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BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 7510399-040 – PDF DOWNLOAD
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BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 7510399-040 – PDF DOWNLOAD
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BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 7510399-040 – PDF DOWNLOAD
FILE DETAILS:
BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 7510399-040 – PDF DOWNLOAD
Language : English
Pages : 826
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File Type : PDF
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TABLE OF CONTENTS:
BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 7510399-040 – PDF DOWNLOAD
1 – Contents........................................................................................................ 3 2 – General introduction............................................................................................ 23 2.1 How to use this manual...................................................................................... 23 2.2 Warning symbols............................................................................................. 24 2.3 Pictograms.................................................................................................. 24 3 – General safety rules............................................................................................ 25 3.1 Work safety................................................................................................. 25 3.2 Electrical systems.......................................................................................... 26 3.3 Safe lifting................................................................................................ 27 4 – Descriptions of functions....................................................................................... 29 4.1 Chassis 0000................................................................................................ 29 4.1.1 Operator’s cabin (0500)............................................................................... 29 Versions for cold-store cabs............................................................................ 29 Emergency exit from the cab............................................................................. 30 4.1.2 Cab windows (0530).................................................................................... 31 Electrically heated windows............................................................................. 31 4.1.3 Operator's seat (0620)................................................................................ 32 Adjustment:............................................................................................. 32 Button for seat heater.................................................................................. 32 4.1.4 Cab heating/ventilation (0630)........................................................................ 33 Climate control knobs................................................................................... 33 Ventilation............................................................................................. 33 Temperature............................................................................................. 33 4.1.5 Operator protection (0840)............................................................................ 34 Studs................................................................................................... 34 Protective overhead guard............................................................................... 36 4.2 Motors 1000................................................................................................. 37 4.2.1 General............................................................................................... 37 4.2.2 Electric pump motor (1710)............................................................................ 37 General................................................................................................. 37 Design.................................................................................................. 37 4.2.3 Electric steering motor (1730)........................................................................ 39 General................................................................................................. 39 Design.................................................................................................. 39 4.2.4 Fan motor/fan (1740).................................................................................. 40 4.2.5 Electric drive motor (1760)........................................................................... 41 General................................................................................................. 41 Design.................................................................................................. 41 4.3 Drive gear - 2000........................................................................................... 42 4.3.1 General............................................................................................... 42 4.3.2 Design................................................................................................ 43 4.4 Brake system 3100........................................................................................... 44 4.4.1 General............................................................................................... 44 Travel brake............................................................................................ 44 Parking brake........................................................................................... 44 Emergency brake......................................................................................... 44 4.4.2 Drive motor brake (travel brake)...................................................................... 45 Accelerator released.................................................................................... 45 Changing the direction of travel........................................................................ 45 4.4.3 Multiple disc brake, support arm (travel brake)....................................................... 46 General................................................................................................. 46 Design.................................................................................................. 46 4.4.4 Support arm wheel disc brake (travel brake)........................................................... 47 General................................................................................................. 47 Design.................................................................................................. 47 4.4.5 Disc brake on the drive motor (parking brake)......................................................... 48 General................................................................................................. 48 Design.................................................................................................. 48 4.5 Steering system 4000........................................................................................ 49 4.5.1 General............................................................................................... 49 4.5.2 Design................................................................................................ 49 4.5.3 Sensor................................................................................................ 50 Steering reference sensor............................................................................... 50 4.6 Operator compartment........................................................................................ 51 4.6.1 Truck control, overview............................................................................... 51 Right-hand control panel, single control................................................................ 51 Right-hand control panel, multi-control................................................................. 51 Emergency switch off.................................................................................... 52 Steering wheel module................................................................................... 52 Pedals.................................................................................................. 53 4.6.2 Single-function control............................................................................... 54 4.6.3 Multi-function control................................................................................ 55 4.6.4 Central Information Display – CID..................................................................... 56 Navigation.............................................................................................. 56 LED symbols............................................................................................. 59 Information symbols..................................................................................... 60 Driver parameter symbols – Overview..................................................................... 61 Catch symbols – Overview................................................................................ 62 Service symbols – Overview.............................................................................. 63 Service functions....................................................................................... 64 Calibration functions................................................................................... 66 Configuration functions................................................................................. 69 Other functions......................................................................................... 72 4.6.5 Load Information Display – LID (option)............................................................... 74 LED symbols............................................................................................. 74 Symbols in the display part............................................................................. 75 4.7 sensors and sensors (5800).................................................................................. 76 4.7.1 Inductive sensors..................................................................................... 76 4.7.2 Position sensor....................................................................................... 76 4.7.3 Magnetic sensor....................................................................................... 77 4.8 Operation and connection sequences.......................................................................... 