the plugs on the tilt hoses.

• Fit the tilt hoses on the side of the mast (10).
• Cut off the upper steel band on the mast.
• Connect 48 V DC to the truck and lift the forks approx. 1000 mm.
• Fit the forks on the fork yoke.
• Place the load support on the forks and secure the lower bolts (11).
• Fold up the load support (12) and secure the remaining bolts (13).
• Tighten the load support to a torque of 45 Nm.
• Bolt on the protective plate (14) above the main valve on reach car-
riage.
• Gather together the cables and hoses so they are not damaged.
• Dry or wipe off any oil spillage on the truck.

46- 6 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.3
Dismantling the mast
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 691-692

46.5 Dismantling the mast

For illustrated references, see section Assembling the mast.
• Always use a collection tray for escaping hydraulic oil and have
cloths at hand when the couplings on the hydraulic hoses are dis-
connected.
• Extend the reach carriage fully.
• Set all hydraulic functions on the mast in the offload position, fork
carriage fully lowered, tilt and side-shift in the
centre positions.
WARNING
Risk of spurting oil
Some parts of the hydraulic system may still hold a residual pressure
despite the system being offloaded.
Make sure there are no other persons in the vicinity of the truck and
that you are standing to the side of the coupling you are about to dis-
connect.
Loosen the hydraulic couplings carefully so that any residual pres-
sure can trickle out.
• Switch off the current and disconnect the battery by pulling out the
battery plug.
• Dismantle the load support and forks, if this is judged to be neces-
sary.
• Dismantle the protective plate above the main valve on the reach
carriage.
• Secure the mast using an overhead crane and tool 11-1091.
• Dismantle the tilt hoses (10) from the mast.
• Fit protective plugs to the tilt hoses and nipples on the mast.
• Disconnect the lowering cable.
• Dismantle the feeder hose (2) from the main valve (8).
• Fit protection plugs on the main valve and feeder hose.
• Dismantle the feeder hose’s hose clip from the reach carriage wall
(7) and loosen the manifold block.
• If the truck is fitted with extra hydraulic functions, loosen the hydrau-
lic hoses from the valve block on the reach carriage. Fit protective
plugs on the hoses and valve block.
• Loosen the mast bolts (5) on the reach carriage and on the cap to
the pin holders (4) a little. Remove the mast shims (6).
NOTE!
Mark the shims from right respective left sides so that the correct
mast angle is obtained when reassembling.
• Carefully lift the mast out of the pin holder, at the same time as the
feeder hose (2) is eased out of the reach carriage.
• Carefully lower the mast to the floor.

© TIEE SARL Service Manual 7FBRE 46- 7

 Main mast – 7100.3
Adjust the play
T-code Valid from serial number Date Order number
691-692 423260- 2005-07-01 201004-040

• Place the mast on a pallet on the floor or for a more comfortable

working height on a pair of trestles.
CAUTION!
Unexpected/uncontrolled movement
When the mast is laid down a shifting of the centre of gravity can
mean that the mast slides to the ground.
Ensure no one is within the area in which the mast can move: mast
length + 2 metres safety distance. Always stand to the side of the
mast at a safe distance, as far away as the controls of the overhead
crane will allow.
• Dry or wipe off any oil spillage on the truck.

46.6 Adjust the play

• Dismantle the mast from the truck
NOTE!
Oil leakage.
Risk of valve or cylinder failure if dirt enters the hydraulic connec-
tions.
Plug all hydraulic connections.
• Place the mast horizontally on a number of pallets or the like.

46- 8 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.3
Adjust the play
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 691-692

• Dismantle:
- Dismantle the twin hose and connector X50 (1) from the fork car-
riage.
- The twin hose reel (2) from the free lift cylinder.
- The twin hose (3) from the mast, but let it remain in the outer run-
ner.
- The manifold block with the feeder hose (4) from the feeder pipe
to the main lift cylinders.
- The feeder hose bracket (5) and the feeder hose (6) from inner
runner.

© TIEE SARL Service Manual 7FBRE 46- 9

 Main mast – 7100.3
Adjust the play
T-code Valid from serial number Date Order number
691-692 423260- 2005-07-01 201004-040

46- 10 Service Manual 7FBRE © TIEE SARL

 Main mast – 7100.3
Adjust the play
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 691-692

• Dismantle:
- Any chain guard from the bracket
- The free lift chain (7) from the fork carriage and the free lift cylin-
der.
- The main lift cylinders (8).
- The main lift chains (9) but allow them to remain in the outer run-
ners.
- The main chain sprockets (10) and the twin hose reel (11) in the
bottom of mast.
• Dismantle:
- The fork carriage (12) from the mast.
- The inner runner (13) from the mast with the following lifting yoke:
11-1020
Pull out the inner runner, full stroke length and lift out the runner.

• Clean the mast’s component runners and rollers as well as the fork
carriage rollers.

46.6.1 Adjusting the mast play.

The mast’s rollers are mounted on angled pins. When the mast is
adjusted with regard to play adjust as follows:

Lateral play
• By shimming the mast rollers the lateral mast play can be adjusted.
- Use an indicator gauge and a crowbar to measure the play.
- Measure the retracted and extended mast.
NOTE!
Max. play on the lower edge is 1 mm.
Max. play on the upper edge is 0.4 mm.
• Dismantle:
- The runner from the mast.
- The rollers that need to be shimmed.
• Assemble:
- The shims on the roller pins.
- The rollers.
- The runner in the mast.
© TIEE SARL Service Manual 7FBRE 46- 11
 Main mast – 7100.3
Assembling
T-code Valid from serial number Date Order number
691-692 423260- 2005-07-01 201004-040

• Control measure.
• Secure the intermediate and outer runners next to each other
• Fit the inner runners in the mast.
• Measure and shim as set out in the instructions above.
• Fit the fork carriage in the mast.
• Measure and shim as set out in the instructions above.

46.6.2 Radial play

• The play between the rollers and the contact surfaces on respective
beams must not exceed 0.4 mm. Check using feeler gauges. If the
play is greater the rollers must be replaced with oversized rollers.
Oversized rollers (classified) are available in increments of 0.4 mm.
• When fitting oversized rollers the play may be <0, under the condi-
tion that the mast can be pushed together/drawn apart by hand,
even if difficult. After a short period of use, the rollers will give an im-
print of the contact surface as play > 0.

46.7 Assembling
• Assemble:
- Free lift chain.
- Any chain guard.
- The main lift cylinders.
- The main lift chain sprockets.
- The main lift chains.
- The twin hose and connector X50 in the fork carriage.
- Twin hose reel on the free lift cylinder.
- Manifold block with the feeder hose on the feeder pipe on the
main lift cylinders.
- Feeder hose bracket on inner guide.
NOTE!
The triple hose can separate.
Risk that the triple hose can break.
Make sure the triple hose rollers are in line.
• Fit the mast in the truck.

46- 12 Service Manual 7FBRE © TIEE SARL

 Main lift chain system – 7120
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

47- Main lift chain system – 7120

47.1 General
Applies to all machines with a mast.
NOTE!
On machines with T-code 407 7FBRE25 and 408 7FBRE25C the chains
should be replaced every 2.5 years.

47.2 Checking the chain setting

The lift chains must be adjusted at regular periods due to stretching,
see below. The chain setting is checked during servicing as set out in
the maintenance schedule.
Any adjustment is made with the chain mounting bolts.
Adjust the fork height according to C code 7100, 7420, 7700 and 7800
as applicable.

47.3 Chain inspection

The chains are exposed to two types of wear, outline wear and stretch-
ing. Wear to the bolts and disc holes is caused by stretching. The
chains are also affected by the environment they are used in.

47.3.1 Noise
If lubrication has been insufficient there will be metallic friction on the
chain and this will result in noise.
The chain should be replaced.

47.3.2 Surface rust

Surface rust is easy to recognize as the chain will be reddish brown.
Deep-seated rust has generally started and the chain has impaired
strength.
The chain should be replaced

47.3.3 Rusty links

Fretting corrosion results in a reddish brown powder being visible by
the outer discs. It can also appear as if the chain is bleeding when lubri-
cated.
The chain should be replaced.

© TIEE SARL Service Manual 7FBRE 47- 1

 Main lift chain system – 7120
Chain inspection
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

47.3.4 Stiff links

If it is not possible to pull out the chain to its normal position this can be
because of link rust or seizing.
The chain should be replaced.

47.3.5 Bolt rotation

Bolt rotation can be a phenomenon of stiff links. The fault is easy to see
when comparing with a new chain.
The chain should be replaced
.

47.3.6 Loose bolts

If a bolt is loose it will protrude from the side of the chain, which is due
to a stiff link or bolt rotation.
The chain should be replaced.

47- 2 Service Manual 7FBRE © TIEE SARL

 Main lift chain system – 7120
Chain inspection
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

47.3.7 Outline wear

H2 H3

P = Pitch
H2 = Nominal disc height.
H3 = Minimum disc height.
A new lift chain has a specific nominal disc height, defined as H2 in the
figure. As the truck is used the lift chain wears radically, on the side that
runs over the chain sprocket. The minimum disc height is define as H3
in the figure and denotes the minimum permitted value of the disc
height.
Maximal permitted outline wear is 5% of the height H2. If a lift chain
reaches the maximum level of wear, the chain should be replaced.
The nominal and minimum disc heights for respective lift chains are
stated in the table in the chapter “Stretching”.

© TIEE SARL Service Manual 7FBRE 47- 3

 Main lift chain system – 7120
Chain inspection
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

47.3.8 Stretching
The amount of stretch on a lift chain is measured on the part of the
chain that runs over the chain sprocket. The amount of stretch may, at
the most, be 2% on the most worn section of the chain. Measurement is
suitably made over 300-1000 mm of the chain.
The nominal and maximum permitted chain lengths for lift chains are
stated in the table below.

Type of Nominal Minimum Pitch P Nominal chain Maximum permitted

chain disc height disc height (mm) length for 20/30/ chain length for 20/
H2 ( mm) H3 (mm) 50 discs (mm) 30/50 discs (mm)
3/4”, 2x3 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 3x4 17.8 16.9 19.05 381/572/953 389/583/972
3/4”, 4x6 17.8 16.9 19.05 381/572/953 389/583/972
1”, 4x4 23,6 22,4 25,4 508/762/1270 518/777/1295
1”, 6x6 23,6 22,4 25,4 508/762/1270 518/777/1295
Wear to the bolts and around the holes on the discs are a reason why
the chain stretches. The chain should be replaced if stretching is
more than 2%.

47.3.9 Damage
The chain should be replaced if damaged in any way.

47- 4 Service Manual 7FBRE © TIEE SARL

 Main lift chain system – 7120
Cleaning
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

47.3.10 Damaged discs

If a disc has broken on the chain, this can be due to overloading or cor-
rosion.
The chain should be replaced.

47.3.11 Damaged bolts

It can be difficult to discover whether a bolt has broken. It can appear as
bolt rotation and/or that the outer disc is loose.
The chain should be replaced.

47.3.12 Dirty chain

If a chain is very dirty it is first and foremost recommended that it is
replaced. It can also be dismantled and cleaned as set out in the chap-
ter “Cleaning”.

47.4 Cleaning
If a chain is very dirty it is recommended that it is replaced.
Dirty chains should be cleaned before they are lubricated, e.g. by
washing with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated
directly after cleaning
NOTE!
Exercise care with degreasing agent as these can contain abrasives.

