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RRE160
BT RRE160 User Manual
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© BT
Rep
air Manual
en
RRE140/160/180/200/250
V
alid from serial number: 6051502
Order number: 261828-
040
Issued: 2008-08-2
1 ITS
2
Table of Contents
Table of Contents
3
Contents
4
General Introduction
13
How to Use the Manual
13
Warning Symbols
14
Pictograms
14
General Safety Rules
15
Safety While Working
15
Electrical System
16
Safe Lifting
17
Functions and Parameters
19
Chassis 0000
19
Driver Protection (0840)
19
Tilt Stops
19
Overhead Guard
20
Motors 1000
21
General
21
Electric Pump Motor (1710)
21
Design
21
Electric Steering Motor (1730)
22
General
22
Design
22
Fan Motor/Fan (1740)
23
Electric Drive Motor (1760)
24
General
24
Design
24
Drive Gear - 2000
25
General
25
Design
26
Brake System 3100
27
General
27
Travel Brake
27
Parking Brake
27
Emergency Brake
27
Drive Motor Brake (Travel Brake)
28
Accelerator Released
28
Changing the Direction of Travel
28
Multiple Disc Brake, Support Arm (Travel Brake)
29
General
29
Design
29
Disc Brake on the Drive Motor (Parking Brake)
30
General
30
Design
30
Steering System 4000
31
General
31
Design
31
Operator Compartment
32
Truck Control, Overview
32
Right-Hand Control Panel, Single Control
32
Right-Hand Control Panel, Multi-Control
32
Emergency Switch off
32
Steering Module
33
Pedals
34
Single Control
35
Multi-Control
36
Central Information Display - CID
37
CID LED Symbols
37
CID Information Symbols in the Display Area
38
CID Disable Indications in the Display Area
39
CID Service Symbols in the Display Area
40
Driver Parameter Symbols
41
Navigation
42
Load Information Display - LID (Option)
45
LID LED Symbols
45
LID Symbols in the Display Area
46
Operation and Connection Sequences
47
Functions
61
General Overview
61
Key
61
Components
61
MCU - Main Control Unit
62
General
62
System Communication
62
ACT/ACH Transistor Regulators
62
General
63
Start-Up
63
Shutdown
63
Driving
64
Introduction
64
Acceleration and Speed Reduction
64
Reversing
65
Brake
65
Travel Speed
66
Steering
67
Steering Position Check
67
Steering Speed
67
Steering Reference
68
Travel Speed Limitation
68
Compass Card
68
Hydraulic System
69
Definitions
69
Controls
69
Lift
69
Reach Movement
70
Lift Height Limitation
70
Maximum Height Limitation
70
Auxiliary/Extra Functions (Option)
71
Height Preselector, Description of Function
72
Using the Height Preselector
72
Symbols
72
Buzzer
72
Height Preselector Levels
73
Level Selection
73
Height Programming
74
Height Preselector and Truckcom
75
Lift/Lowering Movement
75
Hydraulic System 6000
76
General
76
Tank
76
Filter
76
Return Filter
76
Dehumidification Filter
76
Hydraulic Pump
77
Valve Block
77
Main Valve Block
77
Other Valve Blocks
78
Cylinders
79
Main Lift Cylinder
79
Free Lift Cylinder
79
Cylinders for the Reach Movement, Cabin Tilt, Sideshift and Fork
79
Lift and Lowering Function
80
Lifting and Lowering of Free Lift
80
Transition from Free Lift to Main Lift
80
Lifting and Lowering of Main Lift
80
Reach Movement, in and out
80
Simultaneous Operation of Mast Lift and Reach Movement
81
Extra Functions
81
Cabin Tilt (RRE Ergo)
81
Hydraulic Priority System
81
Cabin Tilt (RRE Ergo) During Servicing
82
Mast 7000
83
Mast and Reach Carriage
83
Lifting Devices
84
Fork Extensions
84
Telescopic Forks
84
Parameters
86
General
86
Displaying/Changing Parameters
87
Parameters
87
Operator Parameters, Overview
87
Service Parameters, Overview
88
Factory Parameters, Overview
93
Calibration Parameters, Overview
95
