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Repair manual 7575392-040

R112, R114, R116.

Repair manual 7575392-040 R112, R114, R116.
Repair manual 7575392-040 R112, R114, R116.

Document revisions:

Issue date

Order

Changes

number

2015-10-01

7575392-040

Chapter 6: Updated with instructions for PIN codes Bleeding the system Chapter 8: Error codes 4:180-4:187 and 5:181-5:184 Troubleshooting Chapter 9: Information on tilt stops Chapter 14: Description of the height system New information symbols (180- and 360-degree steering) Chapter 15: Adjustment table for pressure limiting valve Chapter 16: Replacing the free lift chain Chapter 20: Update with sensor B46 Chapter 22: Updated part number for Castor-USB Chapter 23: Lubricant specification for motor shaft

2016-10-24

7575392-040

Chapter 7 - Updating the maintenance schedule. Chapter 15 - Updating the tightening torque when replacing the hose rupture valve, 15.12.2.

This manual contains information on the following trucks:

Model

T-Code

Valid from serial number

R112, R114,

   

R116

1006

6308581

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

1. Table of content

2.

General introduction

2–1

2.1 How to use this manual

2–1

2.2 Abbreviations

2–2

2.3 Warning symbols

2–3

2.4 Pictograms

2–4

2.4.1 Screws/Nuts

2–4

2.4.2 Repairable

2–5

2.4.3 Other pictograms

2–6

3.

General safety rules

3–1

3.1 Work safety

3–1

3.2 Electrical system

3–3

3.3 Safe lifting

3–4

3.4 Truck modifications

3–5

4.

Operation and connection sequences

4–1

4.1

Description

4–1

5.

Parameters

5–1

5.1 General

5–1

5.2 Parameter settings

5–2

5.3 Operator parameters

5–4

5.3.1 Overview

5–5

5.3.2 Description

5–8

5.4 Service parameters

5–9

5.4.1 Overview

5–9

5.4.2 Description

5–9

5.4.3 Description

5–21

5.5 Factory parameters

5–31

5.5.1 General factory parameters

5–31

5.5.2 Factory parameters, activation of options

5–34

5.5.3 Factory parameters, calibration

5–36

6.

Installation

6–1

6.1 Transporting the truck

6–1

6.2 Transporting the mast

6–1

6.3 Transporting the truck

6–1

6.4 Taking into operation

6–2

6.4.1

Battery

6–2

6.5 Dismantling the mast

6–4

6.5.1

Dismantling the working light

6–8

6.6 Putting into operation

6–9

6.6.1 Installing the mast in the truck

6–9

6.6.2 Fitting the working light

6–15

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

7.

Maintenance

 

7–1

7.1 Introduction

7–1

7.2 Safety precautions for maintenance work

7–2

7.3 Maintenance instructions

7–3

 

7.3.1 Cleaning and washing

7–3

7.3.2 High-pressure washers

7–3

7.3.3 Degreasing agents

7–3

7.3.4 Cleaning the exterior

7–4

7.3.5 Cleaning the chain

7–4

7.3.6 Cleaning the motor compartment

7–4

7.3.7 Electric components

7–4

7.4 Symbols

 

7–5

7.5 CCrack detection

7–6

 

7.5.1 Visual inspection

7–6

7.5.2 Crack detection

7–7

7.6 Safety checks

 

7–8

7.7 Periodic maintenance

7–9

 

7.7.1

Every 500 operating hours/180 days

7–9

7.7.2

Every 1000 operating hours/360 days

7–11

7.7.3

Every 2000 operating hours/720 days

7–17

7.7.4

Every 3000 operating hours/1080 days

7–19

7.7.5

Every 4000 operating hours/1440 days

7–21

7.7.6

7–21

7.7.7

Every 5000 operating hours/1800 days

7–21

7.7.8

Annual status inspection

7–21

8.

Troubleshooting

8–1

8.1 Auxiliary functions

8–1

 

8.1.1 Error log menu

8–1

8.1.2 Error information menu

8–2

8.1.3 Diagnostic screens

8–2

8.2 Initial troubleshooting

8–15

8.3 Troubleshooting using blocking symbol

8–16

8.4 Troubleshooting using error codes

8–20

 

8.4.2

MCU and other warnings and errors

8–25

8.5 Troubleshooting without indications

8–62

 

8.5.1 Mechanical brake (3000)

8–62

8.5.2 Steering (4000)

8–63

9.

Chassis C0000

 

9–1

9.1 Overview

9–1

9.2 Description

9–2

9.3 Floor C0330

9–2

 

9.3.1 Overview

9–2

9.3.2 Description

9–3

9.3.3 Replacing the floor

9–3

9.3.4 Protective covers

9–6

9.4 Support arm C0350

9–16

9.5 Battery compartment parts C0390

9–16

 

