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BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 6070557 – PDF DOWNLOAD
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BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 6070557 – PDF DOWNLOAD
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BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 6070557 – PDF DOWNLOAD
Language : English
Pages : 732
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File Type : PDF
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TABLE OF CONTENTS:
BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 6070557 – PDF DOWNLOAD
1 - Contents.................................................................................................................................................................. 3 2 - General introduction...................................................................................................................................................... 19 2.1 How to use the manual................................................................................................................................................. 19 2.2 Warning symbols....................................................................................................................................................... 20 2.3 Pictogram............................................................................................................................................................. 20 3 - General safety rules...................................................................................................................................................... 21 3.1 Safety while working.................................................................................................................................................. 21 3.2 Electrical system..................................................................................................................................................... 22 3.3 Safe lifting.......................................................................................................................................................... 23 4 - Function descriptions..................................................................................................................................................... 25 4.1 Chassis 0000.......................................................................................................................................................... 25 4.1.1 Operator’s cabin (0500)......................................................................................................................................... 25 Versions for cold-store cabs...................................................................................................................................... 25 Emergency exit from the cab....................................................................................................................................... 26 4.1.2 Cab windows (0530).............................................................................................................................................. 27 Electrically heated windows....................................................................................................................................... 27 4.1.3 Driver's seat (0620)............................................................................................................................................ 28 Adjustment:....................................................................................................................................................... 28 Button for seat heater............................................................................................................................................ 28 4.1.4 Cab heating/ventilation (0630).................................................................................................................................. 29 Climate control knobs............................................................................................................................................. 29 Ventilation....................................................................................................................................................... 29 Temperature....................................................................................................................................................... 29 4.1.5 Driver protection (0840)........................................................................................................................................ 30 Tilt stops........................................................................................................................................................ 30 Overhead guard.................................................................................................................................................... 32 4.2 Motors 1000........................................................................................................................................................... 33 4.2.1 General......................................................................................................................................................... 33 4.2.2 Electric pump motor (1710)...................................................................................................................................... 33 General........................................................................................................................................................... 33 Design............................................................................................................................................................ 33 4.2.3 Electric steering motor (1730).................................................................................................................................. 34 General........................................................................................................................................................... 34 Design............................................................................................................................................................ 34 4.2.4 Fan motor/fan (1740)............................................................................................................................................ 35 4.2.5 Electric drive motor (1760)..................................................................................................................................... 36 General........................................................................................................................................................... 36 Design............................................................................................................................................................ 36 4.3 Drive gear - 2000..................................................................................................................................................... 37 4.3.1 General......................................................................................................................................................... 37 4.3.2 Design.......................................................................................................................................................... 38 4.4 Brake system 3100..................................................................................................................................................... 39 4.4.1 General......................................................................................................................................................... 39 Travel brake...................................................................................................................................................... 39 Parking brake..................................................................................................................................................... 39 Emergency brake................................................................................................................................................... 39 4.4.2 Drive motor brake (travel brake)................................................................................................................................ 40 Accelerator released.............................................................................................................................................. 40 Changing the direction of travel.................................................................................................................................. 40 4.4.3 Multiple disc brake, support arm (travel brake)................................................................................................................. 41 General........................................................................................................................................................... 41 Design............................................................................................................................................................ 41 4.4.4 Disc brake on the drive motor (parking brake)................................................................................................................... 42 General........................................................................................................................................................... 42 Design............................................................................................................................................................ 42 4.5 Steering system 4000.................................................................................................................................................. 43 4.5.1 General......................................................................................................................................................... 43 4.5.2 Design.......................................................................................................................................................... 43 4.5.3 Sensors......................................................................................................................................................... 44 Steering reference sensor......................................................................................................................................... 44 4.6 Operator compartment.................................................................................................................................................. 45 4.6.1 Truck control, overview......................................................................................................................................... 45 Right-hand control panel, single control.......................................................................................................................... 45 Right-hand control panel, multi-control........................................................................................................................... 45 Emergency switch.................................................................................................................................................. 46 Steering wheel module............................................................................................................................................. 47 Pedals............................................................................................................................................................ 47 4.6.2 Single control.................................................................................................................................................. 48 4.6.3 Multi-control................................................................................................................................................... 49 4.6.4 Central Information Display - CID............................................................................................................................... 50 Navigation........................................................................................................................................................ 50 LED symbols....................................................................................................................................................... 53 a. Travel direction - left. Flashes when no travel direction is selected, comes on permanently when travel direction is the same as drive wheel direction..... 53 b. Parking brake. Comes on when the parking brake is engaged.............................................................................................. 53 c. Travel direction - right. Flashes when no travel direction is selected, comes on permanently when travel direction is the same as fork direction....... 53 d. Stop. The truck has been stopped due to a critical fault............................................................................................... 53 e. Cabin tilt. Cabin tilting is possible (RRE Ergo)....................................................................................................... 53 f. Warning. Comes on when a warning is active............................................................................................................. 53 g. Low battery. Battery capacity is low: flashing lamp when 10% remaining, comes on permanently at 0%..................................................... 53 h. Extra. Comes on when an extra hydraulic function is selected........................................................................................... 53 Information symbols............................................................................................................................................... 54 Driver parameter symbols - Overview............................................................................................................................... 55 Catch symbols - Overview.......................................................................................................................................... 56 Service functions................................................................................................................................................. 58 Calibration functions............................................................................................................................................. 60 Configuration functions........................................................................................................................................... 62 Other functions................................................................................................................................................... 65 4.6.5 Load Information Display - LID (option)......................................................................................................................... 67 LED symbols....................................................................................................................................................... 67 a. Height preselector active (green).......................................................................................................................... 67 b. Not used............................................................................................................................................... 67 c. Sideshift in initial position (green).................................................................................................................. 67 e. Aux (yellow)........................................................................................................................................... 67 f. Not used............................................................................................................................................... 67 Symbols in the display part....................................................................................................................................... 68 4.7 Transducers and sensors (5800)........................................................................................................................................ 69 4.7.1 Inductive sensors............................................................................................................................................... 69 4.7.2 Position sensor................................................................................................................................................. 69 4.7.3 Magnetic sensor................................................................................................................................................. 