Installation
97
Transporting the Truck
97
Method 1
97
Method 2
97
Initial Operation
98
Placing the Battery
98
Parameters on Initial Operation
99
Battery
99
Load Indicator
99
Ergo Cabin
99
Cold Store Cabin
100
Parameters for Optional Equipment
100
Height Measurement (Option)
100
Travel Speed Limitation, Height-Dependent
100
Travel Speed Limitation, Reach Movement Dependent
100
Travel Speed Limitation, Parameter-Dependent
101
Collision Sensor (BT)
101
Mast, Fitting
101
Maintenance
103
Introduction, Maintenance
103
Periodic Maintenance
104
Every 500 B-Hours/180 Days
104
Every 1000 B-Hours/360 Days
106
Every 2000 B-Hours/720 Days
111
Every 3000 B-Hours/1080 Days
111
Every 5000 B-Hours/1800 Days
113
Annual Status Inspection
113
Maintenance Instructions
114
Cleaning and Washing
114
High-Pressure Washers
114
Degreasing Agents
114
Cleaning the Exterior
114
Cleaning the Chain
115
Cleaning the Motor Compartment
115
Electrical Components
115
Troubleshooting
117
Error Log Menu
117
Error Information Menu
117
Service Diagnostics Menu
118
General
118
Diagnostics States
119
State 1 - Voltage from Levers
119
State 2 - Digital Signals from Truck Controls to MCU
120
State 3 - Voltages to MCU
121
State 4 - Digital Input Signals to MCU
122
State 5 - Digital Output Signals from MCU
123
State 6 - PWM Outputs from MCU
124
State 7 - FCU (Not Used)
124
State 8 - FCU (Not Used)
124
State 9 - GFU (Not Used)
124
State 10 - GFU (Not Used)
124
State 11 - Temperature Signals
125
State 12 - Voltage Levels
125
State 13 - Travel Information
126
State 14 Steering Information
127
State 15 - Lift/Lowering Information
128
State 16 - Reach Movement
129
State 17 - Hydraulic Information
130
Warning and Error Codes
131
Abbreviations Used in this Section
131
Error Code Structure
131
Error Codes
133
ACT/ACH Transistor Regulators
150
Cable Connections and Pole Bolts
150
Symptom Tables
154
Brake
154
Telescopic Forks
155
Frame/Chassis 0000
157
General
157
Motor Hood (0340)
157
Opening the Motor Compartment
157
Rre 160-Rre 250
157
Operator Cabin (0500)
158
Cabin Tilting RRE 160-250 Ergo
158
Operator Compartment (0600)
159
Internal Fittings (0680)
159
Safety Equipment (0800)
160
Checking the Overhead Guard (0810)
160
Adjusting the Tilt Stops (0840)
161
Motors 1000
163
Motor Sensors
163
Temperature Sensor
163
Retrofitting of External Temperature Sensor
163
Replacing the Motor Speed Sensor
164
Pump Motor (1710)
165
General
165
The Pump Motor Dismantled
165
Replacing the Bearing on the Pump Motor
166
Dismantling the Pump Motor
166
Assembling the Pump Motor
168
Steering Motor and Steering Unit (1730)
169
General
169
Layout of the Flange Holes
169
Removing the Steering Motor from the Truck
170
Placing the Steering Motor in the Truck
170
Fan Motor/Fan (1740)
171
General
171
Replacing the Frequency Converter Cooling Fan
171
Standard Truck
171
Ergotruck
171
Replacing the Motor Compartment Cooling Fan
173
Drive Motor (1760)
174
General
174
The Drive Motor Dismantled
174
Removing the Drive Motor from the Truck
175
Dismantling the Drive Motor
177
Cleaning
178
Assembling the Drive Motor
179
Fitting the Drive Motor to the Truck
181
Drive Gear 2000
183
General
183
Leakage from the Bottom Cap
183
Replacing the Drive Gear
184
Special Tools
184
Exposing the Drive Gear
184
Removing a Drive Motor from the Truck
184
Removing a Steering Motor from the Truck
184
Removing the Drive Gear from the Truck
185
Replacing the Pinion Gear, Input Shaft
187
Remove the Pinion Gear
187
Placing a New Ball Bearing
188
Fitting the Sealing Ring
188