78 4.9 Functions...................................................................................................110 4.9.1 General overview......................................................................................110 Terminology.............................................................................................110 Components..............................................................................................110 4.9.2 MCU – main control unit...............................................................................111 General.................................................................................................111 Downloading software....................................................................................111 System communication....................................................................................111 4.9.3 ACT/ACH transistor regulators.........................................................................112 General.................................................................................................112 4.9.4 Start-up..............................................................................................112 4.9.5 Shutdown..............................................................................................113 4.9.6 Driving...............................................................................................113 Introduction............................................................................................113 Acceleration and speed reduction........................................................................113 Reversing...............................................................................................114 Brake...................................................................................................114 Travel speed............................................................................................115 4.9.7 OTP...................................................................................................116 Travel speed reduction - steering angle.................................................................116 Travel speed reduction - extension of reach carriage....................................................116 Speed reduction - main lift range.......................................................................116 Prevention of lifting/lowering the forks................................................................116 Reduced extension speed.................................................................................116 4.9.8 Steering..............................................................................................117 Steering position control...............................................................................117 Steering speed..........................................................................................117 Steering reference......................................................................................118 Travel speed limitation.................................................................................118 Compass rose............................................................................................118 4.9.9 Hydraulic system......................................................................................119 Definitions.............................................................................................119 Controls................................................................................................119 Lift....................................................................................................119 Reach movement..........................................................................................120 Lift height limitation..................................................................................120 Maximum height limitation...............................................................................120 Auxiliary/Extra functions (option)......................................................................121 4.10 Height preselector, description of function................................................................122 4.10.1 Using the height preselector.........................................................................122 4.10.2 Symbols..............................................................................................122 4.10.3 Travel warning.......................................................................................122 4.10.4 Height preselector levels............................................................................123 4.10.5 Level selection......................................................................................123 4.10.6 Height programming...................................................................................124 4.10.7 Height preselector and TruckCom......................................................................125 4.10.8 Lift/lowering movement...............................................................................125 4.10.9 Parameter settings braking at height preselector.....................................................126 4.11 Hydraulic system 6000......................................................................................127 4.11.1 General..............................................................................................127 4.11.2 Tank.................................................................................................127 4.11.3 Filter...............................................................................................127 Return filter...........................................................................................127 Dehumidification filter.................................................................................127 4.11.4 Hydraulic pump.......................................................................................128 4.11.5 Valve unit...........................................................................................128 Main valve block........................................................................................128 Second valve block......................................................................................129 4.11.6 Cylinders............................................................................................130 Main lift cylinders.....................................................................................130 Free-lift cylinder......................................................................................130 Cylinders for the reach movement, cabin tilt, sideshift and fork tilt...................................130 4.11.7 Lift and lowering function...........................................................................131 Lifting and lowering of free lift.......................................................................131 Transition from free lift to main lift..................................................................131 Lifting and lowering of main lift.......................................................................131 Reach movement, in and out..............................................................................131 Simultaneous operation of mast lift and reach movement..................................................132 4.11.8 Extra functions......................................................................................132 4.11.9 Cabin tilt (RRE Ergo)................................................................................132 Hydraulic priority system...............................................................................132 Cabin tilt (RRE Ergo) during servicing..................................................................133 Cabin tilt in the event of hydraulic or electrical power loss...........................................133 4.12 Mast 7000..................................................................................................134 4.12.1 Mast and reach carriage..............................................................................134 4.13 Lifting devices............................................................................................135 4.13.1 Fork extensions......................................................................................135 4.13.2 Telescopic forks.....................................................................................135 4.14 Accessories 9000...........................................................................................137 4.14.1 Radio equipment......................................................................................137 4.14.2 Extra lighting.......................................................................................137 4.14.3 Extra warning lights/alarm...........................................................................138 4.14.4 Turn signal lights...................................................................................138 4.14.5 Movement alarm.......................................................................................139 4.14.6 Positioning/TV equipment.............................................................................140 4.14.7 Extra electrical equipment...........................................................................142 4.14.8 Other extra equipment................................................................................143 Fork spacers............................................................................................143 Load rest...............................................................................................144 E-bar...................................................................................................145 Fire extinguisher.......................................................................................146 5 – Parameters......................................................................................................147 5.1 General.....................................................................................................147 5.2 Displaying/changing parameters..............................................................................147 5.3 Operator parameters.........................................................................................148 5.3.1 Overview..............................................................................................148 5.3.2 Connection to logged-in operator......................................................................149 5.3.3 Description...........................................................................................150 Parameter 1 – Steering..................................................................................150 Parameter 2, 3 – Maximum travel speed...................................................................152 Parameters 4 and 5 – Acceleration/Deceleration..........................................................152 Parameter 6 – Cab tilt..................................................................................152 5.4 General service parameters..................................................................................153 5.4.1 Overview..............................................................................................153 5.4.2 Description...........................................................................................153 Parameter 101/104 – Service/Log-out.....................................................................153 Parameter 105/106/114/115/117 (Travel alarms 1 and 2)...................................................154 Parameter 107/108 – Battery.............................................................................156 Parameter 109/110/111/112 – Collision sensor............................................................159 Parameter 113 (shunt value).............................................................................160 Parameter 116 (Door on cold store cabs).................................................................161 5.5 Service parameters, travel functions........................................................................162 5.5.1 Overview..............................................................................................162 5.5.2 Description...........................................................................................162 Parameter 201 – Retardation when reversing..............................................................162 Parameter 202/203/204 – Adjusting erroneous, maximum travel speeds......................................163 Parameter 205/206/207 – Adjusting function-related maximum travel speeds................................163 Parameter 208 - Creep speed in travel direction control.................................................164 Parameter 209/210 – Reduced maximum travel speed above a certain lift height............................164 Parameter 211/212 – Reduced maximum travel speed with a certain reach length............................165 Parameter 213 – Permanently reduced maximum travel speed................................................165 Parameter 214 – Adjusting the maximum travel speed in main lift range...................................165 Parameters 215/216/217 – Adjusting OTP speed, and starting and ending angle.............................166 5.6 Service parameters, hydraulics..............................................................................167 5.6.1 Overview..............................................................................................167 5.6.2 Description...........................................................................................170 Parameter 301/302/303/304 – Extra valve function........................................................170 Parameter 305/306/307/308 – Max. oil pressure through valve Q8..........................................172 Parameter 313/314/315/316 – Closing time................................................................173 Parameter 317/318/319/320 – Max. oil flow through