9.5.1

Overview, battery support

9–16

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

9.6 Operator's seat C0620

9–17

9.6.1 Overview

9–17

9.6.2 Description

9–17

9.6.3 Replacing the operator’s seat (Basic)

9–18

9.6.4 Seat switch

9–24

9.6.5 Replacing the backrest, chair seat

9–26

9.6.6 Replacing the seat plate

9–29

9.7 Operator controls C0640

9–31

9.7.1 Overview

9–31

9.7.2 Description

9–31

9.7.3 Preconditions

9–31

9.7.4 Accelerator/Brake pedal

9–32

9.7.5 Safety pedal

9–33

9.8 Interior fittings C0680

9–35

9.9 Mirrors C0740

9–35

9.10 Overhead guard/Roof C0810

9–35

9.10.1 Overview

9–35

9.10.2 Description

9–36

9.10.3 Replacing the overhead guard roof

9–36

9.10.4 Replacing the front roof support

9–38

9.10.5 Replacing the rear roof support

9–40

9.11 Finger-foot guard C0820

9–41

10. Motors C1000

10–1

10.1 Overview

10–1

10.2 Description

10–1

10.3 Electric pump motor C1710

10–2

10.3.1 Overview

10–2

10.3.2 Description

10–3

10.3.3 Replacing the pump motor

10–4

10.3.4 Replacing the temperature sensor

10–9

10.4 Steering motor C1730

10–11

10.4.1 Overview

10–11

10.4.2 Description

10–12

10.4.3 Layout of the flange holes

10–14

10.4.4 Steering servo motor replacement

10–15

10.5 Electric fan motor / fan

10–18

10.5.1 Fan for frequency converter

10–18

10.5.2 Replacing the frequency converter fan

10–19

10.5.3 Motor compartment fan

10–21

10.5.4 Replacing the motor compartment fan

10–22

10.6 Electric drive motor C1760

10–24

10.6.1 Overview

10–24

10.6.2 Description

10–25

10.6.3 Replacing the drive motor

10–26

10.6.4 Replacing the temperature sensor

10–28

10.6.5 Replacing the

10–30

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

11.

Mechanical Drive Gear Unit C2000

11–1

11.1 Overview

 

11–1

11.2 Description

11–2

11.3 Checking the oil level

11–3

11.4 Oil change

 

11–5

11.5 Leakage from the lower cover

11–7

11.6 Replacing the drive gear

11–8

 

11.6.1 Removing the drive gear

11–8

11.6.2 Fitting the drive gear

11–10

11.7 Replacing the Steering bearings

11–11

12. Brake system/Wheels C3000

12–1

12.1 Brake system C3100

12–1

 

12.1.1 Overview

12–1

12.1.2 Description

12–2

12.1.3 Drive motor brake (travel brake)

12–3

12.2 Parking brake C3370

12–4

 

12.2.1 Overview

12–4

12.2.2 Description

12–5

12.2.3 Replacing the parking brake

12–6

12.2.4 Replacing the dust plug

12–8

12.2.5 Replacing the hub

12–10

12.2.6 Replacing the rubber gaiter

12–12

12.2.7 Checking the parking brake's brake force

12–14

12.2.8 Checking the parking brake air gap

12–15

12.3 Wheels C3500

12–16

 

12.3.1 Description

12–16

12.3.2 Wheel wear

12–17

12.4 Drive wheel C3530

12–17

 

12.4.1 Overview

12–17

12.4.2 Replacing the drive wheel

12–18

12.5 Support arm wheel C3550

12–21

 

12.5.1 Overview

12–21

12.5.2 Replacing an unbraked support arm wheel

12–22

12.5.3 Replacing bearings

12–24

12.5.4 Replacing the wheel bolt

12–26

13. Steering system C4000

13–1

13.1 Description

 

13–1

13.2 Electric steering wheel C4310

13–2

 

13.2.1 Overview

13–2

13.2.2 Description

13–2

13.2.3 Adjustment

13–3

13.2.4 Replacing pulse transducer [B13]

13–4

13.2.5 Replacing the steering console

13–5

13.2.6 Replacing the wiring harness in the steering console

13–7

13.2.7 Fit the steering console in the truck

13–9

13.2.8 Replacing the steering wheel

13–9

13.3 Steering unit C4330

13–10

 

13.3.1

Description

13–10

13.4 Steering reference sensor (4350)

13–10

 

13.4.1

Replacing the reference sensor [B17]

13–11

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

14. Electrical system C5000

14–1

14.1 Description

14–1

14.2 OTP

14–1

14.3 Battery C5110

14–1

14.3.1 Battery recommendations

14–1

14.3.2 Measuring discharge current

14–1

14.3.3 Measuring voltage

14–1

14.3.4 Charging the battery

14–1

14.3.5 BDI algorithm and parameter setting

14–3

14.3.6 Performance limitations due to battery status

14–3

14.3.7 Performance limitations due to battery status

and parameter setting

14–3

14.3.8 CID symbol

14–3

14.3.9 Resetting the battery indicator (BDI)

14–3

14.3.10 Battery weight

14–3

14.3.11 Parameter overview, battery

14–4

14.3.12 Battery cable harness

14–4

14.3.13 Battery cable replacement, machine part

14–5

14.3.14 Battery cable replacement, battery part

14–6

14.4 Signal / Alarm (Sound-light) C5160

14–7

 