© TIEE SARL Service Manual 7FBRE 47- 5

 Main lift chain system – 7120
Lubrication
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

47.5 Lubrication
Mineral and synthetic oils can be used to relubricate Rexnord chains.
NOTE!
Lubricant must not contain substances such as molybdenum disul-
phide, PTFE or the like.
A lift chain should be offloaded from the weight of the fork carriage
(hanging free) when lubricated.
• Lubrication intervals:
- 500 hours with normal operations
- 100 hours when driving in rugged environments such as cold
stores and corrosive environments.
The chains are sprayed with lubricant. Note the entire chain must be
lubricated, even the fastening bolts. It is especially important that the
part of the chain which runs over the chain sprocket is well lubricated.
The lubricate must comply with the viscosity demands at respective
temperatures as set out in the table below. The following lubricants are
recommended:
Ambient Viscosity Recommended Products*
temperature class
> - 40°C VG 15 Klüberoil 4UH 1-15, Klüber
Lubrication
< - 30°C
> - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber
Lubrication
< + 5°C
Anticorit LBO 160 TT, Fuchs
DEA
> + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber
Lubrication
< + 45°C
Anticorit LBO 160, Fuchs DEA
Rexoil, Rexnord Kette
>+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber
Lubrication
<+ 80°C
* Equivalent products from another manufacturer may be used.
NOTE!
Do not use a special rust protective agent to prevent
rust on the lift chains.
These agents impair the lubrication of the chains. Regular lubrication
is the best method to prevent rust attack.

47- 6 Service Manual 7FBRE © TIEE SARL

 Battery charger – 8340
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

48- Battery charger – 8340

48.1 General
This is a technical description of the battery charger BTM. BTM is a
microprocessor controlled Wa charger intended for open lead acid bat-
teries. Wa-charger means that the charging current is high when charg-
ing begins to then drop as the battery voltage increases. The micro-
processor monitors the charging process and ensures the battery
receives the right charge irrespective of the depth of discharge, temper-
ature and age. The computer registers the charging output and limits it
if necessary through temporarily shutting down. The display shows the
voltage, current, charged Ah, ampere-hours, charging time, etc. The
statistics from the charging process are saved.

48.2 Installation
• Make sure the charger is placed in a dry area.
• Make sure the charger’s ventilation holes are not covered.
• Hang small chargers on the wall.
• Place large chargers on the floor.
• Check the charger’s rating plate to see the mains voltage it is intend-
ed for.
NOTE:
The charger’s transformer has a relatively high starting current,
which is why slow burn fuses must be used.
There is a switching option inside the enclosure for high or low mains
voltage and high or low charging current. This may only be adjusted by
qualified personnel. The battery and mains voltage should then be dis-
connected.

© TIEE SARL Service Manual 7FBRE 48- 1

 Battery charger – 8340
Functional description
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

48.3 Functional description

48.3.1 Display functions

Program versions 1.20-1F, 1.20-2F and 1.20-3F contain functions to
show information in plain text. Only a few languages are available.
Consequently, the program also contains functions to simulate a
numerical display with codes. If the display show plain text in a lan-
guage you do not understand, make sure the program version is 1.20-
xF or later, the last letter is the edition. The program’s version is shown
when the charger is started.
To switch to the numerical display proceed as follows:
• Press the # key until the display shows the text “language“. Now
press 2 followed by # and *. Wait a few seconds. Switch off and re-
start the charger. The display now acts as a numerical display.

48.3.2 Charging process

• Connect the charger to the battery.
• Set the mains switch in position 1.
The display now briefly shows the program version, e.g. 1.21. During
this time the computer checks the counter-voltage, mains voltage, the
charger’s temperature, etc. Charging starts and the charger’s status is
shown using three LEDs. The display shows the charging current and
an orange LED lights. At some times the computer stops the charging
and gathers measurement data, which is used to calculate correct
recharging. The fan starts and stops depending on the temperature.
Abnormal events during charging are registered, one or more LEDs
flash and an error message is displayed. Important information about
the charging process is stored, if a power failure occurs. Charging takes
place from the right level when the mains power is restored.
When the computer has calculated the correct recharge level based on
the collected measurement data the yellow LED lights until the battery
is fully charged. Charging is switched off and the green LED lights.
When the battery voltage has fallen to the set value (normally 2.17 V/
cell) a maintenance charging pulse is started and runs for two minutes.
The time between two pulses is never less than 30 minutes irrespec-
tive of the battery voltage.
Gathered measurement data is stored in a non volatile memory. This
data can be read off on the display at any time by using the keyboard.
NOTE:
Old values are written over during a new charging process.

48- 2 Service Manual 7FBRE © TIEE SARL

 Battery charger – 8340
Functional description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

48.3.3 Shutdown conditions

The most important demand on the charger’s function is that shutdown
takes place when the battery has received the correct charge. BTM has
parallel running shutdown programs. The program monitors that the
correct ampere-hours are charged.

48.3.4 Delayed power on and charging

There are two functions to delay the start of the charger.
The first can be programmed from 0–31 seconds and is activated each
time the charger starts. Some program versions show the remaining
time on the display. This function prevents several chargers restarting,
if a power failure occurs during charging, simultaneously resulting is a
fuse blowing.
The other can be programmed between 0–7 hours and is activated only
with a new charging process. Some program versions show the
remaining time on the display. This function makes it possible to charge
the battery during off peak periods.

48.3.5 Extra charging

The function is only available in program version 1.19 or later.
The function restarts the charger after a programmable number of
hours, at least six hours after the start of a new charging process. Extra
charging acts as if a battery change has taken place and is intended to
give a fresher battery after a weekend.
Example: The battery is put on charge on Friday at 5.00 p.m. and the
extra charge starts after 56 hours, default value, at 1.00 a.m. on Mon-
day morning. The function shuts down automatically when the battery
is fully charged.

48.3.6 Equalised charging

The function is only available in program version 1.19 or later.
The function charges 20% of the programmed battery capacity at the
earliest six hours after the end of the normal charge. The equalising
charge can only continue for five hours and only takes place once per
programming session. The function is erased after the equalising
charge is complete, and must be reprogrammed when the equalising
charge is required. The equalising charge is only used a few times per
year to counteract unequal cell voltage and sulphating.

48.3.7 Current and voltage characteristics

The charger’s direct voltage varies with the load and is 2.0 – 2.1 V/cell
at 100% current and 2.55 – 2.65 V/cell at 25% current. The voltage var-
ies with the mains voltage and temperature.

© TIEE SARL Service Manual 7FBRE 48- 3

 Battery charger – 8340
Functional description
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

48.3.8 Safety shutdowns

The computer switches off the main contactor if anything abnormal
occurs to prevent damage to the battery and other components.
Temporary shutdowns occur with:
• Incorrect mains voltage.
• Too high charging output.
• Too high temperatures.
Definite shutdown takes place and maintenance charging is connected
if the following occurs:
• Recharging capacity is too high.
• Charging with voltage over 2.37 V/cell, more than 6 hours, without
approved measurement values. The function “cold storage charg-
ing“ (charging of cold batteries) permits 8 hours.
Shutdown takes place and maintenance charging is disconnected if:
• The battery is faulty.
• The charging current’s momentary value is higher than double the
rated current.
• The battery is disconnected without the mains switch being switched
off.
If the computer fails, charging is cut by a separate total time circuit after
12 hours without contactor connection.

48.3.9 Display and keyboard

The charger’s panel contains, among others, a display, keyboard and
three LEDs.
• The LEDs show the current charging phase and any errors.
• The display shows different measurement values and the gathered
data. During charging the display shows the normal charging current
and during measurement and resting the battery voltage.
• You can control the displayed information and program the compu-
ter from the keyboard.

48- 4 Service Manual 7FBRE © TIEE SARL

 Battery charger – 8340
Functional description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Reading of analogue measurement values

You can read off the analogue measurement values during the current
charge on the display. The significance of the codes is shown in the fol-
lowing table:
• Press * code *.
:

Code The display shows

10 The voltage on the charger’s output (V)
11 Total charging time during the main and post charging
(hh.mm)
12 Recharged ampere-hours (Ah)
13 Charging time with voltage under 2.37 V/cell (hh.mm)
14 Charging time with voltage over 2.37 V/cell (hh.mm)
15 Charging current (A)
16 Mains voltage (VAC)
17 Air temperature around the mother board (°C)
18 Temperature on one of the wound units (transformer in
V2-V3, choke in others) (°C)
19 Temperature on one of the diode heatsinks (°C)

© TIEE SARL Service Manual 7FBRE 48- 5

 Battery charger – 8340
Functional description
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Error indication and error messages

When one or more LEDs flash an error has occurred, after which the
display automatically, or after pressing the # key, shows the error
codes. Older program versions demand the # key to be pressed once
per error code.

Code Error messages

E01 Error code has been entered
E02 Entered value is too large
E03 Error in EE-prom
E10 Mains error
E11 Direct voltage error
E12 Interrupted secondary fuse
E13 Safety shutdown
E14 High temperature
E17 Error in EE-prom
E20 Great need of maintenance charging
E21 High counter-voltage, across 2.4 V/cell
E22 Low counter-voltage, across 1.8 V/cell
E23 Overcurrent, more than double the rated current
E25 Too low current, less than 1% of the rated current
E26 Tripped secondary fuse
E30 High temperature, on transformer or choke
E31 High temperature on the diode heatsink
E32 High ambient temperature
E36 Fan fault
E40 Too low current, less than 1% of the rated current
E43 Charged capacity> programmed capacity × recharging
factor
E44 Long charging time with voltage over 2.37 V/cell
E52 Phase missing on 3 phase charger
E60 Checksum error in EE-prom
E61 Keyboard error. Key pressed > 20 seconds
E62 Communication error with printer

48- 6 Service Manual 7FBRE © TIEE SARL

 Battery charger – 8340
Functional description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Code Error messages

E63 Error in EE-prom
E67 Battery acknowledgement error
E70 Data in the mother board’s EE-prom is not valid
E72 Error in the mother board’s EE-prom
E76 Error in EE-prom
E77 The content in the computer board’s and the mother
board’s EE-prom is not the same.

Reading statistics from the previous charge

The statistics remain in the system until a new charging process is
started or the battery is replaced. The statistics are stored in a register
with a three-digit number in the range 290–500. The most important are
shown in the following table.
• Press * register number *.

Register Function (resolution, unit)

290 Voltage before start, 10 mV/cell.
291 Start current, % of the charger’s rated current.
320 Final voltage, 10 mV/cell.
321 Final current, % of the charger’s rated current.
340 Calculated withdrawn capacity, Ah
360 Total recharged capacity, non maintenance charge,
including recharging factor, Ah

© TIEE SARL Service Manual 7FBRE 48- 7

 Battery charger – 8340
Functional description
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Reading of long term statistics

BTM saves statistics of how the battery and charger have been utilised
from a long term perspective. The recharging factor is discarded in
these statistics.
Battery utilisation can be read from five registers. Depending on the
depth of discharge, each charge is stored in one of these registers.
The limits shown in the following table are delivery settings, but can be
changed.
• Press * register number *.

Register Number of cycles with utilised capacity

610 0-30% of the programmed battery capacity
620 31-50% of the programmed battery capacity
630 51-70% of the programmed battery capacity
640 71-90% of the programmed battery capacity
650 over 90 % of the programmed battery capacity

Register Function
660 Total recharged Ah
670 Total recharged Ah × 65535
760 Number of charges shutdown due to too long time
over 2.37 V/cell

Storing parameters
Parameters used by the program and that can be changed are stored in
a parameter memory (EE-prom). This type of memory holds informa-
tion when switched off, yet permits the contents to be changed.
Chargers with program version 1.19 or later contain two EE-proms for
secure data storage. Important data is stored in both and is monitored
by a special program function that warns of non conformity. If an error
should occur in one of the memories, the program automatically copies
data from the other memory.
If an intentional change is made, e.g. while programming, the program
approves this, but warns that the change has only be written to one of
the memories (E77).
Older chargers with only one EE-prom store information in two sepa-
rate areas of the memory. If the contents of these memory areas are not
the same the program gives a warning through the error code E.60.

