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BT RRE140 User Manual

BT RRE140
366 pages
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© BT
Repair Manual en
RRE140/160/180/200/250
Valid from serial number: 6051502
Order number: 261828-040
Issued: 2008-08-21 ITS

Table of Contents

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BT RRE140 Specifications

General IconGeneral
BrandBT
ModelRRE140
CategoryForklifts
LanguageEnglish

Summary

General Introduction

How to Use the Manual

Explains the manual's structure and content organization for users.

Warning Symbols

Details danger, warning, and important symbols used in the manual.

Pictograms

Explains pictograms used for actions, screw types, and tie wrap removal.

General Safety Rules

Safety While Working

Provides essential safety precautions for working on the truck to prevent accidents.

Electrical System

Outlines safety guidelines when working on the truck's electrical system.

Safe Lifting

Details crucial safety procedures and precautions for lifting the truck safely.

Functions and Parameters

Chassis 0000

Covers chassis components and driver protection features like tilt stops and overhead guards.

Motors 1000

Details the truck's motors: drive, pump, and steering, including their specifications and designs.

Drive Gear 2000

Explains the drive gear's integration with motor/brake, its sizes, and design features.

Brake System 3100

Explains the three types of brakes: travel, parking, and emergency, detailing their operation.

Steering System 4000

Covers the fully electric steer-by-wire system, including pulse generators and EPS.

Operator Compartment

Describes the operator's controls, displays (CID, LID), and safety features within the compartment.

Operation and Connection Sequences

Outlines sequences for battery connection and various login procedures.

Functions

Provides a general overview of truck functions, key components, and system communication.

Height Preselector, Description of Function

Explains how to use the height preselector, its symbols, buzzer, levels, and programming.

Hydraulic System 6000

Details the hydraulic system components: tank, filters, pump, valve blocks, and cylinders.

Mast 7000

Covers mast and reach carriage types and replacement procedures.

Lifting Devices

Describes fork extensions, telescopic forks, and their maintenance.

Parameters

Details operator, service, factory, and calibration parameters, including their overview and settings.

Installation

Transporting the Truck

Provides methods and load capacities for transporting the truck using a forklift.

Initial Operation

Guides through initial truck setup, including battery placement and parameter settings.

Parameters on Initial Operation

Details crucial parameters for initial setup, including battery, load indicator, and cabin settings.

Parameters for Optional Equipment

Explains parameters for optional features like height measurement and speed limitations.

Mast, Fitting

Refers to the procedure for fitting the mast on the truck.

Maintenance

Introduction, Maintenance

Introduces the importance of maintenance for truck safety and minimizing downtime.

Periodic Maintenance

Outlines periodic maintenance schedules based on operating hours and days.

Maintenance Instructions

Provides detailed instructions for cleaning and washing the truck and its components.

Troubleshooting

Error Log Menu

Explains how to access and interpret the error log and detailed error information menus.

Service Diagnostics Menu

Guides on accessing the service diagnostics menu and viewing different diagnostic states.

Warning and Error Codes

Provides an overview of warning and error codes, their structure, and abbreviations used.

ACT/ACH Transistor Regulators

Details cable connections and pole bolts for ACT/ACH transistor regulators.

Symptom Tables

Offers troubleshooting advice based on common truck symptoms related to brakes and forks.

Frame/Chassis 0000

General

Provides a general overview of the truck chassis structure.

Motor Hood (0340)

Details how to open and close the motor compartment cover.

Operator Cabin (0500)

Explains the procedure for tilting the operator cabin for servicing and safety precautions.

Operator Compartment (0600)

Describes the internal fittings and panels of the operator compartment.

Safety Equipment (0800)

Covers safety equipment checks, specifically the overhead guard and tilt stops.

Motors 1000

Motor Sensors

Explains temperature sensors and their resistance readings, and retrofitting an external sensor.

Pump Motor (1710)

Details the pump motor, its integration with the hydraulic pump, and instructions for bearing replacement.

Steering Motor and Steering Unit (1730)

Covers the steering motor, its general function, and replacement procedures.

Fan Motor/Fan (1740)

Describes the two cooling fans in the motor compartment and their replacement.

Drive Motor (1760)

Details the drive motor, its integration with the drive gear, and replacement procedures.

Drive Gear 2000

General

Explains the drive gear's integration with motor/brake and instructions for replacement.

Leakage from the Bottom Cap

Provides steps to address leakage from the drive gear's bottom cap.

Replacing the Drive Gear

Outlines the procedure for exposing and removing the drive gear.

Replacing the Pinion Gear, Input Shaft

Details how to remove and replace the pinion gear and bearing.

Placing the Drive Gear in the Truck

Guides on correctly installing the drive gear into the truck chassis.

Refitting

Covers the final steps for refitting components after drive gear work.