14.4.1 Horn

14–7

14.4.2 Replacing the horn

14–8

14.5 Main contactor C5190

14–9

14.5.1

Replacing the contactor

14–9

14.6 Instrument panel C5200

14–10

14.6.1 Operating controls

14–11

14.6.2 Replacing the operating controls

14–11

14.6.3 Replacing the switch for travel direction selection / horn

14–13

14.6.4 Replacing the controls on the operating panel

14–13

14.6.5 Central Information Display (CID)

14–13

14.6.6 Replacing the CID

14–22

14.7 Height indication

14–23

14.7.1 Replacing the sensor bearing

14–24

14.7.2 Replacing the height reference sensor

14–24

14.7.3 Hight indication wire

14–25

14.7.4 Check and adjust the wire

14–26

14.7.5 Replacing the height indication wiring

14–26

14.8 Travel function wiring/ fuse C5390

14–27

14.8.1 Chassis wiring

14–27

14.8.2 Operator control wiring

14–28

14.9 Drive motor cables/resistor/fuse C5430

14–28

14.9.1

Replacing motor cables

14–28

14.10 Transistor panel C5460

14–29

14.10.1 Replacing the ACT

14–31

14.10.2 Replacing ACH

14–33

14.11 Work function harnesses / fuse C5590

14–35

14.11.1 Fuse panel

14–35

14.11.2 Checking fuses

14–36

14.11.3 Roof wiring

14–37

14.11.4 Replacing the roof wiring

14–37

14.11.5 Mast wiring

14–37

14.11.6 Replacing the mast harness

14–38

14.11.7 Check and adjust the mast wiring

14–40

14.11.8 Reach carriage wiring

14–41

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

14.12 Main processor – MCU C5710

14–42

14.12.1

Replacing the MCU

14–46

14.13 Sending units and sensors C5800

14–48

14.13.1 Inductive sensors

14–48

14.13.2 Position sensor

14–48

14.13.3 Pressure sensor

14–50

14.13.4 Pulse transducer

14–50

14.14 Safety sensor / - sensors C5830

14–52

14.14.1 Emergency switch off

14–52

14.14.2 Emergency switch off [S21]

14–52

14.14.3 Safety pedal [B31]

14–54

14.15 Height measurement system

14–58

14.16 Calibration

14–59

14.16.1 Calibration of the joystick

14–59

14.16.2 Height measurement/reach movement length calibration

14–60

14.16.3 Reference sensor, main lift. (Screen 1)

14–60

14.16.4 Pulse length for main lift sensor bearing (Screen 2)

14–61

14.16.5 Max. lift height. (Screen 3)

14–61

14.16.6 Calibration of the reach carriage extension

14–61

14.16.7 Valve calibration

14–62

14.16.8 Lowering valve, starting value. (Screen 1-S)

14–62

14.16.9 Lowering valve, final value. (Screen 1-E)

14–62

14.16.10 Lifting height limiting

14–63

15. Hydraulic system C6000

15–1

15.1 General

15–1

15.2 Hydraulic hygiene

15–1

15.2.1 Washing

15–1

15.2.2 Packaging

15–2

15.2.3 Handling

15–2

15.2.4 Storage

15–2

15.2.5 Work procedures

15–2

15.3 Bleeding the air from the hydraulic system

15–3

15.4 Hose inspection

15–3

15.5 Hydraulic couplings C6230

15–3

15.5.1 Quick change connectors

15–4

15.5.2 Tightening torques for hydraulic connections

15–6

15.6 Hydraulic unit C6100

15–9

15.6.1 Hydraulic oil tank C6110

15–9

15.6.2 Hydraulic hoses C6120

15–13

15.6.3 Filter C6130

15–14

15.7 Hydraulic pump C6140

15–16

15.7.1 Replacing the hydraulic pump

15–17

15.7.2 Replacing the driver

15–18

15.8 Main valve unit C6210

15–20

15.8.1 Definitions

15–22

15.8.2 Replacing a complete valve unit

15–26

15.8.3 Replacing a valve

15–26

15.9 Control valve C6220

15–32

15.10 Chassis-mounted hydraulic hoses C6230

15–34

15.10.1 Replacing the supply hose

15–34

15.10.2 Replacing the return hose

15–34

15.11 Mast hydraulic conduits C6320

15–35

15.11.1

Fork carriage

15–36

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

15.12 Main lift cylinder C6610

15–39

15.12.1 Removing the air cylinder from the mast

15–41

15.12.2 Replacing the hose rupture valve

15–42

15.12.3 Dismantling the cylinder

15–43

15.12.4 Dismantling the

15–44

15.12.5 Dismantling the cylinder head

15–45

15.12.6 Fitting the cylinder head seals

15–47

15.12.7 Fitting the piston guide belt

15–48

15.12.8 Assembling the cylinder

15–49

15.12.9 Assembling a mast cylinder

15–51

15.13 Free lift cylinder C6620

15–53

15.13.1 Removing the free lift cylinder from the truck

15–55

15.13.2 Replacing the hose rupture valve, free lift cylinder

15–55

15.13.3 Dismantling the cylinder

15–56

15.13.4 Dismantling the piston

15–57

15.13.5 Dismantling the cylinder head

15–58

15.13.6 Fitting the cylinder head seals

15–59

15.13.7 Fitting the piston seals

15–61

15.13.8 Assembling the cylinder

15–63

15.13.9 Assembling the free lift cylinder in the mast

15–64

15.14 Reach/telescopic cylinder C6650

15–65

15.14.1

Removing the reach cylinder from the truck

15–68

15.15 Dismantling the cylinder

15–69

15.15.1

Fitting the reach cylinder in the truck

15–70

15.16 Tilting cylinder C6660

15–71

15.16.1 Remove the tilt cylinder from the truck

15–72

15.16.2 Fit the tilt cylinder in the truck

15–74

15.17 Sideshift cylinder C6670

15–75

15.17.1 Overview

15–76

15.17.2 Dismantling the cylinder from the truck

15–78

15.18 Dismantling the cylinder

15–79

15.18.1 Removing the piston rod

15–81

15.18.2 Fitting the cylinder head seals

15–85

15.18.3 Mounting the piston rod

15–87

15.18.4 Assembling the cylinder

15–89

15.18.5 Refitting the cylinder in the truck

15–90

16. Mast C7000

16–1

16.1 Description

16–1

16.1.1 The available combinations of truck and

16–2

16.1.2 Ordering replacement masts

16–2

16.1.3 Mast type and weight

16–2

16.2 Installing a mast in a newly delivered truck

16–2

16.2.1

Adjusting/setting mast inclination

16–3

16.3 Main mast C7100

16–4

16.4 Main lifting chain system C7120

16–4

16.4.1 Check

16–4

16.4.2 Lubrication

16–8

16.4.3 Replacing the free lift chain

16–9

16.4.4 Replacing the mast chain

16–11

16.4.5 Replacing the mast harness

16–13

Repair manual: Table of content

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

16.5 Fork carriage C7130

16–15

 

16.5.1 Checking the fork carriage’s wear strip

16–15

16.5.2 Lubricating the fork carriage

16–16

16.5.3 Replacing the fork yoke

16–17

16.6 Main mast suspension C7190

16–18

16.7 Forks C7410

16–18

 

16.7.1 Overview

16–18

16.7.2 Inspection procedures

16–18

16.7.3 Repairs and testing

16–22

17.