valve Q8..............................................173 Parameter 321/322/323/324 – Max. oil flow through valve Q9..............................................174 Parameter 325/326/327/328 – Opening/closing time valve Q8...............................................174 Parameter 329/330/331/332 – Opening/closing time valve Q9...............................................175 Parameters 333/334 Button for setting extra safety hydraulic function...................................175 Parameter 341/342 – Reducing the lifting/lowering speed.................................................176 Parameter 343 – Reduction of reach speed................................................................177 Parameter 344 - Reduction of fork lowering speed before floor level.....................................177 Parameter 345- Lift/lower sensitivity...................................................................177 Parameter 346- Ramping for the hydraulic functions Lifting, Lowering and Reach in/out...................178 Parameter 347/348 – Prevent the lifting/lowering of forks...............................................178 Parameter 349 - Fork weight.............................................................................179 Parameter 350 – Multi-function..........................................................................179 Parameters 351/352 Button for setting extra safety hydraulic function...................................180 Parameters 358/359/360 – Deactivation of hydraulic functions............................................181 Parameters 361/362/363/364/365 /366 – Function related, maximum lifting/lowering speeds.................182 Parameter 367/368 – Fork limit for deactivating the extension of the fork carriage and for sideshift....183 Parameter 369 through 379 – Height preselector..........................................................184 Parameter 380/381 - Lift height limitations.............................................................186 Parameters 387/388 – Configuration of lift height limitations...........................................186 Parameters 395/396/397 – Function-related, maximum lift heights.........................................187 Parameters 398/399 – Operator profile dependent, maximum lift heights...................................188 5.7 Service parameters, CID.....................................................................................189 5.7.1 Overview..............................................................................................189 5.7.2 Description...........................................................................................190 Parameter 503 – Login method............................................................................190 Parameter 504/505/506/507 – Smart Access................................................................191 Parameters 508/509/512/513/514 – CID configuration......................................................194 Parameter 510/511 - Height preselector..................................................................195 5.8 General factory parameters..................................................................................196 5.8.1 Overview..............................................................................................196 5.8.2 Description...........................................................................................197 Parameter 1001 - Truck type.............................................................................197 Parameter 1002 - (Drive motor)..........................................................................197 Parameter 1003 – Pedal type.............................................................................197 Parameter 1004 - Steering servo.........................................................................198 Parameter 1005 - Pump motor.............................................................................198 Parameter 1006 – Hydraulic pump.........................................................................198 Parameter 1007 – Activation of hydraulic levers.........................................................199 Parameter 1008 – Mast type..............................................................................199 Parameter 1009 – Height indication......................................................................200 Parameter 1010 - Weight indication......................................................................200 5.9 Factory parameters, activation of options...................................................................201 Parameter 1115 (Steering angle).............................................................................202 Parameter 1116 (Extended mast)..............................................................................204 Parameter 1117 (Weight of load and fork height).............................................................204 Parameter 1118 (Main lift range)............................................................................205 5.10 Factory parameters, calibration............................................................................208 6 – Installation....................................................................................................211 6.1 Transporting the truck......................................................................................211 6.2 Transporting the mast.......................................................................................211 6.3 Transporting the truck......................................................................................212 Method 1....................................................................................................212 Method 2....................................................................................................212 6.4 Taking into operation.......................................................................................213 6.4.1 Tools.................................................................................................213 6.4.2 Battery...............................................................................................213 Placing the battery.....................................................................................213 Battery parameters......................................................................................214 6.4.3 Mast, fitting.........................................................................................214 6.4.4 Parameters on initial operation.......................................................................214 Load indicator..........................................................................................214 Ergo cabin..............................................................................................214 Cold store cabin........................................................................................215 6.4.5 Parameters for optional equipment.....................................................................215 Height measurement (option).............................................................................215 Travel speed limitation, height-dependent...............................................................215 Travel speed limitation, reach movement dependent.......................................................215 Travel speed limitation, parameter-dependent............................................................216 Collision sensor (BT)...................................................................................216 7 – Maintenance.....................................................................................................217 7.1 Introduction, maintenance...................................................................................217 7.2 Safety precautions for maintenance work.....................................................................218 7.3 Safety precautions for maintenance work.....................................................................219 7.4 Maintenance instructions....................................................................................220 7.4.1 Cleaning and washing..................................................................................220 7.4.2 High-pressure washers.................................................................................220 7.4.3 Degreasing agents.....................................................................................221 7.4.4 Cleaning the truck exterior...........................................................................221 7.4.5 Cleaning the chain....................................................................................221 7.4.6 Cleaning the motor compartment........................................................................222 7.4.7 Electric components...................................................................................222 7.5 Checks for cracks...........................................................................................223 7.5.1 Visual inspection.....................................................................................223 7.5.2 Crack detection.......................................................................................224 Crack detection with liquid penetrant...................................................................224 Crack detection with magnetic yoke......................................................................224 7.6 Periodic maintenance........................................................................................225 7.6.1 Every 500 B-hours/180 days............................................................................225 7.6.2 Every 1000 B-hours/360 days...........................................................................227 7.6.3 Every 2000 B-hours/720 days...........................................................................234 7.6.4 Every 3000 B-hours/1080 days..........................................................................234 7.6.5 Every 5000 B-hours/1800 days..........................................................................236 7.6.6 Annual status inspection..............................................................................236 7.7 Maintenance instructions....................................................................................237 7.7.1 Cleaning and washing..................................................................................237 High-pressure washers...................................................................................237 Degreasing agents.......................................................................................237 Cleaning the truck exterior.............................................................................237 Cleaning the chain......................................................................................238 Cleaning the motor compartment..........................................................................238 Electric components.....................................................................................238 8 – Troubleshooting.................................................................................................239 8.1 Abbreviations used in this section..........................................................................239 8.2 Truck help functions........................................................................................239 8.2.1 Error log menu........................................................................................239 Description.............................................................................................239 Access..................................................................................................239 8.2.2 Error information menu................................................................................240 Description.............................................................................................240 Access..................................................................................................240 8.2.3 Diagnostic screens....................................................................................240 Access..................................................................................................240 State 1 – Voltage from the control console levers.......................................................241 