BT RRE200 - Page 112

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6 – 10 Repair Manual RRE140/160/180/200/250 © BT

Maintenance

Periodic maintenance

T-code Valid from serial number Date Publication No.

815, 816 6051502 2008-08-21 261828-040

6140.1

0640.1

1700.1

5000.1

5390.1

5590.1

5110.4

5110.5

5110.6

5200.1

Main Page

Table of Contents3
Contents4
General Introduction13
How to Use the Manual13
Warning Symbols14
Pictograms14
General Safety Rules15
Safety While Working15
Electrical System16
Safe Lifting17
Functions and Parameters19
Chassis 000019
Driver Protection (0840)19
Tilt Stops19
Overhead Guard20
Motors 100021
General21
Electric Pump Motor (1710)21
Design21
Electric Steering Motor (1730)22
General22
Design22
Fan Motor/Fan (1740)23
Electric Drive Motor (1760)24
General24
Design24
Drive Gear - 200025
General25
Design26
Brake System 310027
General27
Travel Brake27
Parking Brake27
Emergency Brake27
Drive Motor Brake (Travel Brake)28
Accelerator Released28
Changing the Direction of Travel28
Multiple Disc Brake, Support Arm (Travel Brake)29
General29
Design29
Disc Brake on the Drive Motor (Parking Brake)30
General30
Design30
Steering System 400031
General31
Design31
Operator Compartment32
Truck Control, Overview32
Right-Hand Control Panel, Single Control32
Right-Hand Control Panel, Multi-Control32
Emergency Switch off32
Steering Module33
Pedals34
Single Control35
Multi-Control36
Central Information Display - CID37
CID LED Symbols37
CID Information Symbols in the Display Area38
CID Disable Indications in the Display Area39
CID Service Symbols in the Display Area40
Driver Parameter Symbols41
Navigation42
Load Information Display - LID (Option)45
LID LED Symbols45
LID Symbols in the Display Area46
Operation and Connection Sequences47
Functions61
General Overview61
Key61
Components61
MCU - Main Control Unit62
General62
System Communication62
ACT/ACH Transistor Regulators62
General63
Start-Up63
Shutdown63
Driving64
Introduction64
Acceleration and Speed Reduction64
Reversing65
Brake65
Travel Speed66
Steering67
Steering Position Check67
Steering Speed67
Steering Reference68
Travel Speed Limitation68
Compass Card68
Hydraulic System69
Definitions69
Controls69
Lift69
Reach Movement70
Lift Height Limitation70
Maximum Height Limitation70
Auxiliary/Extra Functions (Option)71
Height Preselector, Description of Function72
Using the Height Preselector72
Symbols72
Buzzer72
Height Preselector Levels73
Level Selection73
Height Programming74
Height Preselector and Truckcom75
Lift/Lowering Movement75
Hydraulic System 600076
General76
Tank76
Filter76
Return Filter76
Dehumidification Filter76
Hydraulic Pump77
Valve Block77
Main Valve Block77
Other Valve Blocks78
Cylinders79
Main Lift Cylinder79
Free Lift Cylinder79
Cylinders for the Reach Movement, Cabin Tilt, Sideshift and Fork79
Lift and Lowering Function80
Lifting and Lowering of Free Lift80
Transition from Free Lift to Main Lift80
Lifting and Lowering of Main Lift80
Reach Movement, in and out80
Simultaneous Operation of Mast Lift and Reach Movement81
Extra Functions81
Cabin Tilt (RRE Ergo)81
Hydraulic Priority System81
Cabin Tilt (RRE Ergo) During Servicing82
Mast 700083
Mast and Reach Carriage83
Lifting Devices84
Fork Extensions84
Telescopic Forks84
Parameters86
General86
Displaying/Changing Parameters87
Parameters87
Operator Parameters, Overview87
Service Parameters, Overview88
Factory Parameters, Overview93
Calibration Parameters, Overview95
Installation97
Transporting the Truck97
Method 197
Method 297
Initial Operation98
Placing the Battery98
Parameters on Initial Operation99
Battery99
Load Indicator99
Ergo Cabin99
Cold Store Cabin100
Parameters for Optional Equipment100
Height Measurement (Option)100
Travel Speed Limitation, Height-Dependent100
Travel Speed Limitation, Reach Movement Dependent100
Travel Speed Limitation, Parameter-Dependent101
Collision Sensor (BT)101
Mast, Fitting101
Maintenance103
Introduction, Maintenance103
Periodic Maintenance104
Every 500 B-Hours/180 Days104
Every 1000 B-Hours/360 Days106
Every 2000 B-Hours/720 Days111
Every 3000 B-Hours/1080 Days111
Every 5000 B-Hours/1800 Days113
Annual Status Inspection113
Maintenance Instructions114
Cleaning and Washing114
High-Pressure Washers114
Degreasing Agents114
Cleaning the Exterior114
Cleaning the Chain115
Cleaning the Motor Compartment115
Electrical Components115
Troubleshooting117
Error Log Menu117
Error Information Menu117
Service Diagnostics Menu118