48- 8 Service Manual 7FBRE © TIEE SARL

 Battery charger – 8340
Functional description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Once all the changes have been made a copy-over can be made with
code 22.
• Press * 22 * 2451 *.
2451 is a safety code to avoid data being changed unintentionally. If
charging is in progress the contactors release during the actual copying
process.

Reading parameters
The program and component circuit boards have the same design irre-
spective of the charger’s rated voltage or current. Values are set by
storing parameters concerning the battery and charger in the parame-
ter memory (EE-prom). These values are written during final testing of
the device.
NOTE:
There are other parameters that are set at the factory and are not de-
scribed here. Default values are values written during the functions
basic programming. The significance of the register is shown in the
following table:
• Press * register *.

Battery specific parameters

Register Function (resolution, unit) Default

value
200 Battery capacity, Ah 0
210 Recharging factor, % 15
230 No. of cells 0
220 Current that loads the battery during charging, 100 mA 0
224 Cold storage operations, 0 = no, 1 = yes 0
2151) Start voltage for maintenance charging pulse, 10 mV/cell. 217

2041) Lower statistic level ((25 + (y×5))%) 1

y=at value between 1 and 15, e.g. ((25 + (2×5))%)=35%
2051) Statistic range ((z×2)%) 10
z=optional value for the required range, e.g. ((10×2)%)=20%

1) Only applies to program version 1.19 or later.

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 Battery charger – 8340
Functional description
T-code Valid from serial number Date Order number
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Charger specific parameters

Register Function Default

value
232 Charger’s rated current, A 0
240 Mains voltage code, see separate table 9

2131) Extra charging, 0 = no, 1 = yes 1

2251) Time for extra charging, hours 56

2171) Equalising charge , 0 = no, 1 = yes 0

2161) Pause in equalising charge, hours 10

2211) Delayed start, seconds 0

2261) Delayed charging, hours 0

242 Fan installed, 0 = no, 1 = yes 1

Mains voltage codes

Main voltage Design of the charger

1-phase 3-phase
220 0 8
380 1 9
500 2 10
127 3 11
346 4 12

Other functions

Register Function Default

value
2331) Automatic hardcopy of statistics, 0 = no, 0
1 = yes

2341) Hardcopy of charging, 0 = no, 1 = yes 0

2351) Hardcopy range, hours 5

2031) Hardcopy language, dependent on pro- 0

gram version

1) Only applies to program version 1.19 or later.

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 Battery charger – 8340
Functional description
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Changing parameters
The parameter values can be changed if necessary.
Example: The charger is programmed for battery 2500 Ah, and you
require 300 Ah.
• Press * 200 *, the display shows 250.
• Press, * 2451 * 300 * within 10 seconds.
• Do not forget to copy-over, * 22 * 2451 *, when all the changes have
been made.

48.3.10 Acid circulation

48.3.1 General
Under normal charging the recharging factor is 1.15–1.20, i.e. when the
recharged amount is equal to that withdrawn from the battery a further
15–20% Ah will be charged. This “over charging“ is necessary, firstly to
avoid sulphating, and secondly through gassing to mix the electrolyte
so that electrolyte of a greater density does not collect at the bottom of
the cells resulting in corrosion.
If it possible to mechanically mix the electrolyte, the recharging factor
can be lowered to 1.05–1.07. This makes it possible to save charging
time, maintenance and reduce liquid consumption due to gassing.
One way to achieve this is to blow air into the battery cells and in doing
so cause the electrolyte to circulate.
To charge acid circulation batteries either requires a charger or battery
equipped with an air pump, a.k.a. acid circulation pump.

BTM with acid circulation

There are two systems for acid circulation available for BTM.
Pump type APE or VPM, which is a surface mounted system available
in different sizes depending on the number of battery cells. The small-
est model gives 200l/h and is used for up to 12 cells. Use the next size
up for a greater number of cells, this gives 350l/h. Both types are com-
patible with all BTM models irrespective of the enclosure.
Some batteries require a higher volume of air. Accordingly, there are
two other models of which the largest gives 600l air per hour.
There is also an integrated model API, which is solely used in a floor
cabinet.

© TIEE SARL Service Manual 7FBRE 48- 11

 Battery charger – 8340
Service and maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Pump type APE, VPM

The pump is mounted in a separate enclosure, which is bolted to the
top of the charger with spacers. The connection of the pump takes
place across the charger’s contactors, possibly via the terminal close to
the charger’s mains connection.
The pump is equipped with pressure monitoring. Indication is via LEDs
and an acoustic signal. The underpressure alarm, under 30 mbar, is indi-
cated by a red flashing LED and a buzzer signal and is delayed by a few
seconds. Overpressure, over 120 mbar, is indicated by red/green flash-
ing LEDs and a buzzer. Normal pressure is indicated by a green LED.
The APE pump can be used by all program versions. However, it is
important to reduce the recharging factor, normally 15-20%, by 5% for
Varta batteries and 7% for Tudor batteries. Other makes of battery,
please contact the battery supplier.

Pump type API

The pump is fitted inside the charger and is equipped with a pressure sen-
sor connected to the charger’s electronic card. This allows the pressure to
be monitored. In the event of an error the charging factor is automatically
reset so that the battery always receives the correct recharge.
This type of pump only works with program version 1.24. This program
version is fully compatible with program version 1.20, except for the
addition of API pump support. The charging factor should be set to 5-
7% depending on the make of battery.

48.4 Service and maintenance

48.4.1 Basic programming, code 30
The function is only available in program version 1.19 or later.
The function automatically resets all parameters to default values.
• Press * 30 * 2451 *.
After basic programming the battery capacity, number of cells and the
charger’s rated current need to be programmed. The mains voltage
code is adjusted if necessary.

48.4.2 Resetting the statistics, code 31

The function is only available in program version 1.19 or later.
The function resets the long term statistics.
• Press * 31 * 2451 *.

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Service and maintenance
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

48.4.3 Calibrating the measurement value

The electronic components in BTM have a specific margin of error.
Instead of calibrating the error margins using a trimming resistance or
potentiometers, the computer in BTM stores trimming constants in the
parameter memory, EE-prom. These trimming constants are calculated
using trimming functions and are activated via the keyboard.
Calibration takes place by first measuring the values to be calibrated
with an accurate instrument. Using the calibration function you enter
the true values into the computer. The computer calculates a trimming
constant, which is stored in the parameter memory and used to com-
pensate the entered values.
The trimming constants are stored in the same way as the parameters.
Calibration therefore gives the error message E.77 or E.60. When cali-
bration is complete you use the copy-over function to copy the data to
the other memory.

Calibrating the current’s zero value and tempera-

tures, code 21
NOTE:
The battery must not be connected. The charger shall be cold.
• Ensure the charger and its components have the same temperature
as the ambient temperature.
• Measure the ambient temperature
• Press *21 * 2451 * temperature °C*.
Example: If the ambient temperature is 19°C,
press * 21 * 2451 * 19 *).
The current display is reset when calibrating. The temperature of the
transformer, choke and diodes is set to that of the ambient temperature.

Calibrating the battery voltage’s measurement val-

ue, code 20
• Connect the charger to the battery.
• Measure the voltage across the charger’s terminals.
• Wait until the battery voltage has stabilised.
• Press * 20 * 2451 * voltage and the first decimal *.
Example: If the voltage is measured to 56.4 V.
Press * 20 * 2451 * 564 *).

© TIEE SARL Service Manual 7FBRE 48- 13

 Battery charger – 8340
Service and maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Calibrating the charging current, code 25

• Ensure that the charger delivers at least 50% of the rated current.
• Measure the current using a clamp-on ammeter intended for direct
current.
• Press * 25 * 2451 * current and the first decimal *.
Example: If the current is measured to 68.5 A.
Press * 25 * 2451 * 685 *).

Calibrating the mains voltage display, code 26

• Measure the voltage between two phases. With single phase, be-
tween the phase and negative.
• Press * 26 * 2451 * voltage *.
Example: If the voltage is measured to 396 V.
Press * 26 * 2451 * 396 *).

48.4.4 Calibrating and programming API

Calibrating zero pressure
• Loosen the air hose from the charger’s air nipple. Start the charger
with a battery connected.
• When the charger and pump start, press * 35 * 2451 *. The measure-
ment system is now set to the pumps zero pressure.

Calibrating the pressure

• Connect a pressure meter with adjuster screw to the charger’s air
nipple. Turn the adjuster screw so that a counter pressure equivalent
to 90-110 mbar is obtained.
Press * 35 * 2451 * enter the mbar to one decimal *.
All calibration is completed by calculating a new checksum with * 22 *
2451 *.

Programming the alarm limits

Register 246 contains the limits for the underpressure. Each unit corre-
sponds to 10 mbar The charger is usually programmed for 30 mbar, i.e.
register 246 contains the value 3.
Register 247 contains the limits for the overpressure. Exactly as for the
underpressure each unit corresponds to 10 mbar. The charger is usual-
ly programmed for 120 mbar overpressure, i.e. register 247 contains
the value 12.

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 Battery charger – 8340
Service and maintenance
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Programming the API function

The register 245 shall contain the value 1 for the program to activate
the pressure monitoring function. Press * 245 * to check the content of
the register. Use the same programming procedure as for other regis-
ters.
All calibration is completed by calculating a new checksum with * 22 *
2451 *.

48.4.5 Adjusting the charging characteristics

The charging characteristics can be adjusted by moving a strap if the
charger delivers too high or too low current at the start of charging. The
strap is located to the right of the transformer. There is one or three
straps depending on the type of charger. Next to the strap is a sign
describing how strapping shall take place.

1. Low mains voltage and high charging current.

2. Low mains voltage and low charging current.
3. Normal mains voltage and high charging current.
4. Normal mains voltage and low charging current.

48.4.6 Trouble shooting

If an error occurs during charging this normally results in one or more
error messages. Some errors are such that the computer does not dis-
play the error, e.g. a fault on the electronic card. Here follows a compi-
lation of errors and appropriate actions

© TIEE SARL Service Manual 7FBRE 48- 15

 Battery charger – 8340
Service and maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Error message, analysis and action

E.22 = low counter-voltage.
The connected battery has too low counter-voltage.
• Check the battery and its connections.
E.30 - E.36 = high temperature on component parts.
• Check the fan
• Check that the ventilation openings are not covered.
• Check that the mains voltage adaptation is correct.
• Check that the ambient temperature is not too high.
E.25 = low current.
• Check that there is no play on the battery plug or battery poles.
• Check that the battery is not sulphated.
• Check the contactors.
• Check the temperature fuses.
• Check for a possible error on the mother board.
E.52 = phase fault.
• Check the fuses on the mains.
• Check that all phases are present.
• Check for play on the mains terminal.
• Check for any diode failure.
• Check that the right mains voltage code has been programmed.
E.60, E.70 = incorrect information in the mother board’s EE-prom.
• Reprogram and calibrate if necessary.
• Copy over the data.
• Switch off the charger and then restart.
• Check that the error message has disappeared.
E.72 error in the mother board’s EE-prom
• Check the EE-prom.
• Check the computer board.
E.76 error in the computer board’s EE-prom.
• Check that the computer board’s EE-prom is not missing or faulty.
• Check that an older type of display or printer has not been connect-
ed.
E.77 = data in the computer board and mother board EE-prom is valid
but not the same.
• Check that copy-over of data has been performed.
• Check that the computer board does not come from another device.

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Errors without indication

• If the charger does not work, check that the computer board and dis-
play board are fitted correctly and are connected.
• If the mains fuse blows during power up, compare the fuse value
with the charger’s rated data.
• Check the fuses and connections.
• Check the diodes.
• Check the insulation between phases and the charger’s casing.