70 4.8 Operation and connection sequences.................................................................................................................................... 71 4.9 Functions.............................................................................................................................................................104 4.9.1 General overview................................................................................................................................................104 Key...............................................................................................................................................................104 Components........................................................................................................................................................104 4.9.2 MCU - main control unit.........................................................................................................................................105 General...........................................................................................................................................................105 Downloading software..............................................................................................................................................105 System communication..............................................................................................................................................105 4.9.3 ACT/ACH transistor regulators...................................................................................................................................106 General...........................................................................................................................................................106 4.9.4 Start-up........................................................................................................................................................106 4.9.5 Shutdown........................................................................................................................................................107 4.9.6 Driving.........................................................................................................................................................107 Introduction......................................................................................................................................................107 Acceleration and speed reduction..................................................................................................................................107 Reversing.........................................................................................................................................................108 Brake.............................................................................................................................................................108 Travel speed......................................................................................................................................................109 4.9.7 OTP.............................................................................................................................................................110 Travel speed reduction - steering angle...........................................................................................................................110 Travel speed reduction - extension of reach carriage..............................................................................................................110 Travel speed reduction - mast splitting...........................................................................................................................110 Prevention of lifting/lowering of the forks.......................................................................................................................110 Reduced extension speed...........................................................................................................................................110 4.9.8 Steering........................................................................................................................................................111 Steering position check...........................................................................................................................................111 Steering speed....................................................................................................................................................111 Steering reference................................................................................................................................................112 Travel speed limitation...........................................................................................................................................112 Compass card......................................................................................................................................................112 4.9.9 Hydraulic system................................................................................................................................................113 Definitions.......................................................................................................................................................113 Controls..........................................................................................................................................................113 Lift..............................................................................................................................................................113 Reach movement....................................................................................................................................................114 Lift height limitation............................................................................................................................................114 Maximum height limitation.........................................................................................................................................114 Auxiliary/Extra functions (option)................................................................................................................................115 4.10 Height preselector, description of function..........................................................................................................................116 4.10.1 Using the height preselector...................................................................................................................................116 4.10.2 Symbols........................................................................................................................................................116 4.10.3 Buzzer.........................................................................................................................................................116 4.10.4 Height preselector levels......................................................................................................................................117 4.10.5 Level selection................................................................................................................................................117 4.10.6 Height programming.............................................................................................................................................118 4.10.7 Height preselector and TruckCom................................................................................................................................119 4.10.8 Lift/lowering movement.........................................................................................................................................119 4.10.9 Parameter settings, braking at height preselection.............................................................................................................120 4.11 Hydraulic system 6000................................................................................................................................................121 4.11.1 General........................................................................................................................................................121 4.11.2 Tank...........................................................................................................................................................121 4.11.3 Filter.........................................................................................................................................................121 Return filter.....................................................................................................................................................121 Dehumidification filter...........................................................................................................................................121 4.11.4 Hydraulic pump.................................................................................................................................................122 4.11.5 Valve block....................................................................................................................................................122 Main valve block..................................................................................................................................................122 Second valve block................................................................................................................................................123 4.11.6 Cylinders......................................................................................................................................................124 Main lift cylinders...............................................................................................................................................124 Free lift cylinder................................................................................................................................................124 Cylinders for the reach movement, cabin tilt, sideshift and fork tilt.............................................................................................124 4.11.7 Lift and lowering function.....................................................................................................................................125 Lifting and lowering of free lift.................................................................................................................................125 Transition from free lift to main lift............................................................................................................................125 Lifting and lowering of main lift.................................................................................................................................125 Reach movement, in and out........................................................................................................................................125 Simultaneous operation of mast lift and reach movement............................................................................................................126 4.11.8 Extra functions................................................................................................................................................126 4.11.9 Cabin tilt (RRE Ergo)..........................................................................................................................................126 Hydraulic priority system.........................................................................................................................................126 Cabin tilt (RRE Ergo) during servicing............................................................................................................................127 Cabin tilt in the event of hydraulic or electrical power loss.....................................................................................................127 4.12 Mast 7000............................................................................................................................................................128 4.12.1 Mast and reach carriage........................................................................................................................................128 4.13 Lifting devices......................................................................................................................................................129 4.13.1 Fork extensions................................................................................................................................................129 4.13.2 Telescopic forks...............................................................................................................................................129 4.14 Accessories - 9000...................................................................................................................................................131 4.14.1 Radio equipment................................................................................................................................................131 4.14.2 Extra work lights..............................................................................................................................................131 4.14.3 Extra warning light/alarm......................................................................................................................................132 4.14.4 Direction indicators...........................................................................................................................................132 4.14.5 Travel alarm...................................................................................................................................................133 4.14.6 Positioning/TV equipment.......................................................................................................................................134 4.14.7 Extra electrical equipment.....................................................................................................................................136 4.14.8 Extra equipment, miscellaneous.................................................................................................................................137 Fork spacers......................................................................................................................................................137 Load support......................................................................................................................................................138 E-bar.............................................................................................................................................................139 Fire extinguisher.................................................................................................................................................140 5 - Parameters................................................................................................................................................................141 5.1 General...............................................................................................................................................................141 5.2 Displaying/changing parameters........................................................................................................................................141 5.3 Operator parameters...................................................................................................................................................142 5.3.1 Overview........................................................................................................................................................142 5.3.2 Coupling to logged-in operator..................................................................................................................................143 5.3.3 Description.....................................................................................................................................................144 Parameter 1 (Steering)............................................................................................................................................144 Parameter 2 and 3 - Maximum travel speed..........................................................................................................................146 Parameters 4 and 5 - Acceleration/Retardation.....................................................................................................................146 Parameter 6 - Cab