Inserting the Pinion Gear in the Drive Gear
188
Placing the Drive Gear in the Truck
189
Placing the Steering Motor in the Truck
190
Placing the Drive Motor in the Truck
190
Refitting
190
Brake and Wheel 3000
191
Travel Brake System (3100)
191
Removing the Support Arm's Multiple Disc Brake
191
Dismantling the Multiple Disc Brake
191
Inspection
192
Adjusting Play
192
Assembling the Multiple Disc Brake
193
Placing the Multiple Disc Brake in the Truck
193
Parking Brake (3300)
194
General
194
Emergency Release of the Parking Brake
195
Checking the Brake Force
195
Removing the Parking Brake from the Truck
196
Dismantling and Checking Wear
196
Assembling the Parking Brake
197
Adjusting Play
197
Placing the Parking Brake in the Truck
198
Drive Wheel (3530)
199
General
199
Removing the Drive Wheel from the Truck
199
Placing the Drive Wheel on the Truck
199
Wheel Bolt (3530)
200
General
200
Replacing Wheel Bolts
200
Support Arm Wheel (3550)
201
Removing the Support Arm Wheel from the Truck
201
Replacing a Wheel Bearing - Braked Wheel (A)
202
Replacing a Wheel Bearing - Unbraked Wheel (B)
203
Placing the Support Arm Wheel in the Truck
204
Steering System 4000
205
Electric Steering Wheel (4310)
205
General
205
Replacing the Pulse Transducer on the Steering Wheel Module
205
Removing the Operating Console from the Truck
206
Replacing the Wiring Harness in the Operating Console
207
Placing the Operating Console in the Truck
209
Steering Reference Sensor (4350)
210
General
210
Replacing the Reference Sensor
210
Steering Bearings (4380)
211
Removing a Steering Bearing from the Drive Gear
211
Placing a Steering Bearing on the Drive Gear
211
Electrical System 5000
213
Battery (5110)
213
Exide Gel Batteries (Sonnenschein, for Example)
213
Hawker Evolution Gel Batteries
213
Battery Installation
214
Setting Battery Parameters
214
Parameter Settings for Valve-Controlled Batteries (VRLA)
214
Instructions for Verifying Parameter Settings
214
Control Console (5510)
215
General
215
Replacement/Installation of a Control
215
Removing the Control Console from the Truck
216
Replacing the Access Card's Circuit Board
217
Dismantling the Control Console
218
General
218
Installing an Extra Push Button
220
Replacing the Travel Direction Selector with Signal Button
220
Replacing the Display
221
Assembling the Control Console
221
Placing the Control Console in the Truck
222
Parameter Settings
223
Configuration Menu
223
Calendar/Hour Counter Menu
223
Parameter Menu (PAR)
223
Driver Parameter Modification
224
PIN Menu
225
Calibrations
226
Valve Calibration
226
Free Lift and Main Lift Valve Calibration
226
Free Lowering and Main Lowering Valve Calibration
226
Reach Movement Valve Calibration
227
Joystick Calibration
228
Weight Calibration
228
Calibrating the Weight Indicator
228
Height Measurement/Reach Movement Length Calibration
229
Calibrating Height Measurement (Option)
229
Calibrating Reach Movement Length
230
Transition/Mast Separation Calibration
231
Emergency Lowering of Forks
239
Replacing the Complete Main Valve Block
240
Adjustment of Maximum Opening Point
242
Hydraulic Connections (6230)
243
Tightening Torque for Hydraulic Connections
243
Conical Connection with O-Ring
243
Tredo Seal
243
Pipe Coupling
244
Quick Change Connector
246
Assembling the Quick Change Connector
246
Dismantling the Quick Change Connector
247
Hydraulic System, Mast (6300)
248
Mast-Mounted Hose Reel (6370)
248
General
248
Fitting the Hose Reel
248
Spring Preloading (Turns)
248
Checks after Fitting
249
Main Lift Cylinder (6610)
250
General
250