State 2 – Digital signals from the truck control to CID.................................................242 State 3 – Voltage from control/sensor to MCU............................................................243 State 4 – Digital input signals to MCU..................................................................244 State 5 – Digital output signals from MCU...............................................................245 State 6 – PWM output signals from MCU...................................................................246 State 7 – FCU (not used)................................................................................246 State 8 – FCU (not used)................................................................................246 State 9 – GFU (not used)................................................................................246 State 10 – GFU (not used)...............................................................................246 State 11 – Temperature signals..........................................................................247 State 12 – Voltage levels...............................................................................247 State 13 – Travel information...........................................................................248 State 14 – Steering information.........................................................................249 State 15 – Lift/lowering information....................................................................250 Stage 16 – Reach movement information...................................................................251 Stage 17 – Hydraulic information........................................................................252 State 18 – VNA (not used)...............................................................................252 State 19 – Pressure sensor for free and main lifts......................................................253 8.3 Initial troubleshooting.....................................................................................254 8.4 Troubleshooting using blocking symbol.......................................................................255 8.5 Troubleshooting using error codes...........................................................................263 8.5.1 CID, warnings and errors..............................................................................265 8.5.2 MCU and other warnings and errors.....................................................................269 8.5.3 Drive system error....................................................................................280 8.5.4 Hydraulic system error................................................................................294 8.5.5 Steering system, warnings and errors..................................................................330 8.5.6 GFU, warnings and errors..............................................................................338 8.6 Troubleshooting without indications.........................................................................340 8.6.1 Mechanical brake (3000)...............................................................................340 8.6.2 Steering (4000).......................................................................................340 8.6.3 Telescopic forks......................................................................................341 8.6.4 Log on was normal, but one or several functions cannot be used........................................342 9 – Frame/Chassis 0000..............................................................................................345 9.1 General.....................................................................................................345 9.2 Motor hood (0340)...........................................................................................345 9.2.1 Opening the motor compartment.........................................................................345 RRE 140-RRE 250.........................................................................................345 Replacing the hood......................................................................................346 Adjusting the hood......................................................................................346 Method..................................................................................................347 9.3 Battery compartment components (0390).......................................................................348 9.3.1 Adjusting the battery bed.............................................................................348 9.4 Operator’s cabin (0500).....................................................................................350 9.4.1 Tilting the cab RRE 140 – 250 Ergo....................................................................350 9.4.2 Ergoled...............................................................................................351 Disassembly.............................................................................................351 9.5.1 Cab windows (0530)....................................................................................354 Fitting a window........................................................................................354 9.5.2 Cab door (0550).......................................................................................356 Disassembly of the door lock............................................................................356 Method..................................................................................................357 Disassembly of the lock device..........................................................................358 Method..................................................................................................359 9.6 Operator's compartment (0600)...............................................................................360 9.6.1 Adjusting the seat:...................................................................................360 Seat heater button (Option).............................................................................360 9.6.2 Replacing the seat assembly...........................................................................361 Method..................................................................................................362 9.6.3 Replacing the seat switch.............................................................................363 Method..................................................................................................364 9.6.4 Replacing the back rest...............................................................................365 Method..................................................................................................365 9.6.5 Replacing the chair seat..............................................................................366 Method..................................................................................................366 9.6.6 Replacing the seat heater switch......................................................................367 Method..................................................................................................367 9.6.7 Installing the safety belt/armrest (Option)...........................................................368 Method..................................................................................................368 9.6.8 Cab heating/ventilation (0630)........................................................................369 Replacing the air filter on the cold store cabin:.......................................................369 Removing the fan and heater.............................................................................370 Replacing the potentiometers............................................................................374 9.6.9 Internal fittings (0680)..............................................................................376 9.6.10 Disassembly/assembly of floor plate, B version 0680..................................................377 9.7 Operator controls (mechanical) C0640........................................................................379 9.7.1 Replacing pedals......................................................................................380 Method..................................................................................................381 9.8 Overhead guard/roof C0810...................................................................................382 9.8.1 Overview..............................................................................................382 9.8.2 Removing the overhead guard...........................................................................384 Method..................................................................................................387 9.8.3 Fastening the overhead guard..........................................................................389 Method..................................................................................................392 9.8.4 Removing the roof cassette............................................................................394 Method..................................................................................................396 9.8.5 Fastening the roof cassette...........................................................................397 Method..................................................................................................400 9.9 Finger/foot guards C0820....................................................................................401 9.9.1 Replacing a figure guard..............................................................................401 Method..................................................................................................401 9.10 Operator protection C0840..................................................................................402 9.10.1 Replacing the fender.................................................................................402 Method..................................................................................................402 9.11 Safety equipment (0800)....................................................................................403 9.11.1 Checking the overhead guard (0810)...................................................................403 9.11.2 Adjusting the support lugs (0840)....................................................................404 10 – Motors 1000....................................................................................................405 10.1 Motor sensors..............................................................................................405 10.1.1 Temperature sensor...................................................................................405 Retrofitting of external temperature sensor.............................................................406 10.1.2 Replacing the motor speed sensor.....................................................................406 10.2 Pump motor (1710)..........................................................................................407 10.2.1 General..............................................................................................407 Disassembled pump motor.................................................................................407 10.2.2 Replacing the bearing on the pump motor..............................................................408 Dismantling the pump motor..............................................................................408 Assembling the pump motor...............................................................................410 10.3 Steering motor and steering unit (1730)....................................................................411 10.3.1 General..............................................................................................411 10.3.2 Layout of the flange holes...........................................................................411 10.3.3 Removing the steering motor from the truck...........................................................412 10.3.4 Fitting the steering motor in the truck..............................................................412 10.4 Fan motor/fan (1740).......................................................................................414 10.4.1 