tilt............................................................................................................................................146 5.4 General service parameters............................................................................................................................................147 5.4.1 Overview........................................................................................................................................................147 5.4.2 Description.....................................................................................................................................................147 Parameter 101/104 - Service/Log-out...............................................................................................................................147 Parameter 105/106/114/115/117 (Travel alarms 1 and 2).............................................................................................................148 Parameter 107/108 - Battery.......................................................................................................................................150 Parameter 109/110/111/112 - Collision sensor......................................................................................................................153 Parameter 113 (shunt value).......................................................................................................................................154 Parameter 116 (Door for cold storage cab).........................................................................................................................155 5.4.3 Service parameters, travel functions............................................................................................................................156 5.4.4 Overview........................................................................................................................................................156 5.4.5 Description.....................................................................................................................................................157 Parameter 201 - Retardation when reversing........................................................................................................................157 Parameter 202/203/204 - Adjusting erroneous, maximum travel speeds................................................................................................157 Parameter 205/206/207 - Adjusting erroneous, maximum travel speeds................................................................................................158 Parameter 208 - Creep speed in travel direction control...........................................................................................................159 Parameter 209/210 - Reduced maximum travel speed above a certain lift height......................................................................................159 Parameter 211/212 - Reduced maximum travel speed with a certain reach length......................................................................................160 Parameter 213 - Permanently reduced maximum travel speed..........................................................................................................160 Parameter 214 - Adjusting the maximum travel speed in main lift range.............................................................................................160 5.5 Service parameters, hydraulics........................................................................................................................................161 5.5.1 Overview........................................................................................................................................................161 5.5.2 Description.....................................................................................................................................................164 Parameter 301/302/303/304 - Extra valve function..................................................................................................................164 Parameter 305/306/307/308 - Max. oil pressure through valve Q8....................................................................................................166 Parameter 313/314/315/316 - Closing time..........................................................................................................................167 Parameter 317/318/319/320 - Max. oil pressure through valve Q8....................................................................................................167 Parameter 321/322/323/324 - Max. oil pressure through valve Q9....................................................................................................168 Parameter 325/326/327/328 - Opening/closing time valve Q8.........................................................................................................168 Parameter 329/330/331/332 - Opening/closing time valve Q9.........................................................................................................169 Parameter 341/342 - Reducing the lifting/lowering speed...........................................................................................................169 Parameter 343 - Reduction of reach speed..........................................................................................................................170 Parameter 344 - Reduction of fork lowering speed before floor level...............................................................................................170 Parameter 347/348 - Prevents the lifting/lowering of forks........................................................................................................171 Parameter 349 - Fork weight.......................................................................................................................................171 Parameter 350 - Multi-function....................................................................................................................................172 Parameter 360 - Deactivation of hydraulic functions...............................................................................................................173 Parameter 361/362/363/364/365 /366 - Function related, maximum lifting/lowering speeds............................................................................174 Parameter 367/368 - Fork limit for deactivating the extension of the fork carriage and for sideshift..............................................................175 Parameter 369 up to and including 379 - Height pre- selection.....................................................................................................176 Parameter 380 up to and including 386 - Lift height limitations...................................................................................................178 Parameters 387 up to and including 393 - Configuring the lift height limitations..................................................................................179 Parameters 395, 396/397 Function-related, maximum lift heights....................................................................................................180 Parameters 398/399 -Operator profile-dependent, maximum lift heights..............................................................................................181 5.6 Service parameters, CID...............................................................................................................................................182 5.6.1 Overview........................................................................................................................................................182 5.6.2 Description.....................................................................................................................................................183 Parameter 503 - Login method......................................................................................................................................183 Parameter 504/505/506/507 - Smart Access..........................................................................................................................184 Parameters 508/509/512/513/514 - CID configuration................................................................................................................188 Parameter 510/511 - Height pre-selector...........................................................................................................................190 5.7 General factory parameters............................................................................................................................................191 5.7.1 Overview........................................................................................................................................................191 5.7.2 Description.....................................................................................................................................................192 Parameter 1001 (Truck type).......................................................................................................................................192 Parameter 1002 - (Drive motor)....................................................................................................................................192 Parameter 1003 - Pedal type.......................................................................................................................................192 Parameter 1004 - Steering servo...................................................................................................................................193 Parameter 1005 - Pump motor.......................................................................................................................................193 Parameter 1006 - Hydraulic pump...................................................................................................................................193 Parameter 1007 - Activation of hydraulic levers...................................................................................................................194 Parameter 1008 - Mast type........................................................................................................................................194 Parameter 1009 - Height indication................................................................................................................................195 Parameter 1010 - Weight indicating................................................................................................................................195 5.8 Factory parameters, activation of options.............................................................................................................................196 5.9 Factory parameters, calibration.......................................................................................................................................198 6 - Installation..............................................................................................................................................................201 6.1 Transporting the truck................................................................................................................................................201 Method 1..............................................................................................................................................................201 Method 2..............................................................................................................................................................201 6.2 Initial operation.....................................................................................................................................................202 6.2.1 Tool............................................................................................................................................................202 6.2.2 Battery.........................................................................................................................................................202 Placing the battery...............................................................................................................................................202 Battery parameters................................................................................................................................................203 6.2.3 Mast, fitting...................................................................................................................................................203 6.2.4 Parameters on initial operation.................................................................................................................................203 Load indicator....................................................................................................................................................203 Ergo cabin........................................................................................................................................................204 Cold store cabin..................................................................................................................................................204 6.2.5 Parameters for optional equipment...............................................................................................................................205 Height measurement (option).......................................................................................................................................205 Travel speed limitation, height-dependent.........................................................................................................................205 Travel speed limitation, reach movement dependent.................................................................................................................205 Travel speed limitation, parameter-dependent......................................................................................................................206 Collision sensor (BT).............................................................................................................................................206 6.2.6 Test driving....................................................................................................................................................206 7 - Maintenance...............................................................................................................................................................209 7.1 Introduction, maintenance.............................................................................................................................................209 7.2 Safety regulations during maintenance work............................................................................................................................210 7.3 Periodic maintenance..................................................................................................................................................212 7.3.1 Every 500 B-hours/180 days......................................................................................................................................212 7.3.2 Every 1,000 B-hours/360 days....................................................................................................................................214 7.3.3 Every 2,000 B-hours/720 days....................................................................................................................................219 7.3.4 Every 3,000 B-hours/1,080 days..................................................................................................................................219 7.3.5 Every 5,000 B-hours/1,800 days..................................................................................................................................221 7.3.6 Annual status inspection........................................................................................................................................221 7.4 Maintenance instructions..............................................................................................................................................222 7.4.1 Cleaning and washing............................................................................................................................................222 High-pressure washers.............................................................................................................................................222 Degreasing agents.................................................................................................................................................222 Cleaning the exterior.............................................................................................................................................222 