Wiring diagram

17–1

17.1 Component list

17–1

17.2 Component location

17–5

17.3 Connections

17–16

 

17.3.1 ACT [T1]

17–16

17.3.2 ACH [T2]

17–16

17.3.3 CID [A1]

17–17

17.3.4 MCU [A5]

17–18

17.3.5 Fuse panel [A9]

17–19

17.3.6 Steering motor [ [A2]

17–19

17.4 General wiring diagram

17–20

17.5 Detailed diagrams

17–22

18.

Hydraulics schematics

18–1

18.1 Component list

18–1

18.2 Component location

18–2

18.3 Valve unit

18–3

 

18.3.1 Main valve unit

18–3

18.3.2 Fork carriage valve

18–4

18.4 Hydraulics schematics

18–5

 

18.4.1

18–5

19.

Tools

19–1

19.1 AMP connectors

19–1

19.2 MQS contacts

19–2

19.3 CPC contacts

19–4

19.4 Other tools

19–5

20.

Service data and grease specifications

20–1

20.1 General tightening torques

20–1

 

20.1.1 Galvanised, non-oiled screws

20–1

20.1.2 Untreated, oiled screws

20–1

20.2 Oil and grease specification

20–2

21.

Technical data

21–1

21.1 Mast type and weight (kg)

21–3

21.2 IP classes on components and units

21–3

21.3 Battery sizes

21–4

21.4 Truck dimensions

21–5

 

21.4.1

21–5

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

2. General introduction

2.1 How to use this manual

The repair manual is divided into chapters containing the following information:

• General safety rules

• Operation and connection sequences – This chapter provides a basic description of the main functions of the truck and their interdependencies.

• Parameters – This chapter provides a basic description of the truck parameters.

• Installation – This chapter describes the preparatory work that is to be done before the truck is used for the first time.

• Maintenance – This chapter provides an overview of periodic maintenance.

• Troubleshooting – This chapter describes the action you should take when the truck is completely or partially malfunctioning. It also describes the cause of the problem together with suggested remedies.

• C Codes – This chapter describes the various truck systems, e.g. the hydraulic system and includes descriptions of system parts and the necessary service procedures. These descriptions are divided according to Cesab's C code system.

• Instructions for disposal instructions – This chapter specifies the proper sorting category for the materials used in the various truck components.

• Wiring diagram – This chapter provides information on electrical components and wiring diagrams.

• Hydraulic diagram – This chapter provides information on electrical components and hydraulic diagrams.

• Tools – This chapter provides a list of the special tools required.

• Service data and grease specifications – This chapter contains information on general tightening torques and an oil and grease specification.

• Technical data

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

2.2 Abbreviations

Abbreviation

Meaning

Des.

Explanation

ACH

Alternate Current Hydraulic

[T2]

Motor control, hydraulics.

ACT

Alternate Current Traction

[T1]

Motor control, drive.

BDI

Battery Discharge Indicator

Unit indicating the state of battery charge.

CAN

Controller Area Network

A standardised interface that enable communication between different electrical units.

CID

Central Information Display

[A1]

Display with menu-based information system that is used as the primary communication tool between operator and truck.

DX

Duplex

Mast with two sections.

EPS

Electronic Power Steering

[A2]

Complete steering servo with its own motor control.

ESO

Emergency Switch Off

[S21]

Emergency switch off.

FCM

Fuse Central Module

[A9]

Fuse panel.

FCU

Fork Control Unit

[A7]

Unit for fork functions.

GFU

General Function Unit

[A8]

Unit for general functions.

HPS

Height Pre-Select

Height pre-selection

LID

Load Information Display

[P6]

Display that provides the operator information such as lift height, load weight and height preselection.

MCU

Main Control Unit

[A5]

Main control unit.

PDA

Personal Digital Assistant

A compact, portable handheld computer.

PPS

Personal Protection System

Personal protection system.

PTC

Positive Temperature Coefficient

 

Electrical property that causes resistance to

 

increase with temperature.

SF

Shuttle Forks

Telescopic fork unit.

TBD

To Be Defined

Means that the instruction/chapter will be supplemented at a later date.

TH

Turret Head

Turret head fork unit

TWIS

Toyota Wireless Information System

TX

Triplex

VNA

Very Narrow Aisle

Narrow aisles

VRE

Very narrow aisle Rider Electric

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

2.3 Warning symbols

The following warning symbols are used in the repair manual:

DANGER! The following warning symbols are used in the repair manual: DANGER! means there is a risk

DANGER! means there is a risk of accident potentially leading to death or serious injury and material loss or damage. This is always indicated by the warning symbol.

WARNING!

WARNING! means that there is a risk of damage to components that are sensitive to electrostatic discharge.This is always indicated by the warning symbol. WARNING! Heed applicable ESD safety regulations. NOTE: Note:

Heed applicable ESD safety regulations.

NOTE:

Note: means there is a risk of material loss or damage if the instructions are not followed. Also used to call attention to various points.

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

2.4 Pictograms

2.4.1 Screws/Nuts

Wherever possible, pictograms have been used to describe certain work operations.

Pictograms are primarily used for operations that require loosening or tightening of screws:

s mm
s mm

× n

The pictograms contain information about the screw head type and have arrows that show if the screw should be loosened or tightened. The text below the pictograms provide additional information, such as:

‘s’: spanner size, ‘n’: number of screws and, where required, ‘T’: the recommended tightening torque.