48.4.7 Trouble shooting acid circulation

• With underpressure, check the hose system, nipples and couples for
leakage. If the charging plug with air connection is used, the O-rings
in the plug may be damaged.
• Also check that the pump is voltage fed.
• With overpressure, check the hose system for pinched hoses.

48.4.8 Service measures

NOTE
Servicing may only be carried out by qualified and authorised person-
nel.
• Disconnect the charger from the mains and battery when servicing
an open charger.
• Check that all cover plates are refitted and that the charger’s door is
closed and lock once serving is complete.

© TIEE SARL Service Manual 7FBRE 48- 17

 Battery charger – 8340
Service and maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Switching to the timer charger

In the event of an error so that computer controlled charging is not pos-

sible, you can temporarily switch to timer charging.
• Switch the service plug, J5, located above the mother board’s con-
trol transformer.
• Set J5 to its right-hand position.
• Set the mains switch in position 1.
Charging starts immediately and continues for the set time, normally 12
hours. The time can be adjusted between 5 and 13 hours using poten-
tiometer, P2. There are settings for 6 and 12 hours. The fan runs contin-
uously in service mode.
• When the fault has been rectified, return J5 to its “normal position“
and P2 is set to 12 hours.

Replacing the display card

• Align the LEDs in the corresponding holes before screwing down the
board.

Replacing the computer board

• Loosen the mother board’s catches on the upper and lower guides.
• Pull out the computer board.
• Check that the new computer board is of the right design and pro-
gram version.
• Install the new computer board.
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If the computer board’s EE-prom has not been written to, this will be updat-
ed when the charger is started. If it has been written to, the error message
E.77 is shown. Perform copy-over using code 22. (* 22 * 2451 *).

Replacing the mother board

• Remove the computer board.
• Remove the bottom grille, applies to the wall mounted model.
• Disconnect all connections.
NOTE:
Exercise care with the thermal wires.
• Loosen the five nuts and lift the mother board out of the charger.
• Install the new mother board.
• Connect the computer board.
• Perform full basic programming, calibration and resetting of statistics.

Replacing the diodes

There are two types of diode: 40HF40 with red connectors, which are
used in charger’s positive cooler and 40HFR40 with blue connections
used in the charger’s negative cooler. Some types have mixed connec-
tions, i.e. both types are mounted in the same cooler. If these types are
not available you can use another diode that withstands at least 40 A,
400 V, and has ¼“ threads.
• Secure the diode so that the body lies against the heatsink, check
using feeler gauges.
• Only tighten by hand. Recommended tightening torque, 2.5 Nm.

48.4.9 Preventive maintenance

In normal environments the charger requires no maintenance. In dusty
premises we recommend regular cleaning to ensure cooling and there-
by the efficiency of the charger. Cleaning may only be carried out by
qualified personnel.

© TIEE SARL Service Manual 7FBRE 48- 19

 Battery charger – 8340
Service and maintenance
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

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 Control/computer equipment – 8700
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

49- Control/computer equipment –

8700
User manual for TruckCom 3.5 - for “Rider Trucks”
This manual is valid for TruckCom 3.5, program number 182147-008.

49.1 General
TruckCom is a communications program that communicates with
trucks equipped with CAN (Controller Area Network) communication.
The program allows the following functions:
• Downloading the software.
• Displaying and adjusting driver and truck parameters and measure-
ment data. You can also save the parameter values (including val-
ues for measurement data) for later reloading.
• Displaying data for various digital inputs/outputs and analogue data
including voltage, current strength and specific temperatures.
The program is a Windows program run under Windows®
95/98, Windows® XP/2000 and Windows® NT.

49.2 Connection
In order to connect to the truck, a CAN interface of the CPC-PP type
with associated cable is required. The interface is connected to the
printer port on a PC, and the cable must be connected between the
interface and the truck’s CAN connection.
The CAN interface is supplied with current from the truck’s electronics
and is protected from any high currents in the truck in the event of a
fault arising.

© TIEE SARL Service Manual 7FBRE 49- 1

 Control/computer equipment – 8700
Layout
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.3 Layout
49.3.1 Main window
When the program starts, the main window, consisting of a menu row,
tool buttons, work area, log window and status window, opens.
Information
Menu row window

Tool
buttons

Nodes

Icons

Status list

Fig. 1 Main window for TruckCom

49.3.2 Nodes
The units connected to and communicating via the CAN interface are
called nodes. The nodes detected on the bus are shown in the node
window. The current node status and incorporated components/infor-
mation are displayed using various icons.

Fig. 2 A typical screen of the node

window

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 Control/computer equipment – 8700
Layout
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

49.3.3 Icons

Icon Description
Node OK is displayed when contact is established
with a node and no fault has been reported.

Node not connected is displayed when there is no

contact with a node in the network.

Node not OK is displayed when a fault has been

reported by a node. Click on the node for more
information.
Program version is shown when there is informa-
tion regarding which software is installed. Click for
more information.
Information is displayed when a node has informa-
tion on, for example, fault codes.

Truck report

Parameters is displayed when a node has informa-

tion on a parameter.

Diagnostics

Conclude

© TIEE SARL Service Manual 7FBRE 49- 3

 Control/computer equipment – 8700
Layout
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.3.4 Tool buttons and menu list

The tool buttons provide direct access to the program’s most common
functions. The menu list provides access to all program functions. An
explanation of each menu button is provided for each section.

Disconnect Download
from PC Truck report
(Connect from PC) (Download) (Truck report)

Search for units

(search for units)

Parameters Diagnostics Information Exit

(Parameters) (Diagnostics) (Conclude)

Fig. 3 Tool buttons and menu list

49.3.5 Information window

The right section of the main window contains a status window where
various messages are displayed.
In order to see previous messages, use the scroll arrows in the right-
hand corner.

49.3.6 Status row

There is a status row at the bottom of the main window that shows var-
ious statuses when the program is run.

REC MACHINE

The following are displayed from the left:

Help text "pop-up" via the mouse cursor, connected/not connected to
the network, truck type connected, initiation result of the CAN interface
and current time.

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49.4 Function for connection

In order to connect the PC to the network, select the "Scan units" func-
tion. This can be done using the <Nodes | Scan units> menu or using
tool button [Scan nodes].
This must be done when the truck is energised and in normal drive
mode. The program now carries out a check and sets CAN interface. A
diagnosis is also carried out to check which units are connected to the
system. The results of this diagnosis are shown in the “Node” window.

49.5 Function for disconnecting

In order to disconnect from the network, select the “Disconnect” func-
tion. This can be done using the <Nodes | Set PC off-Line > menu or
with the tool button [Set PC off-Line].
The CAN interface then resets and it is possible to disconnect the CAN
cable if required. The aim is to be able to connect to another truck with-
out needing to close the program.

49.6 Function for program downloading

In order to download a new program to one of the nodes, select the
"Download" function. This can be done using the <Tools | Download
software... > menu or using tool button [Download].

Type

123456

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 Control/computer equipment – 8700
Function for program downloading
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.6.1 Normal loading

Select Open.. to open the file to be downloaded to a node. File name,
file type and version number are shown in the “ file information” box. If it
is a file for checks, specify the type of checks that are to receive the file.
Start loading by selecting Start... and restart the truck by entering the
driver PIN-code and then pressing the green button on the keypad.
Restart must take place within 20 of the Start button being activated.
Close the loading box once loading is intact and then disconnect the PC
from the network. A new connection can now be made to verify the new
program.

49.6.2 Loading in old versions of the

electronic card
If loading is to take place to an older type of electronics card which does
not support restart with a key, the Old card button... must be used
instead of Start...
Loading takes place in the same way, except restart takes place by
using the battery plug instead of the key.

49.6.3 Emergency loading

If for any reason there is no program in the electronics card (interrupted
loading) E141 will be displayed on the truck display at start. The com-
munication with the truck via the PC will then be minimised. Use “E141”
to download the program to the card.
On certain trucks, there is a counter on the display which continuously
counts up.
NOTE!
The electronic cards for certain trucks can only be upgraded with the
same basic program once they have been programmed. It is therefore
not possible to change the basic program (other machine type).

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Function for truck report
Order number Date Valid from serial number T-code
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49.7 Function for truck report

It is possible to generate a report to a file or disk using the truck’s con-
figuration and status. Select the <Tools | Generate truck report... menu
> or using the Truck report tool button. Save the report in the
Report.file.

NAME

Example of information generated in the truck report:

[GENERAL] [ERROR LOG]
REPORT DATE-TIME=1999-12-09 07:42:14 01=55 99-12-09 06:11
CPC-PP SERIAL No=8002008 02=55 99-12-08 20:54
MACHINE NUMBER=392179 03=55 99-12-08 14:26
CUSTOMER=CUSTOMER 1 04=231 99-12-08 14:16
TECHNICIAN=NONAME 05=55 99-12-08 14:11
COMPANY=COMPANY 1 .
NOTES=Test report .
.
[CAN NODES] 50=55 99-12-08 14:40
MAIN CARD=125
FORK CARD=-1 [DRIVER PARAMETERS]
TRUCK TRACKER=-1 1=3
ACC LIFT CONTROLLER=0 2=100
ACC DRIVE CONTROLLER=0 3=100
CURTIS LIFT CONTROLLER=-1 .
.
[MAIN CARD CONFIGURATION] .
SOFTWARE=169942-001 100=0
HARDWARE=169937-001
SERIAL NO=12112
[TRUCK PARAMETERS]
[HOUR METERS] 11=100
A IGNITION TIME=1 12=80
B TOTAL MOVEMENT=0 13=10
C DRIVE MOTOR TIME=0
D PUMP MOTOR TIME=0
S SERVICE TIME=9
The content of certain rows can vary depending on the truck type.

© TIEE SARL Service Manual 7FBRE 49- 7

 Control/computer equipment – 8700
Function for parameters
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.8 Function for parameters

In order to change the truck’s parameters, select the "Parameter" func-
tion. This can be done using the <Tools | Change parameters > menu or
using tool button [Parameters].
NOTE:
The truck must be in normal mode (i.e. not in parameter mode ) when
connected to TruckCom. Otherwise TruckCom will display “Unable to
determine truck brand”.
The parameter numbers follow the description in each truck’s service
manual.
Fig. 4, fig 5 and fig 6 show the 7FBRE truck.

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Order number Date Valid from serial number T-code
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Fig. 4 Truck file

Fig. 5 Time file

© TIEE SARL Service Manual 7FBRE 49- 9

 Control/computer equipment – 8700
Function for diagnostics
T-code Valid from serial number Date Order number
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49.9 Function for diagnostics

In order to access diagnostics, select the “Diagnostic” function. This
can be done using the <Tools | Diagnostic... menu > or using the [Diag-
nostic] tool button.
NOTE!
If the value “---” is displayed in a field or the status LED lights up red,
communication has been interrupted for some reason and incorrect
data may then be displayed.
NOTE:
The information on the tabs in diagnostics mode depends on which
truck is connected.

49.9.1 Signal colours

The following screenshots have been adapted for improved readability
for printout in black and white.

NOT ACTIVATED
GREEN

RED

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49.9.2 Tab for “Analogue”

When you click on the Analogue tab, the following dialog box is dis-
played:
• Read status – Shows that the measurement function is activated
and functioning.
• Inputs - the measured voltage on each potentiometer is displayed.
The number refers to the input on the main card and which is speci-
fied on the circuit diagram.
• Outputs - the voltage sent out to each component. The number re-
fers to the output on the main card and which is specified on the cir-
cuit diagram.
• Driver controller - Cmd shows the required Ac-figure and the actual
speed for each engine.