Cleaning the chain................................................................................................................................................223 Cleaning the motor compartment....................................................................................................................................223 Electrical components.............................................................................................................................................223 8 - Troubleshooting...........................................................................................................................................................225 8.1 Abbreviations used in this section....................................................................................................................................225 8.2 Truck help functions..................................................................................................................................................225 8.2.1 Error log menu..................................................................................................................................................225 Description.......................................................................................................................................................225 Driver............................................................................................................................................................225 8.2.2 Error information menu..........................................................................................................................................226 Description.......................................................................................................................................................226 Driver............................................................................................................................................................226 8.2.3 Diagnostic screens..............................................................................................................................................226 Driver............................................................................................................................................................226 State 1 - Voltage from the control console levers.................................................................................................................227 State 2 - Digital signals from the truck control to CID...........................................................................................................228 State 3 - Voltage from control/sensor to MCU......................................................................................................................229 State 4 - Digital input signals to MCU............................................................................................................................232 State 5 - Digital output signals from MCU.........................................................................................................................234 State 6 - PWM output signals from MCU.............................................................................................................................235 State 7 - FCU (not used)..........................................................................................................................................235 State 8 - FCU (not used)..........................................................................................................................................235 State 9 - GFU (not used)..........................................................................................................................................235 State 10 - GFU (not used).........................................................................................................................................235 State 11 - Temperature signals....................................................................................................................................236 State 12 - Voltage levels.........................................................................................................................................236 State 13 - Travel information.....................................................................................................................................237 State 14 - Steering information...................................................................................................................................238 State 15 - Lift/lowering information..............................................................................................................................239 Stage 16 - Reach movement information.............................................................................................................................240 Stage 17 - Hydraulic information..................................................................................................................................241 8.3 Initial troubleshooting...............................................................................................................................................243 8.4 Troubleshooting using catch symbol....................................................................................................................................244 8.5 Troubleshooting using error code......................................................................................................................................251 8.5.1 CID, warnings and errors........................................................................................................................................253 8.5.2 MCU and other warnings and errors...............................................................................................................................257 8.5.3 Drive system error..............................................................................................................................................267 8.5.4 Hydraulic system error..........................................................................................................................................279 8.5.5 Steering system, warnings and errors............................................................................................................................314 8.5.6 GFU, warnings and errors........................................................................................................................................321 8.6 Troubleshooting without indications...................................................................................................................................322 8.6.1 Mechanical brake (3000).........................................................................................................................................322 8.6.2 Steering (4000).................................................................................................................................................322 8.6.3 Telescopic forks................................................................................................................................................323 8.6.4 Log-in normal but one or more functions cannot be used..........................................................................................................324 9 - Frame/Chassis 0000........................................................................................................................................................327 9.1 General...............................................................................................................................................................327 9.2 Motor hood (0340).....................................................................................................................................................327 9.2.1 Opening the motor compartment...................................................................................................................................327 RRE 140-RRE 250...................................................................................................................................................327 To open the motor compartment:....................................................................................................................................327 To close the motor compartment:...................................................................................................................................327 Replacing the motor hood..........................................................................................................................................328 Adjustment of motor hood..........................................................................................................................................328 9.3 Battery compartment components (0390).................................................................................................................................330 9.3.1 Adjusting the battery bed.......................................................................................................................................330 9.4 Operator's cab (0500).................................................................................................................................................331 9.4.1 Cab tilting RRE 140 - 250 Ergo..................................................................................................................................331 9.3.1 Cab windows (0530)..............................................................................................................................................332 Fitting a window..................................................................................................................................................332 9.3.2 Cab door (0550).................................................................................................................................................334 Disassembly of the door lock......................................................................................................................................334 Tools required....................................................................................................................................................335 Method............................................................................................................................................................335 Disassembly of the lock device....................................................................................................................................336 9.4 Operator compartment (0600)...........................................................................................................................................338 9.4.1 Operator's seat (0620)..........................................................................................................................................338 Disassembling the entire seat.....................................................................................................................................338 Replacing the seat switch.........................................................................................................................................339 Replacing the back rest...........................................................................................................................................340 Replacing the chair seat..........................................................................................................................................341 Replacing the seat heater switch..................................................................................................................................341 9.4.2 Cab heating/ventilation (0630)..................................................................................................................................342 Replacing the air filter on the cold store cabin:.................................................................................................................342 Removing the fan and heater.......................................................................................................................................343 Replacing the potentiometers......................................................................................................................................347 9.4.3 Internal fittings (0680)........................................................................................................................................349 9.4.4 Disassembling/assembling the floor plate, B version 0680........................................................................................................350 9.5 Safety equipment (0800)...............................................................................................................................................352 9.5.1 Checking the overhead guard (0810)..............................................................................................................................352 9.5.2 Adjusting the tilt stops (0840).................................................................................................................................353 10 - Motors 1000..............................................................................................................................................................355 10.1 Motor sensors........................................................................................................................................................355 10.1.1 Temperature sensor.............................................................................................................................................355 Retrofitting an external temperature sensor.......................................................................................................................356 10.1.2 Replacing the motor speed sensor...............................................................................................................................356 10.2 Pump motor (1710)....................................................................................................................................................357 10.2.1 General........................................................................................................................................................357 The pump motor dismantled.........................................................................................................................................357 10.2.2 Replacing the bearing on the pump motor........................................................................................................................358 Dismantling the pump motor........................................................................................................................................358 Reassembling the pump motor.......................................................................................................................................360 10.3 Steering motor and steering unit (1730)..............................................................................................................................361 10.3.1 General........................................................................................................................................................361 10.3.2 Layout of the flange holes.....................................................................................................................................361 10.3.3 Removing the steering motor from the truck.....................................................................................................................362 10.3.4 Fitting the steering motor in the truck........................................................................................................................362 10.4 Fan motor/fan (1740).................................................................................................................................................363 10.4.1 General........................................................................................................................................................363 10.4.2 Replacing the frequency converter cooling fan..................................................................................................................363 Standard truck....................................................................................................................................................363 Ergo truck........................................................................................................................................................363 