Identification of tools for screws and nuts

Symbols to identify tools to be used for screws/nuts:

Symbol

Designation

Slotted screwtools to be used for screws/nuts: Symbol Designation Phillips PH Pozidrive PZ Torx Allen key Hexagonal

Phillips PHto be used for screws/nuts: Symbol Designation Slotted screw Pozidrive PZ Torx Allen key Hexagonal head

Pozidrive PZscrews/nuts: Symbol Designation Slotted screw Phillips PH Torx Allen key Hexagonal head Hexagonal nut © Cesab

TorxSymbol Designation Slotted screw Phillips PH Pozidrive PZ Allen key Hexagonal head Hexagonal nut © Cesab

Allen keyDesignation Slotted screw Phillips PH Pozidrive PZ Torx Hexagonal head Hexagonal nut © Cesab 2 –

Hexagonal headDesignation Slotted screw Phillips PH Pozidrive PZ Torx Allen key Hexagonal nut © Cesab 2 –

Hexagonal nutDesignation Slotted screw Phillips PH Pozidrive PZ Torx Allen key Hexagonal head © Cesab 2 –

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

2.4.2 Repairable

The unit's ability to be repaired is stated with the pictogram below in the margin for each unit's service actions chapter.

Symbol

Meaning

Unit may be repaired without any limitations.for each unit's service actions chapter. Symbol Meaning Unit has limited ability to be repaired. Larger

Unit has limited ability to be repaired. Larger repairs require special tools, specialist knowledge or

Unit has limited ability to be repaired. Larger repairs require special tools, specialist knowledge or are not economically feasible.

Repair of the unit requires specialist knowledge or special equipment. Only complete units may be replaced.require special tools, specialist knowledge or are not economically feasible. © Cesab 2 – 5 T

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

2.4.3 Other pictograms

Symbol

Procedure

Symbol

Procedure

Visual inspection of condition, wear and loose connections. Component replacement.

Visual inspection of condition, wear and loose connections.

Visual inspection of condition, wear and loose connections. Component replacement.

Component replacement.

Cleaning Measurement

Cleaning

Cleaning Measurement

Measurement

Check of fluid level and check for leaks. Check that bolts, nuts, etc. are tightened

Check of fluid level and check for leaks.

Check of fluid level and check for leaks. Check that bolts, nuts, etc. are tightened to

Check that bolts, nuts, etc. are tightened to torque.

Listening for noise. Lubrication, application.

Listening for noise.

Listening for noise. Lubrication, application.

Lubrication, application.

Check of functions. Calibration

Check of functions.

Check of functions. Calibration

Calibration

Adjustment Welding

Adjustment

Adjustment Welding

Welding

Disassembly/removal Assembly/installation

Disassembly/removal

Disassembly/removal Assembly/installation

Assembly/installation

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

An example of another type of pictogram is “Cut cable ties”:

of another type of pictogram is “Cut cable ties”: Additional information under the pictogram can, for

Additional information under the pictogram can, for example, indicate the number of cable ties to be cut.

— Slut på avsnittet —

Repair manual: General introduction

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Repair manual: General safety rules

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

3. General safety rules

Only personnel trained in servicing and repair of this type of truck are authorised to carry out service and repair activities.

3.1 Work safety

To make work safer and prevent accidents, always ke ep the following in mind:

• Keep the maintenance work site clean. Oil and water on the floor will make it slippery.

• Use the correct working posture. Service work often involves sitting on your knees or bending over forwards. Try sitting on a toolbox, for example, to relieve the strain on your knees and back.

• Loose items and jewellery can get caught in moving parts of the truck. So never wear loose articles or jewellery while working on the truck.

• Exercise caution and always follow applicable local regulations when working at high heights.

• Use the correct tools for the work you are carrying out.

• Keep all tools well maintained.

• Make sure that all safety equipment including guards and covers are properly secured and that they work as intended before starting the repair work. If a guard or cover must be removed in order to perform the repair work, extra care must be taken, and when the repair work is finished the guard or cover must be refitted.

• Relieve the system pressure slowly before starting work on the truck’s hydraulic system.

• Use paper or a stiff piece of cardboard when checking for possible oil leaks. Do not use your hands.

• Drive unit oil and the hydraulic system oil may be hot.

DANGER! • Drive unit oil and the hydraulic system oil may be hot. Risk of burn injury.

Risk of burn injury. Hot drive unit and hydraulic oil. Allow the truck to cool down before changing the oil.

• Only fill the hydraulic system with new and clean oil.

DANGER! • Only fill the hydraulic system with new and clean oil. Risk of damage to the

Risk of damage to the hydraulic system. If the oil is contaminated, the hydraulic components will suffer damage. Always use new and clean oil in the hydraulic system.

• Store and transport changed oil according to applicable local directions.

• Do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way. Follow local disposal regulations.

Repair manual: General safety rules

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

• Disconnect the battery prior to performing any welding work on the truck.

NOTE:

The battery could be damaged.

When welding with an electric welding unit, welding current may enter the battery.

The battery must be disconnected.

may enter the battery. The battery must be disconnected. • Prior to welding or grinding on

• Prior to welding or grinding on painted surfaces, be sure to remove the paint at least 100 mm around the welding/grinding area by using sandblasting equipment or paint remover.

DANGER!

Harmful gasses.

Heated paint gives off harmful gases.

Remove paint 100 mm around the welding/grinding location.

Repair manual: General safety rules

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

R112, R114, R116 Applies from serial number: 6308581 3.2 Electrical system When working on the electrical

3.2 Electrical system

When working on the electrical system of the truck, remember the following:

• Never wear loose items or jewellery when working with the truck.

DANGER!

Short-circuiting/Burn injury.

Short circuits and burn injuries can occur if metal objects come into contact with live electrical connections when working on the truck's electrical system. Remove wristwatches, rings and other metal objects beforehand.

• Always use insulated tools when working on the electrical system.

• Always disconnect the battery before opening any covers to drive units or the electrical system.

• Always disconnect the battery prior to welding work using an electric welding unit. The welding current may damage the battery.

• Always disconnect the battery when carrying out maintenance or repair work on the truck unless otherwise stated in this repair manual.

• Clean electric motors using a rag or a vacuum cleaner.

• Clean electrical panels, electronic cards, contactors, contacts, magnetic valves, etc. with a dampened cloth and a cleaning agent that will not damage the part.