© TIEE SARL Service Manual 7FBRE 49- 11

 Control/computer equipment – 8700
Function for diagnostics
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.9.3 Tab for “Temperature”

When you click on the Temperature tab, the following dialog box is dis-
played:
• Pump/Drive - The current temperatures of the electronics units and
the engines expressed in °C .
• Steering - The steering regulator’s final-stage temperature ex-
pressed in °C.

49- 12 Service Manual 7FBRE © TIEE SARL

 Control/computer equipment – 8700
Function for diagnostics
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

49.9.4 Tab for “Digital”

When you click on the “Digital” tab, the following dialog box is dis-
played:
• Status for digital inputs and outputs for the main card. The number
refers to the outputs and inputs on the main card specified on the cir-
cuit diagram.

© TIEE SARL Service Manual 7FBRE 49- 13

 Control/computer equipment – 8700
Other menu functions
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.10 Other menu functions

49.10.1 Save to file

The truck parameters can be saved in the PC for loading at a later date.
Select <File | Save to file | Parameters >. All parameters in the nodes
that are connected to the bus will be read and saved in a file.
If only the hour meters are required, select <File | Save to file | Hour
meters >.

49.10.2 Loading from a file

A set of parameters can be loaded from the PC to the truck. Select <File
| Load from file | Parameters >. The parameters in the file will be copied
to the nodes connected to the bus. If only the hour meter settings are
required, select <File | Load from file | Hour meters >.

49.10.3 Resetting the CAN adapter

If problems arise when resetting the CAN adapter connected to the PC,
this can be done manually by confirming there is voltage to the adapter
and then selecting <Nodes | Reset CPC-PP >.

49.10.4 Deleting the fault code log

In order to delete the truck's fault code log, start the truck in parameter
mode and then select < Tools | Erase error log >.

49.10.5 Resetting the hour meter

In order to zero the truck’s hour meter, start the truck in drive mode and
then select < Tools | Reset hour meters >.

49.10.6 Reading the fault code log

In order to display the truck’s fault code log, select < Tools | Read error log >.

49.10.7 Adjusting the date/time

In order to rapidly adjust the truck’s date and time, select < Tools |
Adjust date & time >. The time specified on the PC will now be down-
loaded into the truck.
NOTE!
NOT trucks without a real time clock.

49- 14 Service Manual 7FBRE © TIEE SARL

 Control/computer equipment – 8700
Specifications
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

49.10.8 Adjusting the hour meter on older

cards
In order to adjust the hour meter on trucks with older cards, select
< Tools | Adjust Hour meters >. The time on the PC is then downloaded
to the truck.

49.10.9 Help
About TruckCom
In order to view the program information, select <Help | About Truck-
Com... > or the [About] tool button.

49.10.10 Conclude
In order to close the program, select <File | Exit > or the [Exit]´tool button.

49.11 Specifications
CAN-interface
Description Value Unit
Current consumption 40-120 mA
Supply voltage 11-28 V
Speed of transfer 125 kbit/s
Storage temperature -20-80 0C

Operating temperature 0-60 0C

© TIEE SARL Service Manual 7FBRE 49- 15

 Control/computer equipment – 8700
Installation
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

49.12 Installation
NOTE!
Installation of the program must take place from the hard disk.
You must also be administrator with full privilege.
NOTE!
The software may be damaged in the computer and therefore installa-
tion on the PC must be implemented by a person with the necessary
knowledge.
TOYOTA is exempt from all responsibility for any faults resulting from
installation.
NOTE!
All references to the PC operating system functions, menus and com-
mands are based on the English Windows® version.

49.12.1 Installation on a PC with Windows XP/

2000/NT
The software application is supplied on a CD or via a network in ZIP-for-
mat.
Extract the file and put it on the computer’s harddrive.
Start the installation by running X:\SETUP.EXE, where X:\ is the drive
on which the installation application can be found.
Then follow the on-screen instructions.

49.12.2 Installation on a PC with Windows 95/98

If truckCom has been previously installed on the PC, changes must be
made in the System. ini file.
Start the Msconfig.exe Start | Run msconfig program.
Click on System.ini and open the folder (386Enh).
Click away the tick for Device=C:WINDOS\Cpcppvd.vxd
Save and close the program.
Now start the installation
The program is supplied on CD or over the network and the installation
is started by running X:\SETUP.EXE, X = the program location.
Then follow the on-screen instructions.

49- 16 Service Manual 7FBRE © TIEE SARL

 Control/computer equipment – 8700
Installation
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

49.12.3 In the event of any problems with

communication with CAN
Ensure that the computer settings for the printer port in setup (BIOS)
are as follows:
Port address: 0378
IRQ: 7
Mode: Output only
For information on how the setup is changed, see the user manual from
the computer manufacturer.

49.12.4 Uninstallation
TruckCom can be uninstalled from the Windows® start menu < Settings
| Control panel | add/remove programs > . Highlight TruckCom and then
<Add/remove program>.

© TIEE SARL Service Manual 7FBRE 49- 17

 Control/computer equipment – 8700
Installation
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

This page is intentionally left blank

49- 18 Service Manual 7FBRE © TIEE SARL

 Extra hazard warning lights/alarm – 9370
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

50- Extra hazard warning lights/

alarm – 9370

50.1 General
The truck can be equipped with hazard warning lights in order to attract
attention when the driver is operating the truck.

50.2 Assembling
The lamp and relay are interconnected as shown on the wiring dia-
gram.
Lamp H90, 48 V 40 W with BA15d socket.

H90

K80

© TIEE SARL Service Manual 7FBRE 50- 1

 Extra hazard warning lights/alarm – 9370
Setting
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

50.3 Setting
Setting of the operation and time are done as illustrated or according to
the customer’s wishes.

U/t R

.4 .6
.2 .8

.05 1

TIM
E

FU
NC

p
OZM 1

50- 2 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51- Positioning equipment – 9390

51.1 General
This chapter is about height indication and height pre-set.
The height indication system comprises a tachometer that measures
impulses on a wire and relays them to the control card.
The control card then relays the signals to a display panel showing the
height of the forks.
The height pre-set receives impulses from the height indication system.
On the height pre-set, you can program the height at which the forks will
stop to pick up and deposit loads.

51.2 Height indication

A height indicator, which shows the current height of the forks within the
main lift range, is fitted to trucks with high lifting heights.
The display window (A) shows the fork height based on information
from the height meter.

© TIEE SARL Service Manual 7FBRE 51- 1

 Positioning equipment – 9390
Function
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.3 Function
Measuring starts in the main lifting zone when the reference switch
(S45) is activated and sends a signal to the electronic card (A5). The
pulse sensor (U10) sends pulses to A5, which starts by displaying the
programmed free lift height on the display (A8). The pulse sensor has
two channels, A and B, which relay signals with 90° reciprocal ratio.
This gives A5 information on whether the forks are moving up or down.
For connection, see Wiring Diagram, chapter 5000.
For programming the free lift height, see Setting Parameters, chapter
5710.
The steel wire should be wrapped one turn around the measuring
wheel and stretched taut so it does not slip.

S45

5 mm

A8
U10

A5, A2
A7

51- 2 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Display
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.4 Display
The picture shows the rear side of the height indication display, and the
table explains the terminal numbers for contacts where I means input.

1 2 3

4 5

Terminal Connection Function

number
1 I Switching to length display
2 I RX (-) receives data
3 I +48 V
4 I Negative
5 I RX (+) receives data

When supply voltage is connected to terminal 1, the display can be

used for length display.

J1

Unscrew the four screws and strap across clamp J1 to switch the dis-
play from metres to inches.

Display Remarks
Permanently-lit decimal The forks are below the reference
points height
Flashing decimal points The forks are above the reference
height with the ignition on
Four straight lines Communication error with the truck
computer

© TIEE SARL Service Manual 7FBRE 51- 3

 Positioning equipment – 9390
Height pre-set
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.5 Height pre-set

Using the height pre-set, you can lift and lower the forks to up to 99 dif-
ferent pre-programmed levels within the main lift zone.
Lifting and lowering movements are stopped at the desired level based
on information from the height meter. Depositing and pick-up of loads
takes place manually.
Program the right level for loading and unloading on the keypad. The
display window shows the chosen level and any error codes.

51- 4 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Function
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.6 Function
Measuring starts in the main lifting zone when the reference switch
(S45) is activated and sends a signal to the electronic card (A5). The
pulse sensor (U10) sends pulses to A5, which starts by displaying the
programmed free lift height on the displays (A7 and A8). The forks stop
at the first pre-programmed height when A5, via pulse sensor U10,
reaches the correct height. The halt is initiated by A5 regulating the
pump motor speed using A2 and valves for fork lifting and lowering. The
driver picks up or deposits the load manually. When the driver again
presses the hydraulic control for lifting/lowering, the forks continue to
the next pre-programmed level. The pulse sensor has two channels, A
and B, which relay signals with 90° reciprocal ratio. This gives A5 infor-
mation on whether the forks are moving up or down. For connection,
see Wiring Diagram, chapter 5000.
For programming the free lift height, see Setting Parameters, chapter
5710.
The steel wire should be wrapped one turn around the measuring
wheel and stretched taut so it does not slip.

S45

5 mm

A8
U10

A5, A2
A7

© TIEE SARL Service Manual 7FBRE 51- 5

 Positioning equipment – 9390
Display
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.7 Display
The diagram shows the display and the underside of the display for pre-
set height, and the table describes the contactor’s terminal number
where I stands for Input and O stands for output.

7 6 5

4 3 2 1

Terminal Connection Function

number
1 U TX (+) transmits data
2
3 I RX (+) receives data
4 I +48 V
5 U TX (-) transmits data
6 I Negative
7 I RX (+) receives data

51- 6 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Display
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.7.1 Description of the display symbols

Symbol Function
Numerical push-buttons for setting height levels

9
To control the required height level while driving

INFO

STOP
Deletes incorrectly entered height levels in auto-
matic mode, stops programming and removes
stops due to error
Save “LEAVE level” when programming

Save “COLLECT level” when programming

LOAD
Push-button to indicate that there is a load on the
forks when starting

Push-button to access programming routines

PROG

Display window to indicate height levels and error

codes

© TIEE SARL Service Manual 7FBRE 51- 7

 Positioning equipment – 9390
Assembly of height pre-set
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.8 Assembly of height pre-set

• Undo the 11 screws holding the lower panel in place and remove it.
• Undo the plastic rivets and remove the plastic console from the cav-
ity for height pre-set.
• Screw the height pre-set into place.
• Reconnect the connector.
• Screw the lower panel back into place with the 11 screws.

51.9 Programming
• Press the PROG button briefly to enter programming mode. The
LED in the button comes on and the display shows PL00 when the
programming routine has been started. You can now program new
lifting heights, modify or delete programmed values.

51.9.1 Programming a level

You can only program lifting heights in the main lift range.
NOTE!
Forks not horizontal.
The load may slide off the forks or catch on the rack.
The forks must always be horizontal, particularly when the load is be-
ing deposited on or collected from the rack.

Collect level
• Enter programming mode and state the required level (e.g. 1+5=
level 15). The numbers are shown on the display.
• Lift the forks to the required level and press the button COLLECT.
The LED flashes.

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 Positioning equipment – 9390
Programming
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

Leave level
• Pick up the load and wait three seconds. Lift the forks just enough so
that the load can be removed from the rack. Ensure that there is suf-
ficient space for safe handling.
• Now press the LEAVE button and both LEDs for collecting and leav-
ing will start to flash..

• Press the PROG button until both LEDs go out and the display indi-
cates PL00, to save the information.
• Repeat from “LEAVE “ level to program more levels.
• Press the STOP button to return to display mode.