10.4.3 Replacing the motor compartment cooling fan....................................................................................................................365 10.5 Drive motor (1760)...................................................................................................................................................366 10.5.1 General........................................................................................................................................................366 The drive motor dismantled........................................................................................................................................366 10.5.2 Removing the drive motor from the truck........................................................................................................................367 10.5.3 Dismantling the drive motor....................................................................................................................................369 10.5.4 Cleaning.......................................................................................................................................................370 10.5.5 Assembling the drive motor.....................................................................................................................................371 10.5.6 Fitting the drive motor in the truck...........................................................................................................................373 11 - Drive gear 2000..........................................................................................................................................................375 11.1 General..............................................................................................................................................................375 11.2 Repairs/servicing....................................................................................................................................................375 11.3 Actions..............................................................................................................................................................376 11.3.1 Checking the oil level.........................................................................................................................................376 11.3.2 Changing the oil...............................................................................................................................................376 11.3.3 Leakage from the bottom cover..................................................................................................................................378 11.3.4 Replacing the drive gear.......................................................................................................................................379 Special tools.....................................................................................................................................................379 Exposing the drive gear...........................................................................................................................................379 Removing the drive motor from the truck...........................................................................................................................379 Removing the steering motor from the truck........................................................................................................................379 Removing the drive gear from the truck............................................................................................................................380 Replacing the drive gear in the truck.............................................................................................................................382 Fitting the steering motor in the truck...........................................................................................................................383 Fitting the drive motor in the truck..............................................................................................................................383 Completion work...................................................................................................................................................383 12 - Brake and wheel 3000.....................................................................................................................................................385 12.1 Travel brake system (3100)...........................................................................................................................................385 12.1.1 Removing the support arm's multiple disc brake.................................................................................................................385 12.1.2 Dismantling the multiple disc brake............................................................................................................................385 Inspection........................................................................................................................................................386 Adjusting play....................................................................................................................................................386 Assembling the multiple disc brake................................................................................................................................387 12.1.3 Installing the multiple disc brake in the truck................................................................................................................387 12.1.4 Checking the wheel brake's brake force.........................................................................................................................388 12.2 Parking brake (3300).................................................................................................................................................389 12.2.1 General........................................................................................................................................................389 a. Fixing screws..................................................................................................................................................389 b. Magnet housing.............................................................................................................................................389 c. Pressure plate.............................................................................................................................................389 d. Adjusting screws...........................................................................................................................................389 e. Friction disc..............................................................................................................................................389 f. Pressure plate (fixed).....................................................................................................................................389 g. Locking screws.............................................................................................................................................389 h. Hub........................................................................................................................................................389 12.2.2 Emergency release of the parking brake.........................................................................................................................390 12.2.3 Checking the brake force.......................................................................................................................................390 12.2.4 Removing the parking brake from the truck......................................................................................................................391 Dismantling and checking for wear.................................................................................................................................392 Adjusting the air gap.............................................................................................................................................394 12.2.5 Installing the parking brake in the truck......................................................................................................................396 12.3 Drive wheel (3530)...................................................................................................................................................397 12.3.1 General........................................................................................................................................................397 12.3.2 Removing the drive wheel from the truck........................................................................................................................397 12.3.3 Installing the drive wheel on the truck........................................................................................................................397 12.4 Wheel bolt (3530)....................................................................................................................................................398 General...............................................................................................................................................................398 12.4.1 Replacing wheel bolts..........................................................................................................................................398 12.5 Support arm wheel (3550).............................................................................................................................................399 12.5.1 Removing the support arm wheel from the truck..................................................................................................................399 12.5.2 Replacing a wheel bearing - braked wheel (A)...................................................................................................................400 12.5.3 Replacing a wheel bearing - unbraked wheel (B).................................................................................................................401 12.5.4 Fitting the support arm wheel to the truck.....................................................................................................................402 12.5.5 Wheel wear and tear............................................................................................................................................403 13 - Steering system 4000.....................................................................................................................................................405 13.1 Electric steering wheel (4310).......................................................................................................................................405 13.1.1 General........................................................................................................................................................405 13.1.2 Replacing the pulse transducer on the steering wheel module....................................................................................................405 13.1.3 Removing the operating console from the truck..................................................................................................................406 13.1.4 Replacing the wiring harness in the operating console..........................................................................................................407 13.1.5 Fitting the operating console in the truck.....................................................................................................................409 13.2 Steering reference sensor (4350).....................................................................................................................................410 General...............................................................................................................................................................410 13.2.1 Replacing the reference transducer [B17].......................................................................................................................410 13.3 Steering bearings (4380).............................................................................................................................................411 13.3.1 Removing a steering bearing from the drive gear................................................................................................................411 13.3.2 Fitting a steering bearing on the drive gear...................................................................................................................411 14 - Electrical system 5000...................................................................................................................................................413 14.1 Battery (5110).......................................................................................................................................................413 14.1.1 Battery recommendation.........................................................................................................................................413 Exide gel batteries (Sonnenschein, for example)...................................................................................................................413 Hawker Evolution gel batteries....................................................................................................................................413 14.1.2 Battery installation...........................................................................................................................................414 Replacement/installation of battery...............................................................................................................................414 Procedure without battery changing table..........................................................................................................................415 Procedure with battery changing table.............................................................................................................................415 14.2 LID (5200)...........................................................................................................................................................416 14.2.1 Replacement of LID.............................................................................................................................................416 14.2.2 Replacement of LID cold store cab..............................................................................................................................417 14.3 Replacing pedals.....................................................................................................................................................418 14.3.1 Replacing/repairing safety pedal...............................................................................................................................419 14.4 Control console (5510)...............................................................................................................................................420 14.4.1 General........................................................................................................................................................420 14.4.2 Replacement/installation of a control..........................................................................................................................420 14.4.3 Replacing the multi-function control...........................................................................................................................421 Replacing the multi-function control's buttons....................................................................................................................421 14.4.4 Remove the control console from the truck......................................................................................................................422 14.4.5 Replacing the access card's circuit board......................................................................................................................423 14.4.6 Dismantling the control console................................................................................................................................424 Installing an extra push button...................................................................................................................................426 Replacing the travel direction selector with signal button........................................................................................................426 Replacing the display.............................................................................................................................................427 