General..............................................................................................414 10.4.2 Replacing the frequency converter cooling fan........................................................414 Standard truck:.........................................................................................414 Ergotruck...............................................................................................414 10.4.3 Replacing the motor compartment cooling fan..........................................................416 10.5 Drive motor (1760).........................................................................................417 10.5.1 General..............................................................................................417 Disassembled drive motor................................................................................417 10.5.2 Removing the drive motor from the truck..............................................................418 10.5.3 Dismantling the drive motor..........................................................................420 10.5.4 Cleaning.............................................................................................421 10.5.5 Assembling the drive motor...........................................................................422 10.5.6 Fitting the drive motor to the truck.................................................................424 11 – Drive gear 2000................................................................................................427 11.1 General....................................................................................................427 11.2 Repair- and serviceability.................................................................................427 11.3 Measures...................................................................................................428 11.3.1 Checking the oil level...............................................................................428 11.3.2 Oil change...........................................................................................429 Oil refill table........................................................................................429 11.3.3 Leakage from the bottom cap..........................................................................430 11.3.4 Replacing the drive gear.............................................................................431 Special tools...........................................................................................431 Exposing the drive gear.................................................................................431 Removing a drive motor from the truck...................................................................431 Removing a steering motor from the truck................................................................431 Removing the drive gear from the truck..................................................................432 Fit the drive gear back in the truck....................................................................434 Placing the steering motor in the truck.................................................................435 Placing the drive motor in the truck....................................................................435 Concluding work.........................................................................................435 12 – Brake and wheel 3000...........................................................................................437 12.1 Travel brake system (3100).................................................................................437 12.1.1 Removing the support arm's multiple disc brake.......................................................437 12.1.2 Dismantling the multiple disc brake..................................................................437 Inspection..............................................................................................438 Adjusting clearance.....................................................................................438 Assembling the multiple disc brake......................................................................439 12.1.3 Installing the multiple disc brake in the truck......................................................439 12.2 Single disc brake support arm..............................................................................440 12.2.1 Remove the brake disc from the wheel.................................................................441 12.2.2 Assembly of the brake disc in the wheel..............................................................442 12.2.3 Fit the support arm magnet brake.....................................................................443 12.2.4 Disassembly of magnet brake, RRE160R.................................................................444 12.2.5 Remove the brake disc from the hub, RRE160R..........................................................445 12.2.6 Fit the brake disc to the hub, RRE160R...............................................................446 12.2.7 Fit the magnet brake in the support arm, RRE160R.....................................................447 12.2.8 Checking the wheel brake's brake force...............................................................448 12.3 Parking brake (3300).......................................................................................449 12.3.1 General..............................................................................................449 12.3.2 Emergency release of the parking brake...............................................................450 12.3.3 Check of braking force...............................................................................450 12.3.4 Removing the parking brake from the truck............................................................451 Disassembly and inspection of wear......................................................................452 Method..................................................................................................453 Adjusting the air gap...................................................................................454 Method..................................................................................................455 12.3.5 Install the parking brake in the truck...............................................................456 12.4 Drive wheel (3530).........................................................................................457 12.4.1 General..............................................................................................457 12.4.2 Remove the drive wheel from the truck................................................................457 12.4.3 Installing the drive wheel on the truck..............................................................457 12.5 Wheel bolt (3530)..........................................................................................458 General.....................................................................................................458 12.5.1 Replacing the wheel bolt.............................................................................458 12.6 Support arm wheel (3550)...................................................................................459 12.6.1 Removing the support arm wheel from the truck........................................................459 12.6.2 Remove the support arm wheel, RRE160R................................................................460 12.6.3 Replacing the wheel bearing,RRE160R..................................................................461 12.6.4 Fit the support arm wheel to the truck, RRE160R......................................................462 12.6.5 Replacing a wheel bearing - braked wheel (A).........................................................463 Disc brake version......................................................................................464 12.6.6 Replacing a wheel bearing - wheel without brakes (B).................................................465 12.6.7 Fitting the support arm wheel to the truck...........................................................466 12.6.8 Support arm wheel, (280mm wheels with 1050mm support arm width)......................................467 General.................................................................................................467 12.6.9 Dismantling the wheel................................................................................467 12.6.10 Mounting the support arm wheel......................................................................468 12.6.11 Dismantling the wheel bearings......................................................................468 12.6.12 Assembling the wheel bearings.......................................................................468 12.6.13 Wheel wear and tear.................................................................................468 13 – Steering system 4000...........................................................................................471 13.1 Electric steering wheel (4310).............................................................................471 13.1.1 General..............................................................................................471 13.1.2 Replacing the pulse transducer on the steering wheel module..........................................471 13.1.3 Removing the operating console from the truck........................................................472 13.1.4 Replacing the wiring harness in the operating console................................................473 13.1.5 Fitting the operating console in the truck...........................................................475 13.2 Steering reference sensor (4350)...........................................................................476 General.....................................................................................................476 13.2.1 Replacing the reference sensor [B17].................................................................476 13.3 Steering bearings (4380)...................................................................................477 14 – Electrical system 5000.........................................................................................481 14.1 Battery (5110).............................................................................................481 14.1.1 Battery recommendation...............................................................................481 Exide gel batteries (e.g. Sonnenschein).................................................................481 Hawker Evolution gel batteries..........................................................................481 14.1.2 Battery installation.................................................................................482 Replacement/installation of battery.....................................................................482 Procedure without battery changing table................................................................483 Procedure with battery changing table...................................................................483 14.2 LID (5200).................................................................................................484 14.2.1 Replacing the LID....................................................................................484 14.2.2 Replacing the LID cold store cab.....................................................................485 14.3 Replacing pedals (5300)....................................................................................486 14.3.1 Accelerator and brake pedal..........................................................................486 14.3.2 Safety pedal.........................................................................................486 14.4 Control console (5510).....................................................................................487 14.4.1 General..............................................................................................487 14.4.2 Replacement/installation of a control................................................................487 14.4.3 Replacing the multi-function control.................................................................488 Replacing the multi-function control's buttons..........................................................488 14.4.4 Removing the control console from the