51.9.2 Deleting programmed levels

Lower the forks to free lift level when deleting programmed lifting
heights.
• Enter programming mode and state the required level (e.g. 1+5=
level 15). The numbers are shown on the display.
• Press the COLLECT button (the LED flashes) and then press the
LEAVE button (both LEDs start to flash).
• Press the PROG button until both LEDs (COLLECT and LEAVE)
stop flashing and the display shows PL00 to erase the memory.
• Press the STOP button to return to display mode.

© TIEE SARL Service Manual 7FBRE 51- 9

 Positioning equipment – 9390
Automatic driving
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.10 Automatic driving

There are two different automatic operating modes. One where the
forks are raised/lowered to the required level without a load and the oth-
er, with a load.

51.10.1 Collect load

• State the required height level using buttons 0-9 (e.g. 1+2=level 12).
The display shows LE12.
• Raise/lower the forks until they are automatically stopped by the
electronics. If the wrong direction is chosen, no “lift/lower move-
ment” will take place. The electronics expect the correct direction to
be selected.
• When the forks stop and the COLLECT LED comes on, the forks
can be manoeuvred under the load.
NOTE!
Forks not horizontal.
The load may slide off the forks or catch on the rack.
The forks must always be horizontal, particularly when the load is be-
ing deposited on or collected from the rack.
• Raise the forks until they are automatically stopped by the electron-
ics and the LEAVE LED comes on.
• Move the load from the rack. When the work cycle has been com-
pleted, the LEDs will go out.

51- 10 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Automatic driving
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.10.2 Depositing a load

• Press the LOAD button (the LED now comes on).
• State the required height level using buttons 0--9 (e.g. 5=level 5).
The display shows LE05.
• Raise/lower the forks until they are automatically stopped by the
electronics. If the wrong direction is chosen, no “lift/lower move-
ment” will take place. The electronics expect the correct direction to
be selected.
• When the forks stop and the LEAVE LED comes on, the forks can be
slid out from under the load.
NOTE!
Forks not horizontal.
The load may slide off the forks or catch on the rack.
The forks must always be horizontal, particularly when the load is be-
ing deposited on or collected from the rack.
• Lower the forks until they are automatically stopped by the electron-
ics and the COLLECT LED comes on.
• Withdraw the forks from the rack. When the work cycle has been
completed, the LEDs will go out.

51.10.3 Inspection
• Press the button INFO to check the required “collect/leave level”.
The value will be shown for three seconds on the display.

© TIEE SARL Service Manual 7FBRE 51- 11

 Positioning equipment – 9390
Parameters
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.11 Parameters
There are a number of parameters that can be modified in the pre-set
height program.
• Press the button PROG for three seconds to start programming rou-
tines. The LED comes on and the display shows P_ _ _ .
• Enter code 852 using the numerical keys and the display will now
show P_.
• State the required parameter 1 - 9 and then press the LOAD button.
The display shows the factory settings. These can be changed to
any of the max/min. values shown in the table “Programming param-
eters”.
NOTE!
If a value outside the max/min. range is programmed in, this will be re-
placed by the max/min. factory setting.
• Press the STOP button to terminate programming.

51.11.1 Parameter 1
Select the unit of measurement you wish to use (metres or inches).
• Press the PROG button to save the unit you selected. The display
shows P_.

51.11.2 Parameter 2
If the distance between lifting heights is equal on all levels, you can
make a common program:
• State parameter 2 and press the LOAD button. The display shows P
00 and you now enter the number of levels. Press the LOAD button
and the display shows P000.
• Specify the collect height for the first level in increments of 10 mm.
Press the LOAD button and the display shows P000.
• The next value you need to enter is the distance between collect/de-
posit level in increments of 10 mm. Press the LOAD button and the
display shows P000.
• The next value you need to enter is the distance between each de-
posit level in increments of 10 mm. Press the PROG button to save
programmed values. The display shows P_.

51- 12 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Parameters
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.11.3 Parameter 3
Programming the crawling speed for braking distances:
• State parameter 3 and press the LOAD button. The display shows
the previous programmed value for crawling speed lower. Enter the
new value using the numerical keys. The permitted max/min. values
are shown in table “Programming parameters”.
• Press the LOAD button to change the crawling speed lift. The dis-
play shows the value for crawling speed. Enter the new value using
the numerical keys.
• Press the PROG button to save the new values. The display shows
P_.

51.11.4 Parameter 4
Programming the crawling distance when lifting and lowering.
• State parameter 4 and press the LOAD button. The display shows
the previous programmed value for crawling speed lower. Enter the
new value using the numerical keys. The permitted max/min. values
are shown in table “Programming parameters”.
• Press the LOAD button to change the crawling speed lift. The dis-
play shows the value for crawling distance. Enter the new value us-
ing the numerical keys.
• Press the PROG button to save the new values. The display shows
P_.

51.11.5 Parameter 5
Programming the tolerance for the stop levels.
• State parameter 5 and press the LOAD button. The display shows
the previous programmed value for tolerance. Enter the new value
using the numerical keys. The permitted max/min. values are shown
in table “Programming parameters”.
• Press the PROG button to save. The display shows P_.

51.11.6 Parameter 7
Programming the largest and smallest permitted programming distance
between the levels collect and leave.
• State parameter 7 and press the LOAD button. The display shows
the previous programmed value for min. distance. Enter the new
value using the numerical keys, (e.g. 030 = 30 mm). The permitted
max/min. values are shown in table “Programming parameters”.
• Press the LOAD button. The display shows the previous pro-
grammed value for max. distance. Enter the new value using the nu-
merical keys, (e.g. 150 = 150 mm).
• Press the PROG button to save. The display shows P_.
© TIEE SARL Service Manual 7FBRE 51- 13
 Positioning equipment – 9390
Parameters
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

51.11.7 Parameter 8
Resets all the parameters to the factory settings.
NOTE!
Reset to factory settings after upgrading to later program version.
• State parameter 8 and press the LOAD button. The display shows
no value.
• Press the PROG button until the display stops showing PP. Turn the
ignition key on and off to start the new program.

51.11.8 Parameter 9
• Programming the leave/collect levels’ braking distances.
• State parameter 9 and press the LOAD button. The display shows
the braking distance for lower. Enter the new value using the numer-
ical keys, (e.g. 050 = 500 mm).
• Press the LOAD button. The display shows the crawl speed for lift.
Enter the new value using the numerical keys, (e.g. 030 = 300 mm).
• Press the PROG button to save. The display shows P_.

51- 14 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Programming parameters
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.12 Programming parameters

Parameter Max./min. Factory Unit Function

number value setting
P1 001 001 m - 10 mminch - Unit of measurement
002 10ths of an inch
P2 1 - 99 st Programming of several levels at
0 - 999 10 mm equal collect/leave distances.
0 - 255 10 mm Number of levels
0 - 999 10 mm Distance first “collect height”
Distance collect-leave
Distance between “leave levels”
P3 0 - 127 030 % of max speed Crawling speed before stop
0 - 127 010
Lower
Lift
P4 010 mm Crawling distance before stop
005 Lower
Lift
P5 0 - 255 010 mm Permitted error tolerance in stop
position
P7 0 - 255 030 mm Min./max. distance between
0 - 255 150 leave - collect
P8 Resetting of all parameters to
factory settings
P9 Braking distance before stop
0 - 255 050 10 mm Lower
0 - 255 030 10 mm Lift

© TIEE SARL Service Manual 7FBRE 51- 15

 Positioning equipment – 9390
Programming parameters
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Position Function
A Leave level
B Collect level
C Main lifting zone
H2 Free lifting zone

P3
P9 A
P5
P7
H2
B
P3 P5
P9

51- 16 Service Manual 7FBRE © TIEE SARL

 Positioning equipment – 9390
Error codes
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

51.13 Error codes

Error code Remarks

Err 1 Requested height level not programmed or incor-
rect
Err 2 Forks have stopped outside the tolerance zone
(P5)
Err 9 Incorrect value entered when programming
Err flashing Fault in communication between height pre-set
and truck computer

• Four lines appear at start-up. This shows that there has been no
communication between height pre-set and the main electronics.
The lines will disappear when communication is restored between
the units.
• Four dots appear on the display when the forks are in the free lift
zone.
• If the dots are flashing, this is an indication that the reference switch
was activated when the truck was started (e.g. the forks were above
the free lift zone). If the dots continue to flash after the forks have
been lowered, a fault may have occurred in the wiring or the height
reference switch.

© TIEE SARL Service Manual 7FBRE 51- 17

 Positioning equipment – 9390
Error codes
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

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51- 18 Service Manual 7FBRE © TIEE SARL

 TV equipment – 9390
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

52- TV equipment – 9390

52.1 General
The truck can be equipped with one or more cameras and various mon-
itors. We use a 7” colour monitor that can also be used on trucks with a
black & white monitor. This chapter describes the various TV equip-
ment options.

A50

X62

X55

X60
A10

X61
A51

Symbol Designation/function
A10 Voltage converter
A50 Colour monitor
A51 Camera
X55 Contact
X60 Contact
X61 Contact
X62 Contact

© TIEE SARL Service Manual 7FBRE 52- 1

 TV equipment – 9390
Camera mounted on fork
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

52.2 Camera mounted on fork

The equipment consists of a camera mounted on the side of one fork
and a colour monitor in front of the driver.

52.2.1 Colour camera A51

The camera’s electronics and lens system are installed in an aluminium
case. The lens system cannot be exchanged for a different focal dis-
tance. The generation of heat from the electronics is such that no extra
heating is required when it is used in cold stores. The camera can also
be used on trucks equipped with a black/white monitor.
0

~40

52.2.2 Colour monitor A50

The monitor has a colour picture and is fed with 12 V voltage.
Ambient temperature from 0° to +60°C

1 2 3 4

Number Designation/function
1 Switch, changes settings for monitor
2 Switch, AV1/AV2
3 Switch, menu of settings for monitor
4 Switch, power supply

52- 2 Service Manual 7FBRE © TIEE SARL

 TV equipment – 9390
Camera mounted on fork
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

• The monitor can be turned on and off using a switch (4)

• Use the switch (2) to shift mode between inputs AV1 and AV2.
• In order to change the monitor’s settings, use the switch (3). Press-
ing this switch accesses a menu for changing settings for the moni-
tor’s features. The menu includes the following selection of settings:

Menu choice Alters

Bright Brightness from 1-100
Contrast Contrast from 1-100
Colour Colour intensity from 1-100
Default Resets to basic settings
Backlight Backlighting from 1-100
AV2 AV1 or AV2 when turning on monitor

• To change any setting, the menu option must be selected. Then use
the switch (1) up and down to adjust the setting.
• To move between different menu options, press the switch (2).
• To save new settings, hold switch (3) in or turn on and off with switch
(4).
• For further information, see Wiring diagram C code 5000.

© TIEE SARL Service Manual 7FBRE 52- 3

 TV equipment – 9390
Camera mounted on fork
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

52.2.3 Voltage converter A10

A10 converts incoming voltage 48 V into 12 V, which is fed to the TV
monitor and camera.

Parameter Setting Unit Description

Input voltage 48 Volt
Output voltage 13.2 Volt
Max. operating volt- 64 Volt
age
Min. operating voltage 40 Volt
Max. continuous cur- 6 Amp
rent
Max. intermittent cur- 8 Amp
rent
Fuse on input 6.3 Amp

The converter is protected on the input side against polarity variation,

short circuits and thermal overload.
The chassis is not live, and the in/outputs are galvanically separated.
For further information, see Wiring diagram C code 5000.