NOTE:

Risk of short-circuiting that may damage electrical components.

Do not break the warranty seal on the logic cards.

Repair manual: General safety rules

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

R112, R114, R116 Applies from serial number: 6308581 3.3 Safe lifting All lifting must be carried

3.3 Safe lifting

All lifting must be carried out on a level, non-slip and stable surface. Asphalt surfaces should be avoided if possible.

To prevent the truck moving while it is being lifte d, it must not be lifted with anyone on the platform or with the tiller arm in the lowered position.

If the drive wheel, which is braked, is being lifted the other wheels must be chocked to stop the truck from moving.

Select the lifting point so that the lift is as easy as possible, for example lifting one corner at a time. If the truck has marked lifting points on the lower part of the chassis, these must be used to ensure balanced lifting.

Make sure the surface where the jack is placed is clean and free of oil and grease.

Make sure your hands and the jack lever are free of grease and oil.

Only use the lever supplied with the jack. If the lever is too short, more exertion than is necessary will be required. If the lever is too long, there is a risk that the jack will be overloaded.

DANGER!

Risk of crushing since a poorly supported truck could fall down.

Never work under a truck that is not supported by trestles and secured by a lifting device.

Support the truck:

• as close to the lifted part of the chassis as possible in order to reduce the falling height if the truck should collapse

• so the truck cannot move.

Never support the jack on trestles to achieve a higher lift.

Never work under a raised truck without it being properly supported on trestles.

Repair manual: General safety rules

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

3.4 Truck modifications

Any modification of the truck must be approved beforehand. No modification of truck may be performed that may influence the capacity, stability and safety of the truck without prior written approval from the manufacturer, its representative or successor.

In the case of the manufacturer no longer being in business and there being no successor, the user of the truck may arrange for modifications on the precondition that the user:

• makes sure that an engineer with expert knowledge of industrial trucks and their safety designs, tests and implements the modification,

• files all documentation of the designs, tests and implementation of the modification,

• approves and makes the applicable changes to the capacity plate, adhesive labels, markings and operator’s manual and

• affixes a permanent and well visible sign to the truck stating how the truck has been modified, together with the date of the modification and the name and address of the company that carried out the modification work.

— Slut på avsnittet —

Repair manual: General safety rules

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

4. Operation and connection sequences

4.1 Description

The logic cards for the truck contain microprocessors that detect switch settings, control voltages, etc. and provide instructions for external electronic components, relays, valves, etc.

To safeguard all preset information in the electron ic module when the battery is disconnected, all information is stored in an EEPROM circuit, i.e.non- volatile memory. The MCU has a real time clock, which is powered by an internal battery. Any faults detected by the microprocessor are shown on the display.

The truck can be switched to three different operating modes:

• Normal mode

• Service mode

• Emergency driving mode

Each of these modes is separately described in this document.

Event:

1. Battery is connected

Action(s)

The battery [G1] is connected using battery cables, [X1]

Influencing elements

Main contactor [Q10] off Key relay [K20] off Fuse [F60] “+48 VDC ESO Circuit” OK

Resulting conditions

Login possible. Login method controlled by parameter 503.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

2a. Login via keypad

 

Prior event

1. Battery is connected

 

Action(s)

The operator enters a four or five-figure PIN code, depending on the parameter setting, + Enter “green button”

Influencing elements

Parameter 503 = ‘3’ or ‘4’ CID displays:

 
   
     
     
     
     
 

Parameter 503 = ‘5’ or ‘6’ CID displays:

 
   
     
     
     
     
     
 

Resulting conditions

Login approved:

CID shows a status image for approx. 2 seconds:

 
 
 

Main contactor [Q10] on Key relay [K20] on

 

Login rejected:

CID displays:

   
     
 

Main contactor [Q10] off Key relay [K20] off

 

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

2b. Login to emergency driving mode

 

Prior event

1. Battery is connected

 

Action(s)

From the login screen, ‘i’ is pressed, so that the CID displays the “Information screen”. On the information screen, select:

 
   
 

and then press the green button After the green button has been pressed, the screen shows “Emergency travel mode login” and a PIN code must be entered:

   
     
     
     
     
 
and a PIN code must be entered:       Influencing elements – Resulting conditions CID

Influencing elements

Resulting conditions

CID shows a status image for approx. 2 seconds:

 
 
 

Main contactor [Q10] on Key relay [K20] on

 

Event:

3. Driving in fork direction

Action(s)

The travel direction selector [B36] is moved towards the forks and input A1-X503:1 increases from approximately 2.6 V to approximately 4.7 V. The accelerator [B32] is pressed down and input A5-X130:17 is activated.

Influencing elements

Operator parameter 3: Maximum speed in fork direction. Operator parameter 4: Acceleration. Emergency login.

Resulting conditions

The CID's indication for driving and fork direction comes on. Output A5-X131:12 is increased to approximately +48 V and the mechanical brake [Q1] is released. The drive motor is supplied with three-phase voltage from the transistor regulator [T1].

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

4.

Driving in the drive wheel direction

Action(s)

The travel direction selector [B36] is moved towards the drive wheel and input A1-X505:4 decreases from approximately 2.6 V to approximately 0.6 V. The accelerator [B32] is pressed down and input A5-X130:17 is activated.

Influencing elements

Operator parameter 2: Maximum speed in drive wheel direction. Operator parameter 4: Acceleration. Emergency login.

Resulting conditions

The CID's indication for driving and drive wheel direction comes on. Output A5-X131:12 is increased to approximately +48 V and the mechanical brake [Q1] is released. The drive motor is supplied with three-phase voltage from the transistor regulator [T1].

Event:

6.

Braking in neutral

Prior event

4.

Driving in fork direction

or

5.

Driving in drive wheel direction

Action(s)

The accelerator [B32] is released and input A5-X130:17 is activated.