General118
Diagnostics States119
State 1 - Voltage from Levers119
State 2 - Digital Signals from Truck Controls to MCU120
State 3 - Voltages to MCU121
State 4 - Digital Input Signals to MCU122
State 5 - Digital Output Signals from MCU123
State 6 - PWM Outputs from MCU124
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 Signals125
State 12 - Voltage Levels125
State 13 - Travel Information126
State 14 Steering Information127
State 15 - Lift/Lowering Information128
State 16 - Reach Movement129
State 17 - Hydraulic Information130
Warning and Error Codes131
Abbreviations Used in this Section131
Error Code Structure131
Error Codes133
ACT/ACH Transistor Regulators150
Cable Connections and Pole Bolts150
Symptom Tables154
Brake154
Telescopic Forks155
Frame/Chassis 0000157
General157
Motor Hood (0340)157
Opening the Motor Compartment157
Rre 160-Rre 250157
Operator Cabin (0500)158
Cabin Tilting RRE 160-250 Ergo158
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 1000163
Motor Sensors163
Temperature Sensor163
Retrofitting of External Temperature Sensor163
Replacing the Motor Speed Sensor164
Pump Motor (1710)165
General165
The Pump Motor Dismantled165
Replacing the Bearing on the Pump Motor166
Dismantling the Pump Motor166
Assembling the Pump Motor168
Steering Motor and Steering Unit (1730)169
General169
Layout of the Flange Holes169
Removing the Steering Motor from the Truck170
Placing the Steering Motor in the Truck170
Fan Motor/Fan (1740)171
General171
Replacing the Frequency Converter Cooling Fan171
Standard Truck171
Ergotruck171
Replacing the Motor Compartment Cooling Fan173
Drive Motor (1760)174
General174
The Drive Motor Dismantled174
Removing the Drive Motor from the Truck175
Dismantling the Drive Motor177
Cleaning178
Assembling the Drive Motor179
Fitting the Drive Motor to the Truck181
Drive Gear 2000183
General183
Leakage from the Bottom Cap183
Replacing the Drive Gear184
Special Tools184
Exposing the Drive Gear184
Removing a Drive Motor from the Truck184
Removing a Steering Motor from the Truck184
Removing the Drive Gear from the Truck185
Replacing the Pinion Gear, Input Shaft187
Remove the Pinion Gear187
Placing a New Ball Bearing188
Fitting the Sealing Ring188
Inserting the Pinion Gear in the Drive Gear188
Placing the Drive Gear in the Truck189
Placing the Steering Motor in the Truck190
Placing the Drive Motor in the Truck190
Refitting190
Brake and Wheel 3000191
Travel Brake System (3100)191
Removing the Support Arm's Multiple Disc Brake191
Dismantling the Multiple Disc Brake191
Inspection192
Adjusting Play192
Assembling the Multiple Disc Brake193
Placing the Multiple Disc Brake in the Truck193
Parking Brake (3300)194
General194
Emergency Release of the Parking Brake195
Checking the Brake Force195
Removing the Parking Brake from the Truck196
Dismantling and Checking Wear196
Assembling the Parking Brake197
Adjusting Play197
Placing the Parking Brake in the Truck198
Drive Wheel (3530)199
General199
Removing the Drive Wheel from the Truck199
Placing the Drive Wheel on the Truck199
Wheel Bolt (3530)200
General200
Replacing Wheel Bolts200
Support Arm Wheel (3550)201
Removing the Support Arm Wheel from the Truck201
Replacing a Wheel Bearing - Braked Wheel (A)202
Replacing a Wheel Bearing - Unbraked Wheel (B)203
Placing the Support Arm Wheel in the Truck204
Steering System 4000205
Electric Steering Wheel (4310)205
General205
Replacing the Pulse Transducer on the Steering Wheel Module205
Removing the Operating Console from the Truck206
Replacing the Wiring Harness in the Operating Console207
Placing the Operating Console in the Truck209
Steering Reference Sensor (4350)210
General210
Replacing the Reference Sensor210
Steering Bearings (4380)211
Removing a Steering Bearing from the Drive Gear211
Placing a Steering Bearing on the Drive Gear211
Electrical System 5000213
Battery (5110)213
Exide Gel Batteries (Sonnenschein, for Example)213
Hawker Evolution Gel Batteries213
Battery Installation214
Setting Battery Parameters214
Parameter Settings for Valve-Controlled Batteries (VRLA)214
Instructions for Verifying Parameter Settings214
Control Console (5510)215
General215
Replacement/Installation of a Control215
Removing the Control Console from the Truck216
Replacing the Access Card's Circuit Board217
Dismantling the Control Console218
General218
Installing an Extra Push Button220
Replacing the Travel Direction Selector with Signal Button220
Replacing the Display221