52- 4 Service Manual 7FBRE © TIEE SARL

 Truck Logging System, code lock – 9420
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

53- Truck Logging System, code

lock – 9420

53.1 General
TLS Truck Logging System
The truck can be equipped with different models and combinations of
code lock called TLS.
TLS Truck Logging System is designed so that only qualified truck driv-
EV 1
ers can start the truck. The truck is started by entering your personal
7
code on the keyboard or by using your personal code card, depending
8
9 on the system used.
4
5
6 The truck can be driven after you enter the correct code. The display
1
2
3 lights or another visual indication is given when the correct code has
C
*
LR
been entered.
#
ENT
The time the truck is used is registered in the truck log on EV16 and
S16.

EV1
53.2 EV 1,EV 16 and S 16 Keyboard
version

53.2.1 Login using a code (5 digit)

Ev16 You must enter your five digit personal code each time you start the
truck.
7
8
9 • Enter your personal code using the keyboard, 12345 for EV 16 and
4
5
6
S16 and 45312 for EV 1 (standard codes the first time you log in).
1
2
3
• Press # to start the truck.
*
CLR
#
If you enter the code incorrectly press * and start again.
EN T

53.2.2 Logout
When you leave the truck you must always logout.

EV16 and S16 • Press * to logout and make the truck undrivable.
Never press * while working with the truck.
If you do not logout by using *, TLS will automatically logout after a pre-
set time.

© TIEE SARL Service Manual 7FBRE 53- 1

 Truck Logging System, code lock – 9420
EV 1,EV 16 and S 16 Keyboard version
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

53.2.3 Login with fault reporting (5+1 digit)

Valid for EV16 and S16
Truck logging can be programmed so that it allows you to record any
faults on the truck when you start to use it (e.g. mechanical damage,
battery acid level or another fault).

Login
You must enter your five digit personal code plus an additional digit
each time you start the truck.
• Enter your personal code using the keyboard, e.g. 12345.
• Enter a number between 0 and 9 depending on the fault detected in
the truck. If no fault has been detected, enter the number for fault-
free truck.
• Press # to start the truck.
If you enter the code incorrectly, press * and start again.
You must enter a number between 0 and 9 to start the truck.

53.2.4 Login with extra code (5+3 digit)

Valid for EV16 and S16
In this mode you enter, e.g. your employment number as the first five
digits and then a three digit personal code.
• Enter your five digit code using the keyboard, e.g. 12345.
• Then enter your three digit code.
• Press # to start the truck.
The first time you use the truck and have not programmed in a code the
three digit code will be 000.
To change the code, see Changing the personal three digit code.

53.2.5 Login with extra code and fault

reporting (5+3+1 digit)
Valid for EV16 and S16
• Enter your five digit code using the keyboard, e.g. 12345.
• Then enter your three digit code.
• Enter a number between 0 and 9 depending on the fault detected in
the truck. If no fault has been detected, enter the number for fault-
free truck.
• Press # to start the truck.
If you enter the code incorrectly, press * and start again.
You must enter a number between 0 and 9 to start the truck.

53- 2 Service Manual 7FBRE © TIEE SARL

 Truck Logging System, code lock – 9420
EV1, EV16 and S16 code card version
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

53.2.6 Changing the personal three digit code

Valid for EV16 and S16
You can change your personal three digit as follows:
• Enter your five digit code using the keyboard, e.g. 12345.
• Then enter your three digit code.
• Press 9 (green). This informs the truck log that you wish to change
your code.
• Enter the new code, e.g. 678.
• Press 9 (green). This informs the truck log that this is the code you
wish to use.

53.3 EV1, EV16 and S16 code card

version
EV 1

53.3.1 Login
• Place the card in the front of the unit.
• Press the button to start the truck.

53.3.2 Logout
• Press the button to log out and make the truck undrivable.
Never press the button when you are working with the truck.
If you do not logout by using *, TLS will automatically logout after a pre-
EV1 set time.

EV 16

EV16 and S16

© TIEE SARL Service Manual 7FBRE 53- 3

 Truck Logging System, code lock – 9420
EV1, EV16 and S16 code card version
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

EV1
V83
K83
R37

A24

X81 A20
X82

F65
F66
X42

Symbol Designation/function Picture

A20 Main unit
A24 Temperature regulator/filter unit, by Cold
Store Cabin
F65 Fuse for A20-card, 3A
F66 Fuse for heater, 3A
K83 Relay, control
R37 Resistance, current limit
V83 Diode, suppression
X42 Contact
X81 Contact
X82 Contact

53- 4 Service Manual 7FBRE © TIEE SARL

 Truck Logging System, code lock – 9420
EV1, EV16 and S16 code card version
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

53.3.3 Circuit diagram

1/1 Prod A
222577
208

© TIEE SARL Service Manual 7FBRE 53- 5

 Truck Logging System, code lock – 9420
EV1, EV16 and S16 code card version
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

EV16

X80
V83
K83

A24

A22
X44
X81
X82

F65
F66
X42

A20

Symbol Designation/function Picture

A20 In/out-unit
A22 Main unit
A24 Temperature regulator/filter unit, by
Cold Store Cabin
F65 Fuse for A20-card, 3A
F66 Fuse for heater, 3A
K83 Relay, control
V83 Diode, suppression
X42 Contact
X44 Contact
X81 Contact
X82 Contact

53- 6 Service Manual 7FBRE © TIEE SARL

 Truck Logging System, code lock – 9420
EV1, EV16 and S16 code card version
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

S16
X80
V83
K83

A24

A22
X44
X81
X82

F65
F66
X42

A20

Symbol Designation/function Pic-

ture
A20 Input/output unit
A22 Head unit
A24 Thermostat/filter unit, by cold storage
F65 Operating fuse for A20 card, 3A
F66 Operating fuse for heater, 3A
K83 Relay, control
V83 Diode, shielding
X42 Contact
X44 Contact
X81 Contact
X82 Contact

© TIEE SARL Service Manual 7FBRE 53- 7

 Truck Logging System, code lock – 9420
Collision sensor
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

0 53.4 Collision sensor

1 Valid for EV 16 and S 16
The truck can be equipped with a collision sensor. If you should hit an
object the collision sensor will register this, a buzzer sounds and the
truck becomes undrivable. Resetting takes place using a key on the
instrument panel, which is turned to 1 and then back to 0.

X80
V83
K83
A24
K81

H71 A22

X44
X81 S205
X82

F65
F66
X42
A20
A23

Symbol Designation/function Picture

A20 In/out-unit
A22 Main unit
A23 Collision sensor
A24 Temperature regulator/filter unit, by
Cold Store Cabin
F65 Fuse for A20-card, 3A
F66 Fuse for heater, 3A
H71 Buzzer
K81 Relay, collision sensor
K83 Relay, control
S205 Reset key

53- 8 Service Manual 7FBRE © TIEE SARL

 Truck Logging System, code lock – 9420
Collision sensor
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408

Symbol Designation/function Picture

V83 Diode, suppression
X42 Contact
X44 Contact
X81 Contact
X82 Contact

© TIEE SARL Service Manual 7FBRE 53- 9

 Truck Logging System, code lock – 9420
Collision sensor
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

53.4.1 Circuit diagram

½ Prod A
222294
208
202

DRIVE

DRIVE

53- 10 Service Manual 7FBRE © TIEE SARL

 1 2 3 4 5 6 7 8

© TIEE SARL
201004-040

COTROLLER UNIT I/O MODULE UNIT

A22 A20
Order number

A A
X80
432 432
CAN +5V TBA 1 PLA 5 CAN +5V

X80
433 433
CAN 0V TBA3 PLA 4 CAN 0V

X80
Date

434 434
CAN HIGH TBB1 PLA 18 CAN HIGH

B X80 B
435 435
2005-07-01

CAN LOW TBB 2 PLA 19 CAN LOW

X80
423
HEATER - TBC 2

X80
422
HEATER + TBC 1
423260-

Service Manual
C C
ENDAST KEYPAD FRYSHUS / ONLY KEYPAD COLD STORE
THERMOSTAT/FILTER UNIT
A24

X82 X81
21 RED WHITE

7FBRE
Pg. 2 INP. +48VDC OUT. +48VDC

X82 X81
40 BLACK BLACK
Pg. 2 INP. 0V OUT. 0V
Valid from serial number

D D

X3
21
PLA 10 INP. OPTO 3

H71
X3 X66 X66
2 3 139
PLA 24 OUT. OPTO 3 , SCHOCK DETECT

E ELECTRONIC CARD E
T-code

A5
403-408

INP. SPEED REDUCTION 206

222294
2/2 Prod A
F F
Truck Logging System, code lock – 9420
Collision sensor

1 2 3 4 5 6 7 8

53- 11
 Truck Logging System, code lock – 9420
Trouble shooting
T-code Valid from serial number Date Order number
403-408 423260- 2005-07-01 201004-040

53.5 Trouble shooting

53.5.1 EV1
If the truck does not start:
• Check that there is 48 V in cable 421 as measured with cable 40 as
minus reference.
• Make sure the relay has voltage from EV 1 on cable 138.
If it is not possible to cut off the power to the truck:
• Make sure that there is no voltage from EV 1.
• Make sure that the contacts of the relay has not welded together.
For further information see Davis Derby information.

53.5.2 EV16 and S16

If the truck does not start or it is not possible to cut the power:
• Use tool 180815 to check that EV16 and S16 is receiving voltage
from the truck.
• Connect the tool to the contact for the in/out unit.
• Start the truck with switch 4.
• Make sure that there is voltage to the connections for driving LED 1
1 and lifting LED 2 by activating the lifting and driving functions.
2
3 • Start the truck and if the LEDs light up the fault is with
4
5 EV16 and S16.
For further information see Davis Derby information.

53- 12 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
General
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54- Instructions for destruction

54.1 General
These instructions have been drawn up as a part of our environment
management program. An important motive is, by taking nature into
consideration, to economize with resources. In other words, you should
try to recycle material as far as possible, thus minimising the discharge
of environmentally ha-zardous substances.
Dismantling instructions are designed for an F code (truck family) and
then divided into different C codes. These C codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive transmission
• 3000 Brakes/belt/wheel system
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function - lift mast
• 8000 Auxiliary/installation equipment
• 9000 Accessories/optional equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means the instructions
refer to the marking to determine the collection container to use.

54.1.1 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally hazardous substances and metals that it
includes.

© TIEE SARL Service Manual 7FBRE 54- 1

 Instructions for destruction
General
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.1.2 Abbreviations
The following abbreviations for Service Manuals and plastic materials
are used in the dismantling instructions. Abbreviations used are:
SM = Service Manual
PE = Polyethene
PP = Polypropylene
PUR = Polyurethane
PVC = Polyvinyl chloride
PC = Polycarbonate
PMMA = Plexiglass
ABS = Acrylonitrile-butadiene-styrene

54.1.3 Sorting
The sorting method for component parts is based on how you can recy-
cle the parts and whether they must be taken care of in a special way.
• Plastics must first and foremost be sorted into recyclable and non-
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastics. Instructions
either denote in which container the plastic should be placed or
there is a reference to the material marking on the plastic compo-
nent. In those cases where it is stated in which container the plastic
part should be placed, this is done by stating the abbreviation for the
plastic in question.
Sorting is not necessary for non-recyclable plastics. These are
placed in the container intended for combustible material.
• Iron and steel scrap is sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
e.g. plastics, should be sorted separately.
• Oil is collected in the intended container.
• Oil filters are collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses and tanks,
should be sorted separately.
• Batteries should be returned to the manufacturer.
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts such as screws, bolts, nuts, washers, etc. are not includ-
ed in the dismantling instructions. These should be placed in the
container intended for iron and steel scrap.

54- 2 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Frame/chassis (0300)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.2 Frame/chassis (0300)

Main mast mounting (to the left) and cab with supporting leg (to the
right).