truck..........................................................489 14.4.5 Replacing the access card's circuit board............................................................490 14.4.6 Dismantling the control console......................................................................491 Installing an extra push button.........................................................................493 Replacing the travel direction selector with signal button..............................................493 Replacing the display...................................................................................494 14.4.7 Assembling the control console.......................................................................494 14.4.8 Fitting the control console in the truck.............................................................495 14.5 Magnetic sensor (5850).....................................................................................496 General.....................................................................................................496 14.5.1 Replacing the magnetic sensor [B47]..................................................................496 14.5.2 Reference magnet.....................................................................................497 14.6 Parameter settings.........................................................................................498 14.6.1 Configuration menu...................................................................................498 Calendar/hour counter menu..............................................................................498 Parameter menu (PAR)....................................................................................498 Setting operator parameters.............................................................................499 14.7 PIN menu...................................................................................................501 14.7.1 Menu for activating a PIN block......................................................................502 14.7.2 Menu for programming a PIN (P).......................................................................502 14.8 Calibrations...............................................................................................503 14.8.1 Calibrating the hydraulic function control...........................................................503 14.8.2 Height measurement/reach movement length calibration.................................................504 Calibrating height measurement (option).................................................................505 14.8.3 Valve calibration....................................................................................508 Lift valve calibration..................................................................................508 Lowering valve calibration with height indication.......................................................510 Lowering calibration without height indication..........................................................512 Reach movement valve calibration........................................................................514 Calibration of the Ergo cab.............................................................................517 14.8.4 Weight calibration...................................................................................518 Calibrating the weight indicator........................................................................518 14.9 Replacing the wiring harness...............................................................................520 14.10 main computer unit MCU (A5)...............................................................................521 14.10.1 Installing a new card in the truck..................................................................521 14.10.2 Voltage supply......................................................................................522 14.10.3 Battery negative....................................................................................522 14.10.4 Internal status monitoring..........................................................................522 14.10.5 Resetting the battery indicator.....................................................................522 15 – Hydraulic system 6000..........................................................................................523 15.1 Hydraulic hygiene..........................................................................................523 15.1.1 Washing..............................................................................................523 15.1.2 Packaging............................................................................................523 15.1.3 Handling.............................................................................................523 15.1.4 Storage..............................................................................................524 15.1.5 Work procedures......................................................................................524 15.2 Hydraulic unit (6100)......................................................................................525 15.2.1 Hydraulic tank, emptying.............................................................................526 15.2.2 Hydraulic system, bleeding...........................................................................527 15.2.3 Filter...............................................................................................528 Overview................................................................................................528 Filter replacement (air and oil)........................................................................529 Method..................................................................................................529 15.2.4 Remove the pump motor from the truck.................................................................531 15.2.5 Replacing the hydraulic pump or the O-ring...........................................................532 15.2.6 Fitting the pump motor in the truck..................................................................533 15.3 Main valve (6210)..........................................................................................534 15.3.1 Emergency lowering of forks..........................................................................534 15.3.2 Replacing the main valve block.......................................................................535 15.3.3 Replacing the lifting/lowering valves................................................................537 Overview................................................................................................537 Method..................................................................................................538 15.3.4 Adjusting the maximum opening pressure...............................................................540 15.4 Hydraulic connections (6230)...............................................................................542 15.4.1 Tightening torques for hydraulic connections.........................................................542 Tapered coupling with O-ring............................................................................542 Tredo seal..............................................................................................543 Pipe coupling...........................................................................................543 15.4.2 Quick change connector...............................................................................545 Overview................................................................................................545 Assembly................................................................................................545 Disassembly.............................................................................................546 15.5 Hydraulic system, mast (6300)..............................................................................547 15.5.1 Mast-mounted hose reel (6370)........................................................................547 General.................................................................................................547 15.5.2 Fitting the hose reel................................................................................547 Spring preloading (turns)...............................................................................547 15.5.3 Checks after fitting.................................................................................548 15.6 Main lift cylinder 6610....................................................................................549 General.....................................................................................................549 15.6.1 Overview.............................................................................................550 Cylinder nomenclature...................................................................................550 Nomenclature for cylinder head..........................................................................551 Nomenclature for piston.................................................................................551 15.6.2 Removing the air cylinder from the mast..............................................................552 15.6.3 Replacing the hose rupture valve.....................................................................553 15.6.4 Dismantling the cylinder.............................................................................554 Method..................................................................................................555 15.6.5 Dismantling the piston...............................................................................556 Method..................................................................................................556 15.6.6 Dismantling the cylinder head........................................................................556 Method..................................................................................................557 15.6.7 Fitting the cylinder head seals......................................................................558 Method..................................................................................................559 15.6.8 Fitting the piston seals.............................................................................560 Method..................................................................................................560 15.6.9 Assembling the cylinder..............................................................................561 Method..................................................................................................562 15.6.10 Assembling cylinder in the mast.....................................................................563 15.7 Free lift cylinder (6620)..................................................................................565 General.....................................................................................................565 15.7.1 Overview.............................................................................................566 Cylinder nomenclature...................................................................................566 Nomenclature for cylinder head..........................................................................567 Nomenclature for piston.................................................................................567 15.7.2 Removing the free lift cylinder from the truck.......................................................568 15.7.3 Replacing the hose rupture valve, free lift cylinder.................................................569 15.7.4 Dismantling the cylinder.............................................................................570 Method..................................................................................................571 15.7.5 Dismantling the piston...............................................................................571 Method..................................................................................................571 15.7.6 Dismantling the cylinder head........................................................................572 Method..................................................................................................572 15.7.7 Fitting the cylinder head