Brake and Wheel 3000

Travel Brake System (3100)

Details the travel brake system, including multiple disc brake dismantling and assembly.

Parking Brake (3300)

Covers the parking brake, its general operation, emergency release, and force checking.

Drive Wheel (3530)

Explains how to remove and place the drive wheel on the truck.

Wheel Bolt (3530)

Provides instructions for replacing broken wheel bolts.

Support Arm Wheel (3550)

Covers removing and replacing wheel bearings for support arm wheels.

Steering System 4000

Electric Steering Wheel (4310)

Details replacing the pulse transducer and operating console for the electric steering wheel.

Steering Reference Sensor (4350)

Explains how to replace the steering reference sensor on the drive gear housing.

Steering Bearings (4380)

Covers removing and placing steering bearings on the drive gear.

Electrical System 5000

Battery (5110)

Provides recommendations and guidelines for using Hawker Evolution gel batteries.

Control Console (5510)

Details replacement/installation of controls, removal, and dismantling of the control console.

Parameter Settings

Explains the configuration and parameter menus for adjusting truck settings.

Calibrations

Guides on calibrating valves, joysticks, weight indicators, and height/reach measurements.

Hydraulic System 6000

Hydraulic Unit (6100)

Describes the hydraulic unit, tank draining, bleeding, and pump motor removal/replacement.

Main Valve (6210)

Covers emergency lowering of forks and replacing the complete main valve block.

Hydraulic Connections (6230)

Provides tightening torques and procedures for hydraulic connections and quick change connectors.

Hydraulic System, Mast (6300)

Details mast-mounted hose reel installation, checks, and spring preloading.

Main Lift Cylinder (6610)

Explains removing and fitting the main lift cylinder and replacing the hose rupture valve.

Free Lift Cylinder (6620)

Covers removing and placing the free lift cylinder and replacing its hose rupture valve.

Reach Cylinder (6650)

Details removing and placing the reach cylinder.

Fork Tilt Cylinder (6660)

Covers removing and placing the fork tilt cylinder.

Mast/Lift System 7000

Main Mast 1.6-2.5 t (7100)

Covers replacing the full mast and replacing mast damper plates.

Main Lift Chain System (7120)

Details inspecting and lubricating the main lift chains for wear and damage.

Reach Carriage (7190)

Explains adjusting radial and axial play in the reach carriage.

Lifting Devices (7400)

Covers fork inspection, repairs, testing, and fork carriage checks and lubrication.

Fork Carriage

Details checking the fork carriage wear strip and lubricating it.

Fork Spread Unit

Outlines servicing procedures for the fork spread unit, including lubrication and checks.

Fork Extensions with Adjustable Fork Length

Describes fitting, maintenance, and checking fork extensions.

Manual Telescopic Forks

Covers fitting, maintenance, and dismantling manual telescopic forks.

Hydraulic Telescopic Forks

Details fitting and initial operation of hydraulic telescopic forks with separate and integrated flow dividers.

External Equipment 8000

Introduction

States that this section is reserved for future use.

Options 9000

Introduction

States that this section is reserved for future use.

Appendix “Destruction Instructions”

General

Introduces destruction instructions to support environmental protection through recycling.

Marking of Plastics

Explains general markings for products and packaging materials, including plastic types.

Pressure Vessels

Provides instructions for handling pressure vessels like gas dampers, including safety warnings.

Sorting Categories

Details sorting categories for various truck components for recycling and disposal.

Wiring Diagrams

Components

Lists and describes various electrical components used in the truck's wiring.

Overview

Indicates that this section is TBD (To Be Determined).

Wiring Diagrams

Presents detailed wiring diagrams for the truck's electronic systems.

Hydraulics Schematics

Main Valve

Details the main valve block for RRE Std. and RRE Ergo models, including component functions.

Hydraulics Schematics

Explains schematic designations and lists symbols used in hydraulic diagrams.

Wiring Diagrams RRE/RRE Ergo

Shows hydraulic diagrams for RRE and RRE Ergo models, illustrating various functions.

Tool

AMP Connectors

Lists tools for fitting and removing AMP connectors (Power Timer, Junior Power Timer, Micro Power Timer).

AMP Microtimer

Describes tools for fitting and removing AMP microtimer pins/sleeves.

MQS Contacts

Details the MQS Basic toolbox contents for connector repair.

Other Tools

Lists other specialized tools, including service instruments and lifting tools.

Appendix “Service Data and Grease Specifications”

General Tightening Torques

Provides general tightening torque values for galvanized non-oiled and untreated oiled bolts.

Oil and Grease Specifications

Lists recommended lubricants and their specifications for various truck components and ambient temperatures.

Technical Data

Table 2: Technical Data

Presents technical data for different truck models, including drive motor, transmission, and wheel specifications.

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