14.4.7 Assembling the control console.................................................................................................................................427 14.4.8 Placing the control console in the truck.......................................................................................................................428 14.5 Magnetic sensor (5850)...............................................................................................................................................430 General...............................................................................................................................................................430 14.5.1 Replacing the magnetic sensor [B47]............................................................................................................................430 14.5.2 Reference magnet...............................................................................................................................................431 14.6 Parameter settings...................................................................................................................................................432 14.6.1 Configuration menu.............................................................................................................................................432 Calendar/hour counter menu........................................................................................................................................432 Parameter menu (PAR)..............................................................................................................................................432 Setting driver parameters.........................................................................................................................................433 14.7 PIN menu.............................................................................................................................................................434 14.7.1 Menu for activating a PIN block................................................................................................................................435 14.7.2 Menu for programming a PIN (P).................................................................................................................................435 14.8 Calibrations.........................................................................................................................................................436 14.8.1 Calibrating the hydraulic function control.....................................................................................................................436 14.8.2 Height measurement/reach movement length calibration...........................................................................................................437 Calibrating height measurement (option; must have height encoders fitted).........................................................................................438 Calibrating reach movement length.................................................................................................................................439 Calibration of the zero position for the fork tilt................................................................................................................440 14.8.3 Valve calibration..............................................................................................................................................441 Lift valve calibration............................................................................................................................................441 Mast transition lift..............................................................................................................................................442 Lowering valve calibration with height indication.................................................................................................................443 Lowering calibration without height indication....................................................................................................................445 Reach movement valve calibration..................................................................................................................................447 Calibration of the Ergo cabin.....................................................................................................................................450 14.8.4 Weight calibration.............................................................................................................................................451 Calibrating the weight indication.................................................................................................................................451 14.9 Changing cabling.....................................................................................................................................................453 14.10 Main computer unit MCU (A5).........................................................................................................................................454 14.10.1 Installing a new card in the truck............................................................................................................................455 14.10.2 Voltage feed..................................................................................................................................................455 14.10.3 Battery minus.................................................................................................................................................455 14.10.4 Internal status monitoring....................................................................................................................................455 14.10.5 Resetting the battery indicator...............................................................................................................................455 15 - Hydraulic system 6000....................................................................................................................................................457 15.1 Hydraulic hygiene....................................................................................................................................................457 15.1.1 Cleaning.......................................................................................................................................................457 15.1.2 Packaging......................................................................................................................................................457 15.1.3 Handling.......................................................................................................................................................457 15.1.4 Storage........................................................................................................................................................458 15.1.5 Procedure......................................................................................................................................................458 15.2 Hydraulic unit (6100)................................................................................................................................................459 15.2.1 Emptying the hydraulic tank....................................................................................................................................460 15.2.2 Hydraulic system, bleeding.....................................................................................................................................461 15.2.3 Remove the pump motor from the truck...........................................................................................................................462 15.2.4 Replacing the hydraulic pump...................................................................................................................................463 15.2.5 Fitting the pump motor in the truck............................................................................................................................464 15.3 Main valve (6210)....................................................................................................................................................465 15.3.1 Emergency lowering of forks....................................................................................................................................465 15.3.2 Replacing the main valve block.................................................................................................................................466 15.3.3 Replacing the Q4 valve.........................................................................................................................................468 Calibration of valve..............................................................................................................................................469 15.3.4 Adjusting the maximum opening pressure.........................................................................................................................470 15.4 Hydraulic couplings (6230)...........................................................................................................................................472 15.4.1 Hydraulic couplings, tightening torques........................................................................................................................472 Tapered coupling with O-ring......................................................................................................................................472 Tredo seal........................................................................................................................................................473 Pipe coupling.....................................................................................................................................................473 15.4.2 Quick coupling.................................................................................................................................................475 15.5 Hydraulic system, mast (6300)........................................................................................................................................477 15.5.1 Mast-mounted hose reel (6370)..................................................................................................................................477 General...........................................................................................................................................................477 15.5.2 Fitting the hose reel..........................................................................................................................................477 Spring preloading (turns).........................................................................................................................................477 15.5.3 Checks after fitting...........................................................................................................................................478 15.6 Main lift cylinder 6610..............................................................................................................................................479 General...............................................................................................................................................................479 15.6.1 Overview.......................................................................................................................................................480 Cylinder nomenclature.............................................................................................................................................480 Nomenclature for cylinder head....................................................................................................................................481 Nomenclature for piston...........................................................................................................................................481 15.6.2 Remove the lift cylinder from the mast.........................................................................................................................482 15.6.3 Replacing the hose rupture valve...............................................................................................................................483 15.6.4 Dismantling the cylinder.......................................................................................................................................484 15.6.5 Dismantling the piston.........................................................................................................................................486 Method............................................................................................................................................................486 15.6.6 Dismantling the cylinder head..................................................................................................................................486 15.6.7 Fitting the cylinder head seals................................................................................................................................488 15.6.8 Fitting the piston seals.......................................................................................................................................490 15.6.9 Assembling the cylinder........................................................................................................................................492 15.6.10 Assembling the cylinder in the mast...........................................................................................................................494 15.7 Free lift cylinder (6620)............................................................................................................................................496 General...............................................................................................................................................................496 15.7.1 Removing the free lift cylinder from the truck.................................................................................................................497 15.7.2 Replacing the hose rupture valve, free lift cylinder...........................................................................................................498 15.7.3 Fitting the free lift cylinder in the truck....................................................................................................................498 15.8 Reach cylinder (6650)................................................................................................................................................499 15.8.1 General........................................................................................................................................................499 15.8.2 Remove the reach cylinder from the truck.......................................................................................................................499 15.8.3 Fitting the reach cylinder in the truck........................................................................................................................500 15.9 Fork tilt cylinder (6660)............................................................................................................................................501 15.9.1 General........................................................................................................................................................501 15.9.2 Remove the tilt cylinder from the truck........................................................................................................................502 Mast with valve on the fork carriage:.............................................................................................................................502 Mast without valve on the fork carriage:..........................................................................................................................504 15.9.3 Fit the tilt cylinder in the truck.............................................................................................................................506 Mast without valve on the fork carriage...........................................................................................................................508 15.10 Cab tilt cylinder (6660)............................................................................................................................................510 15.10.1 General.......................................................................................................................................................510 15.10.2 