Assembling the Control Console221
Placing the Control Console in the Truck222
Parameter Settings223
Configuration Menu223
Calendar/Hour Counter Menu223
Parameter Menu (PAR)223
Driver Parameter Modification224
PIN Menu225
Calibrations226
Valve Calibration226
Free Lift and Main Lift Valve Calibration226
Free Lowering and Main Lowering Valve Calibration226
Reach Movement Valve Calibration227
Joystick Calibration228
Weight Calibration228
Calibrating the Weight Indicator228
Height Measurement/Reach Movement Length Calibration229
Calibrating Height Measurement (Option)229
Calibrating Reach Movement Length230
Transition/Mast Separation Calibration231
Emergency Lowering of Forks239
Replacing the Complete Main Valve Block240
Adjustment of Maximum Opening Point242
Hydraulic Connections (6230)243
Tightening Torque for Hydraulic Connections243
Conical Connection with O-Ring243
Tredo Seal243
Pipe Coupling244
Quick Change Connector246
Assembling the Quick Change Connector246
Dismantling the Quick Change Connector247
Hydraulic System, Mast (6300)248
Mast-Mounted Hose Reel (6370)248
General248
Fitting the Hose Reel248
Spring Preloading (Turns)248
Checks after Fitting249
Main Lift Cylinder (6610)250
General250
Removing the Air Cylinder from the Mast250
Replacing the Hose Rupture Valve250
Fitting the Cylinder to the Mast251
Free Lift Cylinder (6620)252
General252
Removing the Free Lift Cylinder from the Truck252
Replacing the Hose Rupture Valve, Free Lift Cylinder252
Placing the Free Lift Cylinder in the Truck253
Reach Cylinder (6650)254
General254
Removing the Reach Cylinder from the Truck254
Placing the Reach Cylinder in the Truck254
Fork Tilt Cylinder (6660)255
General255
Removing the Tilt Cylinder from the Fork Carriage255
Mast/Lift System 7000257
Main Mast 1.6-2.5 T (7100)257
Replacing the Full Mast257
Replacing the Mast Damper Plates258
Removing the Mast from the Truck259
Adjusting Mast Play262
General262
Preparations262
Adjusting Lateral Play265
Adjustment of Radial Play266
Adjusting the Damper Parts266
Adjusting the Damper Plate267
Refitting the Mast267
Placing the Mast on the Truck268
Main Lift Chain System (7120)272
General272
Inspecting the Chain272
Noise272
Surface Rust272
Rusty Links272
Stiff Links273
Bolt Rotation273
Loose Bolts273
Plate Wear274
Elongation275
Damage275
Damaged Plates276
Damaged Bolts276
Dirty Chain276
Lubricating the Chain276
Main Lift Chain System, Adjusting the Fork-To-Floor Distance277
Reach Carriage (7190)278
Adjusting Radial Play in the Reach Carriage278
Adjusting Axial Play in the Reach Carriage280
Lifting Devices (7400)281
Forks281
General281
Inspection281
Inspection Intervals281
Surface Cracks281
Difference in Height between the Fork Tips282
Position Locks282
Legible Markings282
Fork Blades and Shafts282
Mounting Fixings on the Fork282
Forks, Repairs and Testing283
Repairs283
Testing the Yield Point283
Fork Carriage284
Checking the Fork Carriage's Wear Strip284
Lubricating the Fork Carriage285
Fork Spread Unit286
Servicing the Fork Spread Unit286
Replacing Bearings287
Replacing the Rollers287
Fork Extensions with Adjustable Fork Length288
Manual Telescopic Forks290
Fitting290
Maintenance291
Hydraulic Telescopic Forks292
Telescopic Forks with Separate Flow Dividers293
Fitting Instructions294
Initial Operation of Telescopic Forks with Separate Flow Dividers294
Telescopic Forks with Integrated Flow Dividers295
Fitting Instructions296
Initial Operation of Telescopic Forks with Integrated Flow Dividers296
Maintenance of Telescopic Forks297
Dismantling Telescopic Forks298
Assembling Telescopic Forks299
External Equipment 8000301
Introduction301
Options 9000303
Introduction303
Appendix "Destruction Instructions305
General305
Marking of Plastics305
General Marking of Products and Packaging Material305
Marking According to Our Standard306
Marking Examples306
Pressure Vessels307
Gas Dampers307
Sorting Categories308
Components308
Overview316
Wiring Diagrams317
Hydraulics Schematics339
Main Valve339
RRE Std339
RRE Ergo340
Hydraulics Schematics340
Schematics Designations341
List of Symbols342
Wiring Diagrams RRE/RRE Ergo343
Tool349
AMP Connectors349
AMP Microtimer350
MQS Contacts351
Other Tools353
Appendix "Service Data and Grease Specifications357
General Tightening Torques357
Galvanised Non-Oiled Bolts357
Untreated Oiled Bolts358
Oil and Grease Specifications359
Technical Data361

BT RRE200 - Page 112

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