54.2.1 Dismantling
• Refer to MSM for the disassembly procedure.

54.2.2 Material handling

The main mast mounting, cab and supporting leg should be treated as
iron and steel scrap.

© TIEE SARL Service Manual 7FBRE 54- 3

 Instructions for destruction
Operator's seat, cushion (0620)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.3 Operator's seat, cushion (0620)

Operator's seat

54.3.1 Dismantling
• Remove the seat.
• Dismantle the back rest cushion, seat cushion and head rest from
the seat frame.
• If fitted, cut loose the seat belt.

54.3.2 Material handling

Place the seat frame in a container intended for iron and steel scrap.
Place the seat cushion, back rest cushion, headrest and seat belt in a
container intended for combustible material.

54- 4 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Driver controls (0640)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.4 Driver controls (0640)

1

54.4.1 Dismantling
• Remove the pedal rack.
• Remove the rubber surface (1) from the pedals.
• Remove the potentiometer (2).

54.4.2 Material handling

Place the pedal rack in a container intended for iron and steel scrap.
Place the pedal rubber in a container intended for combustible material.
Place the potentiometer in a container intended for electronic scrap.

© TIEE SARL Service Manual 7FBRE 54- 5

 Instructions for destruction
Interior fittings (0680)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.5 Interior fittings (0680)

3
5

54.5.1 Dismantling
• Remove the armrest cushion (1) and the armrest panel (2).
• Remove the instrument panel (3).
• Remove the side panel (4).
• Remove the ceiling panel (5).

54- 6 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Rollover guard/head guard (0810)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.5.2 Material handling

Place the armrest cushion in a container intended for combustible
material.
The armrest panel has been material coded and must be placed in the
container intended for that material.
Place the side panel in a container intended for combustible material.
The instrument panel has been material coded and must be placed in
the container intended for that material.
Place the ceiling panel in a container intended ABS material.

54.6 Rollover guard/head guard (0810)

B
A
B

B-B
A-A

54.6.1 Dismantling
• Remove the protection plate.

54.6.2 Material handling

Place the protection plate in a container intended for PC.

© TIEE SARL Service Manual 7FBRE 54- 7

 Instructions for destruction
Finger/foot protectors (0820)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.7 Finger/foot protectors (0820)

54.7.1 Dismantling
• Remove the finger protector.

54.7.2 Material handling

Place the finger protector in a container intended for PMMA.

54- 8 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Finger/foot protectors (0820)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.8 Finger/foot protectors (0820)

54.8.1 Dismantling
• Remove the foot protectors.

54.8.2 Material handling

Place the foot protectors in a container intended for iron and steel
scrap.

© TIEE SARL Service Manual 7FBRE 54- 9

 Instructions for destruction
Finger protectors (0820)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.9 Finger protectors (0820)

1

54.9.1 Dismantling
• Remove the finger protector (1).

54.9.2 Material handling

Place the finger protector (1) in a container intended for PMMA.

54- 10 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Electric motors (1700)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.10 Electric motors (1700)

Steering motor (1), pump motor (2) and travel drive motor (3).

54.10.1 Dismantling
• Remove the cables.
• Remove the steering motor.
• Remove the pump motor including the pump (see 6100).
• Remove the travel drive motor from the transmission.

54.10.2 Material handling

Cables are placed in a container intended for cables.
Place the motors in the container intended for complex scrap.

© TIEE SARL Service Manual 7FBRE 54- 11

 Instructions for destruction
Electric fan motor (1740)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.11 Electric fan motor (1740)

54.11.1 Dismantling
• Remove the cables.
• Remove the fans.

54.11.2 Material handling

Cables are placed in a container intended for cables.
Place the fan in the container intended for complex scrap. The fan
wings of the left fan must be placed in the container intended for com-
bustible material.

54- 12 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Drive unit, final gear (2500)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.12 Drive unit, final gear (2500)

54.12.1 Dismantling
• Drain the oil from the gearbox.
• Remove the gearbox from the drive motor.
• Remove the drive wheel.

54.12.2 Material handling

The oil is poured into a container intended for oil (classified as hazard-
ous waste within the EU).
The gearbox is placed in a container intended for iron and steel scrap.

© TIEE SARL Service Manual 7FBRE 54- 13

 Instructions for destruction
Wheels (3500)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.13 Wheels (3500)

Drive wheel.

54.13.1 Dismantling
• Remove the drive wheel and support arm wheels.

54.13.2 Material handling

If possible, remove the vulcanization from the rims. Place the vulcani-
zation in a container intended for combustible material and the rims in a
container intended for iron and steel scrap. Otherwise place the wheels
in a container intended for complex scrap.

54- 14 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Electric steering system (4300)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.14 Electric steering system (4300)

1
2 5
3
A
4
A 6
A

© TIEE SARL Service Manual 7FBRE 54- 15

 Instructions for destruction
Electric steering system (4300)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.14.1 Dismantling
• Remove the wrist support (1).
• Remove the arm cushion (2).
• Remove the upper (3) and lower (4) steering panels.
• Remove the knob on the steering wheel (5), the steering wheel (6)
and the motor (7).
• Remove the console (8) and the arm (9).

54.14.2 Material handling

Place the wrist guard, the control cushion and knob from the steering
wheel in a container intended for combustible material.
The upper and lower steering panels have been material coded and
must be placed in the container intended for that material.
Place the motor, steering wheel and arm in a container intended for
complex scrap.
Place the console in a container intended for iron and steel scrap.
Place the other fittings in a container intended for combustible material
or complex scrap.

54- 16 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
General electric equipment (5100)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.15 General electric equipment (5100)

Truck battery.

54.15.1 Dismantling
• Remove the cables.
• Remove the battery.

54.15.2 Material handling

Cables are placed in a container intended for cables.
The battery (classified as hazardous waste within the EU) should be
returned to the battery manufacturer or the manufacturer's representa-
tive (see the rating plate on the battery).

© TIEE SARL Service Manual 7FBRE 54- 17

 Instructions for destruction
Control system, drive function (5300)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.16 Control system, drive function

(5300)

Travel direction selector.

54.16.1 Dismantling
• Remove the handle.
• Remove the cables from inside the handle.

54.16.2 Material handling

Cables are placed in a container intended for cables.
Place the handle in a container intended for complex scrap.

54- 18 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Power system, drive function (5400)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.17 Power system, drive function

(5400)

Frequency converter.

54.17.1 Dismantling
• Remove the guard.
• Remove the cables.
• Remove the frequency converter.

54.17.2 Material handling

Place the guard in a container intended for iron and steel scrap.
Cables are placed in a container intended for cables.
Place the frequency converter in a container intended for electronic
scrap.

© TIEE SARL Service Manual 7FBRE 54- 19

 Instructions for destruction
Control system, operation function (5500)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.18 Control system, operation

function
(5500)
4
3
1 1
1 2
1
1

1 1
1
5 5

Control panel (left) and instrument panel (right).

54.18.1 Dismantling
• Remove the switch (1), display (2), height indicator (3), potentiome-
ter (4), contact (5) and associated cables.

54.18.2 Material handling

The component parts are placed in a container intended for electronic
scrap.
Cables are placed in a container intended for cables.

54- 20 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Steering/protective electronics (5700)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.19 Steering/protective electronics

(5700)

Logic card.

54.19.1 Dismantling
• Remove the cables.
• Remove the logic card.

54.19.2 Material handling

Cables are placed in a container intended for cables.
Place the logic card in a container intended for electronic scrap.

© TIEE SARL Service Manual 7FBRE 54- 21

 Instructions for destruction
Hydraulic unit (6100)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.20 Hydraulic unit (6100)

Hydraulic tank (at top left), hydraulic unit (at top right) and hydraulic
pipes to the tank (bottom).

54.20.1 Dismantling
• Drain all oil from the hydraulic tank.
• Remove the oil filter from the oil tank.
• Remove the hydraulic lines.
• Remove the oil tank.
• Remove the hydraulic unit (motor + pump).

54.20.2 Material handling

Pour the oil into a container intended for oil (classified as ha-zardous
waste within the EU).
Place the oil filter in a container intended for oil filters.
Place the hydraulic hoses in a container intended for oil-contaminated
material.
Place the tank in a container intended PE.
Place the motor together with the pump in a container intended for com-
plex scrap.

54- 22 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Hydraulic system, fitted on the chassis (6200)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.21 Hydraulic system, fitted on the

chassis (6200)

Main valve (1).

Routing valve.

54.21.1 Dismantling
• Remove the hydraulic lines.
• Remove the valve plate.

54.21.2 Material handling

Place the hydraulic hoses in a container intended for oil-contaminated
material.
Place the valve plate in the container intended for complex scrap.

© TIEE SARL Service Manual 7FBRE 54- 23

 Instructions for destruction
Hydraulic system, fitted on the mast (6300)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.22 Hydraulic system, fitted on the mast

(6300)

Hydraulic lines on mast (to the left) and fork cradle (to the right).

54.22.1 Dismantling
• Remove the hydraulic lines.

54.22.2 Material handling

Place the hydraulic hoses in a container intended for oil-contaminated
material.
Place the hydraulic pipes in a container intended for iron and steel
scrap.

54- 24 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Hydraulic cylinders (6600)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.23 Hydraulic cylinders (6600)

Main lift cylinder (to the left) and free lift cylinder (to the right)

1
The tilt cylinder (1) and side-shift cylinder (2).

© TIEE SARL Service Manual 7FBRE 54- 25

 Instructions for destruction
Hydraulic cylinders (6600)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

Reach cylinder

54.23.1 Dismantling
• Remove the cylinders.
• Drain all oil from the cylinders.
• Destroy the cylinders by cutting.

54.23.2 Material handling

Place the cylinders a container intended for iron and steel scrap.

54- 26 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Main mast and mast (7100)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.24 Main mast and mast (7100)

Main mast yoke carriage (to the left) and main mast (to the right).

54.24.1 Dismantling
• Refer to MSM regarding removal of the main mast yoke carriage and
the main mast itself.
• Remove the plastic components from the main mast.

54.24.2 Material handling

The main mast yoke carriage and the main mast itself should be treated
as iron and steel scrap.
Place the sliding plate (1) of the yoke carriage in a container intended
for combustible material.
Place the plastic components in a container intended for combustible
material.

© TIEE SARL Service Manual 7FBRE 54- 27

 Instructions for destruction
Lift fork (7410)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.25 Lift fork (7410)

54.25.1 Dismantling
• Remove the forks.

54.25.2 Material handling

The forks should be treated as iron and steel scrap.

54- 28 Service Manual 7FBRE © TIEE SARL

 Instructions for destruction
Optional electric equipment (9300)
Order number Date Valid from serial number T-code
201004-040 2005-07-01 423260- 403-408,689-692

54.26 Optional electric equipment

(9300)

54.26.1 Dismantling
• Remove any optional equipment, such as tape recorders, work
lights, warnings lights, cameras and TV monitors.
• Remove the cables.

54.26.2 Material handling

Cables are placed in a container intended for cables.
Place tape recorders, cameras and TV monitors in a container intended
for electronic scrap.
Place the other fittings in a container intended for complex scrap.

© TIEE SARL Service Manual 7FBRE 54- 29

 Instructions for destruction
Optional electric equipment (9400)
T-code Valid from serial number Date Order number
403-408,689-692 423260- 2005-07-01 201004-040

54.27 Optional electric equipment

(9400)

Log equipment, code lock of truck.

54.27.1 Dismantling
• Remove the cables.
• Remove the log-in terminal and the relays.

54.27.2 Material handling

Cables are placed in a container intended for cables.
Place the log-in terminal and relays in a container intended for electron-
ic scrap.

54- 30 Service Manual 7FBRE © TIEE SARL

©TOYOTA Industrial Equipment
Europe SARL Ancenis, France