seals......................................................................573 Method..................................................................................................573 15.7.8 Fitting the piston seals.............................................................................574 Method..................................................................................................575 15.7.9 Assembling the cylinder..............................................................................576 Method..................................................................................................577 15.7.10 Assembling the free lift cylinder in the mast.......................................................578 15.8 Reach cylinder (6650)......................................................................................579 15.8.1 General..............................................................................................579 15.8.2 Removing the reach cylinder from the truck...........................................................579 15.8.3 Fitting the reach cylinder in the truck..............................................................580 15.9 Fork tilt cylinder (6660)..................................................................................581 15.9.1 General..............................................................................................581 15.9.2 Remove the tilt cylinder from the truck..............................................................582 Mast with valve on the fork carriage....................................................................582 Method..................................................................................................583 Mast without valve on the fork carriage.................................................................584 Method..................................................................................................585 15.9.3 Fit the tilt cylinder in the truck...................................................................586 Mast with valve on the fork carriage....................................................................586 Method..................................................................................................587 Mast without valve on the fork carriage.................................................................588 Method..................................................................................................589 15.10 Cab tilt cylinder (6660)..................................................................................590 15.10.1 General.............................................................................................590 15.10.2 Overview............................................................................................590 Cylinder nomenclature...................................................................................590 Nomenclature for cylinder head..........................................................................591 Nomenclature for piston.................................................................................591 15.10.3 Dismantling the cylinder............................................................................592 Method..................................................................................................593 15.10.4 Dismantling the rod.................................................................................594 Method..................................................................................................595 15.10.5 Dismantling the cylinder head.......................................................................596 Method..................................................................................................597 15.10.6 Fitting the cylinder head seals.....................................................................598 Method..................................................................................................599 15.10.7 Mounting the piston rod.............................................................................600 Method..................................................................................................601 15.10.8 Assembling the cylinder.............................................................................602 Method..................................................................................................603 15.11 Sideshift cylinder (6670).................................................................................604 15.11.1 General.............................................................................................604 15.11.2 Overview............................................................................................605 Cylinder nomenclature...................................................................................605 Nomenclature for cylinder head..........................................................................606 Nomenclature for piston.................................................................................606 15.11.3 Dismantling the cylinder from the truck.............................................................607 Method..................................................................................................607 15.11.4 Dismantling the cylinder............................................................................608 Method..................................................................................................609 15.11.5 Dismantling the rod.................................................................................610 Method..................................................................................................611 15.11.6 Dismantling the cylinder head.......................................................................612 Method..................................................................................................613 15.11.7 Fitting the cylinder head seals.....................................................................614 Method..................................................................................................615 15.11.8 Mounting the piston rod.............................................................................616 Method..................................................................................................617 15.11.9 Assembling the cylinder.............................................................................618 Method..................................................................................................619 15.11.10 Refitting the cylinder in the truck................................................................619 16 – Mast/Lift system 7000..........................................................................................621 16.1 Main mast 1.6-2.5 t (7100).................................................................................621 16.1.1 Replacing the full mast..............................................................................621 16.1.2 Remove the mast from the truck.......................................................................622 16.1.3 Adjusting mast play..................................................................................625 General.................................................................................................625 Preparations............................................................................................625 Adjusting lateral play..................................................................................628 Adjustment of radial play...............................................................................629 Adjusting the damper parts..............................................................................629 Adjusting the damper plate..............................................................................630 Refitting the mast......................................................................................630 16.1.4 Replacing the mast damper plates.....................................................................631 16.1.5 Placing the mast on the truck........................................................................632 16.2 Main lift chain system (7120)..............................................................................636 16.2.1 General..............................................................................................636 16.2.2 Checking the chain...................................................................................636 Noise...................................................................................................636 Surface rust............................................................................................636 Rusty links.............................................................................................636 Stiff links.............................................................................................637 Bolt rotation...........................................................................................637 Loose bolts.............................................................................................637 Outline wear............................................................................................638 Stretching..............................................................................................639 Damage..................................................................................................639 Damaged discs...........................................................................................640 Damaged bolts...........................................................................................640 Dirty chain.............................................................................................640 16.2.3 Lubricating the chain................................................................................640 16.2.4 Adjustment...........................................................................................641 16.2.5 Main lift chain system, adjusting the fork-to-floor distance.........................................641 16.3 Reach carriage (7190)......................................................................................642 Overview:...................................................................................................642 16.3.1 Adjusting the radial clearance in the reach carriage.................................................643 16.3.2 Adjusting the axial clearance in the reach carriage..................................................645 16.4 Lifting devices (7400).....................................................................................646 16.4.1 Forks................................................................................................646 General.................................................................................................646 Inspection..............................................................................................646 Inspection intervals....................................................................................646 Surface cracks..........................................................................................646 Difference in height between the fork tips..............................................................647 Position lock...........................................................................................647 Legibility of markings..................................................................................647 Fork blades and back of fork carriage...................................................................647 Mounting fixtures on the fork...........................................................................647 16.4.2 Forks, repairs and testing...........................................................................648 Repairs.................................................................................................648 Testing the yield point.................................................................................648 Fork....................................................................................................648 16.5 Fork carriage..............................................................................................649 16.5.1 Checking the fork carriage’s wear