Influencing elements

Operator parameter 5: Automatic braking.

Resulting conditions

The frequency of the drive motor three-phase voltage is reduced.

Event:

7.

Reverse braking

Prior event

4.

Driving in fork direction

or

5.

Driving in the drive wheel direction

or

6.

Braking in neutral

Action(s)

The travel direction selector [B36] is moved to the position opposite to the travel direction and input A1-X505:4 is changed from approximately 2.6 V to approximately 0.6 V or to approximately 4.7 V.

Influencing elements

Operator parameter 5: Automatic braking. Service parameter 201: Reversing

Resulting conditions

The frequency of the drive motor three-phase voltage is reduced to change the phase sequence when the motor is idling, and then increases to a frequency that is comparable to the amount the accelerator is pressed down.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

8. Pressing on the brake pedal

Prior event

4.

Driving in fork direction

or

5.

Driving in the drive wheel direction

or

6.

Braking in neutral

Action(s)

The brake pedal [B32] is pressed down and this affects inputs A5-X130:4 & A5-X130:18 in that the voltage is increased at one of them and reduced to a comparable degree at the other.

Influencing elements

Operator parameter 5: Automatic braking. Depressing the brake pedal

Resulting conditions

The frequency of the drive motor three-phase voltage is reduced. When the brake pedal is pressed down more than 90% of its possible maximum travel:

The voltage of output A5-X131:12 is reduced, and the plug brake is activated, and at a speed of 1.5km/h, the mechanical brake [Q1] is activated. When stationary:

When the pedal is pressed down more than 90% of its possible maximum travel, the voltage at output A5-X131:12 is reduced and the mechanical brake [Q1] is activated.

Event:

9. Reach carriage operation: Out:

Action(s)

The control for the reach carriage [B21] is moved away from the operator, and input A1-X505:4 increases from approximately 2.6 V to approximately 4.7 V at the end position of the control.

Influencing elements

Resulting conditions

The pump motor is supplied with three-phase voltage from the transistor regulator [T2]. Voltage is reduced on output A5- X131:24 :OUT.REACH OUT Current flows through the proportional valve [Q7] The proportional valve [Q7] is opened in proportion to the current flowing through it.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

10. Steering

Action(s)

The steering wheel is rotated taking effect on the following inputs:

A1-X504:13 “STEER SENSOR 1 PULSE A”

A1-X504:4 “STEER SENSOR 1 PULSE B”

A1-X504:11 “STEER SENSOR 2 PULSE A”

A1-X504:2 “STEER SENSOR 2 PULSE B”

Influencing elements

Resulting conditions

Information is sent via the CAN bus to the steering servo electronics. The motor of the steering servo turns the drive unit so that speed and direction corresponds to the movements of the steering wheel.

Event:

11. Reach carriage operation: In

Action(s)

The control for the reach carriage [B21] is moved towards the operator and input A1-X505:4 is reduced from approximately 2.6 V to approximately 0.6 V at the end position of the control.

Influencing elements

Resulting conditions

The pump motor is supplied with three-phase voltage from the transistor regulator [T2]. Voltage is reduced on output A5- X131:10 :OUT.REACH IN. Current flows through the proportional valve [Q6] The proportional valve [Q6] is opened in proportion to the current flowing through it.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

12.

Fork lifting

Action(s)

The control for the fork lift [B20] is moved towards the operator, and input A1-X505:3 is reduced from approximately 2.6 V to approximately

0.6

V at the end position of the control.

Resulting conditions

The pump motor is supplied with three-phase voltage from the transistor regulator [T2].

Voltage is reduced on output A5- X131:21 OUT MAST LIFT).

Current through the On/Off valve Q2 and the mast begins to lift.

Event:

13.

Fork lowering

Action(s)

The control for fork lift [B20] is moved away from the operator, and input A1-X505:2 increases from approximately 2.6 V to approximately

4.7

V at the end position of the control.

Resulting conditions

 

Main lift:

Output A5-131:21 “OUT(PWM) MAIN MAST LOWER” reduces the voltage Voltage is maintained on output T2- 108 “OUT.(PWM) MAST LOWER” The proportional valve [Q4] is opened in proportion to the current flowing through it If the truck is equipped with a height indicator:

The speed between the main lift and the free lift is reduced when it enters this range.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

14.

Fork tilt, backwards/upwards

Action(s)

The control for fork tilt [B22] is moved towards the operator and input A1-X505:5 is reduced from approximately 2.6 V to approximately 0.6 V at the end position of the control.

Influencing elements

Resulting conditions

The pump motor is supplied with three-phase voltage from the transistor regulator [T2]. Output A5-X131:37 “OUT.AUX DIRECTION A” reduces the voltage. Output A5-X131:11 “OUT.AUX DIRECTION B” remains high. Current flows through the coil [Q18]. The tilt cylinder is pressurised via the non-return valve. No current flows through the coil [Q9].

Event:

15.

Fork tilt, forward/downward

Action(s)

The control for fork tilt [B22] is moved away from the operator and input A1-X505:5 increases from approximately 2.6 V to approximately 4.7 V at the end position of the control.

Influencing elements

Resulting conditions

Output A5-X131:37 “OUT.AUX DIRECTION A” remains high. Output A5-X131:11 “OUT.AUX DIRECTION B” reduces the voltage. Current flows through the coil [Q19]. The oil in the tilting cylinder is drained to the tank. No current flows through the coil [Q9].

Event:

16.

Sideshift, right

Action(s)

The control for side-shift [B23] is moved towards the operator and input A1-X505:6 is reduced from approximately 2.6 V to approximately 0.6 V at the end position of the control.

Influencing elements

Sideshift as an optional function.