Overview......................................................................................................................................................510 Cylinder nomenclature.............................................................................................................................................510 Nomenclature for cylinder head....................................................................................................................................511 Nomenclature for piston...........................................................................................................................................511 15.10.3 Dismantling the cylinder......................................................................................................................................512 15.10.4 Dismantling the piston rod....................................................................................................................................514 15.10.5 Dismantling the cylinder head.................................................................................................................................516 15.10.6 Fitting the cylinder head seals...............................................................................................................................518 15.10.7 Dismantling the piston rod....................................................................................................................................520 15.10.8 Assembling the cylinder.......................................................................................................................................522 15.11 Sideshift cylinder (6670)...........................................................................................................................................524 15.11.1 General.......................................................................................................................................................524 15.11.2 Overview......................................................................................................................................................525 Cylinder nomenclature.............................................................................................................................................525 Nomenclature for cylinder head....................................................................................................................................526 Nomenclature for piston...........................................................................................................................................526 15.11.3 Dismantling the cylinder from the truck.......................................................................................................................527 15.11.4 Dismantling the cylinder......................................................................................................................................528 15.11.5 Dismantling the piston rod....................................................................................................................................530 15.11.6 Dismantling the cylinder head.................................................................................................................................532 15.11.7 Fitting the cylinder head seals...............................................................................................................................534 15.11.8 Dismantling the piston rod....................................................................................................................................536 15.11.9 Assembling the cylinder.......................................................................................................................................538 15.11.10 Refitting the cylinder in the truck..........................................................................................................................539 16 - Mast/Lift system 7000....................................................................................................................................................541 16.1 Main mast 1.6-2.5 t (7100)...........................................................................................................................................541 16.1.1 Replacing the complete mast....................................................................................................................................541 16.1.2 Removing the mast from the truck...............................................................................................................................542 16.1.3 Adjusting mast play............................................................................................................................................545 General...........................................................................................................................................................545 Preparations......................................................................................................................................................545 Adjusting lateral play............................................................................................................................................548 Adjusting radial play.............................................................................................................................................549 Adjusting the damping elements....................................................................................................................................549 Adjusting the damper plate........................................................................................................................................550 Refitting the mast................................................................................................................................................550 16.1.4 Replacing the mast's damper plates.............................................................................................................................551 16.1.5 Fitting the mast on the truck..................................................................................................................................552 16.2 Main lift chain system (7120)........................................................................................................................................556 16.2.1 General........................................................................................................................................................556 16.2.2 Inspecting the chain...........................................................................................................................................556 Noise.............................................................................................................................................................556 Surface rust......................................................................................................................................................556 Rusty links.......................................................................................................................................................556 Stiff links.......................................................................................................................................................557 Bolt rotation.....................................................................................................................................................557 Loose bolts.......................................................................................................................................................557 Link plate wear...................................................................................................................................................558 Elongation........................................................................................................................................................559 Damage............................................................................................................................................................559 Damaged plates....................................................................................................................................................560 Damaged bolts.....................................................................................................................................................560 Dirty chain.......................................................................................................................................................560 16.2.3 Lubricating the chain..........................................................................................................................................560 16.2.4 Main lift chain system, adjusting the fork-to-floor distance...................................................................................................561 16.3 Reach carriage (7190)................................................................................................................................................562 16.3.1 Adjusting radial play in the reach carriage....................................................................................................................562 16.3.2 Adjusting axial play in the reach carriage.....................................................................................................................564 16.4 Lifting devices (7400)...............................................................................................................................................565 16.4.1 Forks..........................................................................................................................................................565 General...........................................................................................................................................................565 Inspection........................................................................................................................................................565 Inspection intervals..............................................................................................................................................565 Surface cracks....................................................................................................................................................565 Difference in height between the fork tips........................................................................................................................566 Position locks....................................................................................................................................................566 Legibility of markings............................................................................................................................................566 Fork blades and back..............................................................................................................................................566 Mounting elements on the fork.....................................................................................................................................566 16.4.2 Forks, repairs and testing.....................................................................................................................................567 Repair............................................................................................................................................................567 Testing the yield point...........................................................................................................................................567 Fork..............................................................................................................................................................567 a. Fork.......................................................................................................................................................567 b. Clamp..................................................................................................................................................567 c. Locking pin............................................................................................................................................567 d. Washer.................................................................................................................................................567 e. Spring.................................................................................................................................................567 f. Catch..................................................................................................................................................567 16.5 Fork carriage........................................................................................................................................................568 16.5.1 Checking the fork carriage's wear strip........................................................................................................................568 16.5.2 Lubricating the fork carriage..................................................................................................................................569 16.6 Fork spread unit.....................................................................................................................................................570 16.6.1 Servicing the fork spread unit.................................................................................................................................570 Replacing bearings................................................................................................................................................571 Replacing the rollers.............................................................................................................................................571 16.7 Fork extensions with adjustable fork length..........................................................................................................................572 a. Fork extension.....................................................................................................................................................573 b. Fork, main segment.............................................................................................................................................573 c. Fork, extension................................................................................................................................................573 d. Fork, extension................................................................................................................................................573 e. Pin............................................................................................................................................................573 f. Catch..........................................................................................................................................................573 16.8 Manual telescopic forks..............................................................................................................................................574 16.8.1 Fitting........................................................................................................................................................574 16.8.2 Maintenance....................................................................................................................................................575 16.9 Hydraulic telescopic forks...........................................................................................................................................576 16.9.1 Telescopic forks with separate flow dividers...................................................................................................................577 Assembly instructions.............................................................................................................................................578 Initial operation of telescopic forks with separate flow dividers.................................................................................................578 16.9.2 Telescopic forks with integrated flow dividers.................................................................................................................579 a. Telescopic forks, pair of forks................................................................................................................................579 b. Piston.....................................................................................................................................................579 