strip..............................................................649 16.5.2 Lubricating the fork carriage........................................................................650 16.6 Fork spread unit...........................................................................................651 16.6.1 Servicing the fork spread unit.......................................................................651 Replacing bearings......................................................................................652 Roller replacement......................................................................................652 16.7 Fork extensions with adjustable fork length................................................................653 16.8 Manual telescopic forks....................................................................................655 16.8.1 Fitting..............................................................................................655 16.8.2 Maintenance..........................................................................................656 16.9 Hydraulic telescopic forks.................................................................................657 16.9.1 Telescopic forks with separate flow dividers.........................................................658 Fitting instructions....................................................................................659 Initial operation of telescopic forks with separate flow dividers.......................................659 16.9.2 Telescopic forks with integrated flow dividers.......................................................660 Fitting instructions....................................................................................661 Initial operation of telescopic forks with integrated flow dividers.....................................661 16.9.3 Maintenance of telescopic forks......................................................................662 16.9.4 Dismantling telescopic forks.........................................................................663 16.9.5 Assembling telescopic forks..........................................................................664 17 – Peripherals - 8000.............................................................................................665 17.1 Introduction...............................................................................................665 18 – Extra equipment - 9000.........................................................................................667 18.1 Introduction...............................................................................................667 19 – Appendix “Destruction instructions”............................................................................669 19.1 General....................................................................................................669 19.2 Marking of plastics........................................................................................669 19.2.1 General marking of products and packaging............................................................669 19.2.2 Marking according to BT Standard.....................................................................670 Abbreviations...........................................................................................670 Marking examples........................................................................................670 19.3 Pressure vessels...........................................................................................671 19.3.1 Gas dampers..........................................................................................671 19.4 Sorting categories.........................................................................................672 20 – Wiring diagram.................................................................................................675 20.1 Components.................................................................................................675 20.2 Component location.........................................................................................685 Figure 1 (Fork carriage)....................................................................................685 Figure 2 (Chassis wiring harness)...........................................................................686 Figure 3 (Chassis wiring harness)...........................................................................687 Figure 4 (Support leg brake)................................................................................688 Figure 5 (Pedals)...........................................................................................688 Figure 6 (Motor wiring harness).............................................................................689 Figure 7 (Reach carriage wiring harness)....................................................................689 Figure 8 (Level/position meter).............................................................................691 Figure 9 (seat).............................................................................................692 Figure 10 (DC/DC)...........................................................................................693 Figure 11 (Driver position wiring harness)..................................................................694 Figure 12 (Extra hydraulic function(s)).....................................................................695 Figure 13 (Travel alarm)....................................................................................696 Figure 14 (Roof wiring harness).............................................................................697 Figure 15 (Roof)............................................................................................698 Figure 16 (Sound system)....................................................................................699 Figure 17 (Forks camera)....................................................................................700 Figure 18 (Battery harness).................................................................................701 Figure 19 (Fuse box)........................................................................................702 Figure 20 (LID).............................................................................................703 Figure 21 (Mast wiring harness).............................................................................704 Figure 22 (Fork carriage wiring harness)....................................................................705 Figure 23 (Reach carriage wiring harness options)...........................................................706 Figure 24 (Working light wiring harness)....................................................................707 Figure 24 (Extra outlet DC).................................................................................708 Figure 25 (T.W.I.S.)........................................................................................708 Figure 26 (Shock Switch / Impact Manager)...................................................................709 Figure 27 (Heated windows CC)...............................................................................710 Figure 28 (Cabling driver position CC)......................................................................711 Figure 29 (Heater CC).......................................................................................712 Figure 30 (Cab heater wiring harness CC)....................................................................713 Figure 31 (Safety switch for door CC).......................................................................714 Figure 32 (Cab tilt wiring harness).........................................................................714 Figure 33 (Control panel)...................................................................................715 Figure 34 (Control panel)...................................................................................716 Figure 35 (Steering arm)....................................................................................717 Figure 36 (MCU).............................................................................................718 Figure 37 (Control motor)...................................................................................719 Figure 38 (Main valve block)................................................................................720 20.3 Cable connections and terminal posts.......................................................................721 20.3.1 ACT/ACH transistor regulators........................................................................721 20.3.2 Connections to CID...................................................................................723 20.3.3 Connections on the MCU...............................................................................724 20.4 Fuse box A9................................................................................................726 20.5 Overview...................................................................................................727 20.6 Details up to and including serial no. 6206800.............................................................736 20.7 Details cold store cab starting with 6206800...............................................................762 21 – Hydraulics schematics..........................................................................................795 21.1 Main valve unit............................................................................................795 21.1.1 RRE Std..............................................................................................795 21.1.2 RRE Ergo.............................................................................................796 21.2 Hydraulic diagrams.........................................................................................797 21.2.1 Schematics designations..............................................................................797 21.2.2 List of symbols......................................................................................798 21.2.3 Wiring diagrams RRE/RRE Ergo.........................................................................799 22 – Tools..........................................................................................................807 22.1 AMP connectors.............................................................................................807 22.2 MQS connectors.............................................................................................808 22.3 CPC connectors.............................................................................................810 22.4 Other tools................................................................................................811 23 – Appendix “Service data and grease specifications”..............................................................815 23.1 General tightening torques.................................................................................815 23.1.1 Galvanised, non-oiled screws.........................................................................815 23.1.2 Untreated, oiled screws..............................................................................816 23.2 Oil and grease specification...............................................................................817 24 – Technical data.................................................................................................819 Mast, maximum weight and maximum height.........................................................................824
DESCRIPTION:
BT FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL 7510399-040 – PDF DOWNLOAD
The repair manual is divided into chapters containing the following information:
•Safety regulations – This chapter includes general safety regulations regarding 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 – The troubleshooting chapter describes the error codes that are displayed when the truck is partially or completely out of service. It also describes the cause of the problem together with 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 C-code system.
•Appendices – The appendices include:
-Instructions for disposal
-Information about electrical components and wiring diagrams
-Hydraulics diagram
-List of required tools
-Information about general tightening torques
-Oil and grease specifications
-Technical data
S.S 05/01/2025