Removing the Air Cylinder from the Mast
250
Replacing the Hose Rupture Valve
250
Fitting the Cylinder to the Mast
251
Free Lift Cylinder (6620)
252
General
252
Removing the Free Lift Cylinder from the Truck
252
Replacing the Hose Rupture Valve, Free Lift Cylinder
252
Placing the Free Lift Cylinder in the Truck
253
Reach Cylinder (6650)
254
General
254
Removing the Reach Cylinder from the Truck
254
Placing the Reach Cylinder in the Truck
254
Fork Tilt Cylinder (6660)
255
General
255
Removing the Tilt Cylinder from the Fork Carriage
255
Mast/Lift System 7000
257
Main Mast 1.6-2.5 T (7100)
257
Replacing the Full Mast
257
Replacing the Mast Damper Plates
258
Removing the Mast from the Truck
259
Adjusting Mast Play
262
General
262
Preparations
262
Adjusting Lateral Play
265
Adjustment of Radial Play
266
Adjusting the Damper Parts
266
Adjusting the Damper Plate
267
Refitting the Mast
267
Placing the Mast on the Truck
268
Main Lift Chain System (7120)
272
General
272
Inspecting the Chain
272
Noise
272
Surface Rust
272
Rusty Links
272
Stiff Links
273
Bolt Rotation
273
Loose Bolts
273
Plate Wear
274
Elongation
275
Damage
275
Damaged Plates
276
Damaged Bolts
276
Dirty Chain
276
Lubricating the Chain
276
Main Lift Chain System, Adjusting the Fork-To-Floor Distance
277
Reach Carriage (7190)
278
Adjusting Radial Play in the Reach Carriage
278
Adjusting Axial Play in the Reach Carriage
280
Lifting Devices (7400)
281
Forks
281
General
281
Inspection
281
Inspection Intervals
281
Surface Cracks
281
Difference in Height between the Fork Tips
282
Position Locks
282
Legible Markings
282
Fork Blades and Shafts
282
Mounting Fixings on the Fork
282
Forks, Repairs and Testing
283
Repairs
283
Testing the Yield Point
283
Fork Carriage
284
Checking the Fork Carriage's Wear Strip
284
Lubricating the Fork Carriage
285
Fork Spread Unit
286
Servicing the Fork Spread Unit
286
Replacing Bearings
287
Replacing the Rollers
287
Fork Extensions with Adjustable Fork Length
288
Manual Telescopic Forks
290
Fitting
290
Maintenance
291
Hydraulic Telescopic Forks
292
Telescopic Forks with Separate Flow Dividers
293
Fitting Instructions
294
Initial Operation of Telescopic Forks with Separate Flow Dividers
294
Telescopic Forks with Integrated Flow Dividers
295
Fitting Instructions
296
Initial Operation of Telescopic Forks with Integrated Flow Dividers
296
Maintenance of Telescopic Forks
297
Dismantling Telescopic Forks
298
Assembling Telescopic Forks
299
External Equipment 8000
301
Introduction
301
Options 9000
303
Introduction
303
Appendix "Destruction Instructions
305
General
305
Marking of Plastics
305
General Marking of Products and Packaging Material
305
Marking According to Our Standard
306
Marking Examples
306
Pressure Vessels
307
Gas Dampers
307
Sorting Categories
308
Components
308
Overview
316
Wiring Diagrams
317
Hydraulics Schematics
339
Main Valve
339
RRE Std
339
RRE Ergo
340
Hydraulics Schematics
340
Schematics Designations
341
List of Symbols
342
Wiring Diagrams RRE/RRE Ergo
343
Tool
349
AMP Connectors
349
AMP Microtimer
350
MQS Contacts
351
Other Tools
353
Appendix "Service Data and Grease Specifications
357
General Tightening Torques
357
Galvanised Non-Oiled Bolts
357
Untreated Oiled Bolts
358
Oil and Grease Specifications
359
Technical Data
361
4
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BT RRE160 Specifications
General
Load Capacity
1600 kg
Power Source
Electric
Type
Reach Truck
Mast Type
Duplex
Model
RRE160
Rated Capacity
1600 kg
Turning Radius
1675 mm
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