c. Cylinder head..............................................................................................................................................579 d. Slide plate................................................................................................................................................579 e. Outer fork.................................................................................................................................................579 f. Piston rod.................................................................................................................................................579 Assembly instructions.............................................................................................................................................580 Initial operation of telescopic forks with integrated flow dividers...............................................................................................580 16.9.3 Maintenance of telescopic forks................................................................................................................................581 16.9.4 Dismantling telescopic forks...................................................................................................................................582 16.9.5 Assembling telescopic forks....................................................................................................................................583 17 - Peripherals - 8000.......................................................................................................................................................585 17.1 Introduction.........................................................................................................................................................585 18 - Extra equipment - 9000...................................................................................................................................................587 18.1 Introduction.........................................................................................................................................................587 19 - Appendix “Destruction instructions”......................................................................................................................................589 19.1 General..............................................................................................................................................................589 19.2 Marking of plastics..................................................................................................................................................589 19.2.1 General marking of products and packaging material.............................................................................................................589 19.2.2 Marking according to our standard..............................................................................................................................590 Abbreviations.....................................................................................................................................................590 Marking examples..................................................................................................................................................590 19.3 Pressure vessels.....................................................................................................................................................591 19.3.1 Gas dampers....................................................................................................................................................591 19.4 Sorting categories...................................................................................................................................................592 20 - Circuit diagram..........................................................................................................................................................595 20.1 Components...........................................................................................................................................................595 20.2 Component location...................................................................................................................................................603 Figure 1 (Fork carriage)..............................................................................................................................................603 Figure 2 (Chassis cabling)............................................................................................................................................604 Figure 3 (Chassis cabling)............................................................................................................................................605 Figure 4 (Support leg brake)..........................................................................................................................................606 Figure 5 (Pedals).....................................................................................................................................................606 Figure 6 (Motor cabling)..............................................................................................................................................607 Figure 7 (Pushout carriage cabling)...................................................................................................................................608 Figure 8 (Level/position meter).......................................................................................................................................609 Figure 9 (seat).......................................................................................................................................................610 Figure 10 (DC/DC).....................................................................................................................................................611 Figure 11 (Cabling driver position)...................................................................................................................................612 Figure 12 (Extra hydraulic function(s))...............................................................................................................................613 Figure 13 (Travel alarm)..............................................................................................................................................614 Figure 14 (Cabling roof)..............................................................................................................................................615 Figure 15 (Roof)......................................................................................................................................................616 Figure 16 (Sound system)..............................................................................................................................................617 Figure 17 (Forks camera)..............................................................................................................................................618 Figure 18 (Battery cabling)...........................................................................................................................................619 Figure 19 (Fuse box)..................................................................................................................................................620 Figure 20 (LID).......................................................................................................................................................621 Figure 21 (Frame cabling).............................................................................................................................................622 Figure 22 (Fork carriage cabling).....................................................................................................................................623 Figure 23 (Pushout carriage cabling options)..........................................................................................................................624 Figure 24 (Working light cabling).....................................................................................................................................625 Figure 24 (Extra outlet DC)...........................................................................................................................................626 Figure 25 (T.W.I.S.)..................................................................................................................................................626 Figure 26 (Shock Switch / Impact Manager).............................................................................................................................627 Figure 27 (Heated windows CC).........................................................................................................................................628 Figure 28 (Cabling driver position CC)................................................................................................................................629 Figure 29 (Heater CC).................................................................................................................................................630 Figure 30 (Cabling cab heater CC).....................................................................................................................................631 Figure 31 (Safety switch for door CC).................................................................................................................................632 Figure 32 (Cabling cab tilt)..........................................................................................................................................632 Figure 33 (Control panel).............................................................................................................................................633 Figure 34 (Control panel).............................................................................................................................................634 Figure 35 (Steering arm)..............................................................................................................................................635 Figure 36 (MCU).......................................................................................................................................................636 Figure 37 (Control motor).............................................................................................................................................637 Figure 38 (Main valve block)..........................................................................................................................................638 20.3 Cable connections and pole bolts.....................................................................................................................................639 20.3.1 ACT/ACH transistor regulators..................................................................................................................................639 20.3.2 Connections to CID.............................................................................................................................................641 20.3.3 Connections on the MCU.........................................................................................................................................642 20.4 Fuse box A9..........................................................................................................................................................645 20.5 Overview.............................................................................................................................................................646 20.6 Wiring diagram.......................................................................................................................................................650 20.7 Detailed diagram cold-store cab......................................................................................................................................673 21 - Hydraulics schematics....................................................................................................................................................699 21.1 Main valve unit......................................................................................................................................................699 21.1.1 RRE Std........................................................................................................................................................699 21.1.2 RRE Ergo.......................................................................................................................................................700 21.2 Hydraulics schematics................................................................................................................................................701 21.2.1 Schematics designations........................................................................................................................................701 21.2.2 List of symbols................................................................................................................................................702 21.2.3 Wiring diagrams RRE/RRE Ergo...................................................................................................................................703 22 - Tools....................................................................................................................................................................709 22.1 AMP contacts.........................................................................................................................................................709 22.2 MQS contacts.........................................................................................................................................................710 22.3 CPC contacts.........................................................................................................................................................712 22.4 Other tools..........................................................................................................................................................713 23 - Appendix “Service data and grease specifications”........................................................................................................................719 23.1 General tightening torques...........................................................................................................................................719 23.1.1 Galvanised non-oiled bolts.....................................................................................................................................719 23.1.2 Untreated oiled bolts..........................................................................................................................................720 23.2 Oil and grease specification.........................................................................................................................................721 24 - Technical data...........................................................................................................................................................723
DESCRIPTION:
BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 6070557 – PDF DOWNLOAD
General introduction
How to use the manual
The service manual is divided into chapters containing the following information:
• Safety regulations – This chapter includes general safety regulations regaring working with the truck.
• Function – This chapter provides a basic description of the main functions of the truck.
• Parameters – This chapter contains a basic description of the steering system’s parameters.
• Installation – This chapter describes the work that needs to be done before the truck is used for the first time.
• Maintenance – the chapter contains a general periodic maintenance schedule and a detailed description of the maintenance to be carried out.
• Troubleshooting – This chapter describes the error codes that appear in the display when the truck completely or partly stops working. The chapter also describes the reason why the errors occur and suggested remedies.
• Actions chapter – This chapter describes the various parts of the truck, what the parts look like and the service actions that need to be carried out. The various chapters are organised according to BT’s Code system.
• Appendixes – The appendixes contain:
– instructions for disposal
– information about electrical components and wiring diagrams
– hydraulics diagrams
– list of required tools
– information about general tightening torques
– oil and grease specifications
– technical data.
S.S 05/01/2025