Resulting conditions

The pump motor is supplied with three-phase voltage from the transistor regulator [T2]. Output A5-X131:37 “OUT.AUX DIRECTION A” remains high. Output A5-X131:11 “OUT.AUX DIRECTION B” reduces the voltage. Current flows through the coil [Q19]. Voltage is reduced at output A5-X131:38 “OUT.AUX”. Current flows through the coil [Q9]. The piston rod end of the sideshift cylinder is drained to the tank.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Event:

17.

Sideshift, left

Action(s)

The control for side-shift [B23] is moved away from the operator and input A1-X505:6 increases from approximately 2.6 V to approximately 4.7 V at the end position of the control.

Influencing elements

Sideshift as an optional function.

Resulting conditions

The pump motor is supplied with three-phase voltage from the transistor regulator [T2]. Output A5-X131:11 “OUT.AUX DIRECTION B” remains high. Output A5-X131:37 “OUT.AUX DIRECTION A” reduces the voltage. Current flows through the coil [Q18]. Voltage is reduced at output A5-X131:38 “OUT.AUX”. Current flows through the coil [Q9]. The piston rod end of the sideshift cylinder is pressurised.

Event:

18.

Logout

Prior event

2. Login

Action(s)

The operator presses the red button.

Influencing elements

Resulting conditions

The login screen is displayed and login is possible. The screen to be displayed is determined by service parameter 503.

Event:

19. Emergency lowering

Prior event

Action(s)

The emergency lowering valve is opened mechanically.

Influencing elements

Resulting conditions

Oil flows from the free and main lift cylinders, via the emergency lowering valve, to the tank.

Repair manual: Operation and connection sequences

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Repair manual: Parameters

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

5. Parameters

5.1 General

The truck's control system can store a number of different parameters. These are used to configure the truck according to the task to be performed. The parameters are divided into groups:

Operator parameters – The driver parameters (1-100) are used to adapt the truck’s characteristics to a specific driver or task. Up to 10 operator parameter profiles can be stored.

Service parameters – The service parameters (101–999) are used to adapt the truck's performance/actions.

Factory parameters – (1001-1250). Truck-specific parameters.

Calibration parameters – (1251–1500) save the value that is created when calibrating. These must not be changed manually.

Operator parameters are displayed and changed only for a selected operator, but if a CAN service key is connected, the parameters for all operators can be displayed and changed. Operator parameters can be changed by the operator if the truck's program is set up for this.

The service parameters can be changed once a suitable CAN service key or PDA/PC has been connected to the truck.

Factory parameters can ONLY be changed after a specially configured PDA/ PC has been connected to the truck.

Repair manual: Parameters

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

5.2 Parameter settings

To be able to change operator parameters without a service key, parameter 503 must be set to 3 or 5.

With the service key, you can change operator parameters by going to the configuration menu and then selecting the parameter to be changed for a specific operator profile.

Without the service key, via the configuration menu you can read the value of a parameter, but not change it.

i
i

Repair manual: Parameters

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

Parameter menu (PAR)

Access

To be able to change the parameters, a service key must be connected. If the key is not connected, the parameters can only be read. It is not possible to change the factory parameters without TruckCom.

i
i

Parameter screens

Each parameter can be reached by entering the parameter number in the box marked "Par". The parameter value can be entered using the numerical keypad, or the plus/minus buttons.

The plus button increases the number by one step and the minus button reduces it by one step.

The value of the parameter is displayed in the box under "Par". The value is changed by using the arrow key to select this box and then entering the value with the keypad or the plus/minus buttons. The value is saved by pressing the green button (I).

The parameter's factory setting (default value) can be selected by selecting the factory icon and pressing the green button (I).

Repair manual: Parameters

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

5.3 Operator parameters

The operator parameters for the logged-in operator profile can be set from the Operator parameter menu.

a

b

c

d
d

a Operator icon and number of the logged-in operator profile.

b Icons for selected parameter and number of the parameter.

c Icon for resetting to default value.

d Parameter value.

The arrow keys are used for moving between:

• Parameters, where the +/- keys are used to select a parameter

• Reset icon, where the parameter value is reset to the default value when the green button is pressed

• The parameter values

The screen changes appearance depending on which driver parameter has been chosen.

For parameter 1, the steering progressiveness, a screen is shown with two adjustable fields representing high speed – “Hare” – and low speed – “Snail”.

For parameters 2 to 5, a row of bars are displayed. The number of bars depends on how many steps the selected parameter can be adjusted by. The filled bars show the current parameter value.

When parameter values are chosen, the selected value is indicated by an arrow above the bar for that value. The value is changed using the +/- keys and is stored when the green button is pressed.

Repair manual: Parameters

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

5.3.1 Overview

Par.

Description

1 The steering's progressivity

2 Maximum speed, drive wheel direction

3 Maximum speed, fork direction

4 Acceleration

5 Automatic braking when speed is reducing

Connection to logged-in operator

The operator parameters can be adjusted individually to the available log-in profiles. The parameter’s connection to the operator is done by a combination of operator and parameter numbers where the single digit always corresponds to the parameter.

Operator

Parameter

range

1 1 – 10

2 11 – 20

3 21 – 30

4 31 – 40

5 41 – 50

6 51 – 60

7 61 – 70

8 71 – 80

9 81 – 90

10 91 – 100

Repair manual: Parameters

Publication Number: 7575392-040

Date: 2016-10-24

Model(s): R112, R114, R116

Applies from serial number: 6308581

10

9

8

7

6

5

4

3

2

1

s
s
Applies from serial number: 6308581 10 9 8 7 6 5 4 3 2 1 s
Applies from serial number: 6308581 10 9 8 7 6 5 4 3 2 1 s

v

s: steering sensitivity, v: travel speed, snail: low speed range, hare: high speed range

If the steering feels too sluggish or unresponsive in any of the low or high speed ranges, the corresponding value is changed upwards or downwards through the setup screen for driver parameter 1.

On the setup screen, the low speed range is represented by a snail and the high speed range by a hare.

Par.

Description

Min.

Defa