BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-020

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BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-020

$30.00

Type Of Manual: Repair Manual
Manual ID: 7510399-020
: Service Manual PDF
Number of Pages: 816
Size: 54.2MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- RPE140, RPE160, RPE180, RPE200, RPE250

1. Contents
2. General introduction
2.1. How to use the manual
2.2. Warning symbols
2.3. Pictogram
3. General safety rules
3.1. Safety while working
3.2. Electrical system
3.3. Safe lifting
4. Descriptions of functions
4.1. Chassis 0000
4.1.1. Operators cabin (0500)
4.1.2. Cab windows (0530)
4.1.3. Operators seat (0620)
4.1.4. Cab heating/ventilation (0630)
4.1.5. Operator protection (0840)
4.2. Motors 1000
4.2.1. General
4.2.2. Electric pump motor (1710)
4.2.3. Electric steering motor (1730)
4.2.4. Fan motor/fan (1740)
4.2.5. Electric drive motor (1760)
4.3. Drive gear – 2000
4.3.1. General
4.3.2. Design
4.4. Brake system 3100
4.4.1. General
4.4.2. Drive motor brake (travel brake)
4.4.3. Multiple disc brake, support arm (travel brake)
4.4.4. Disc brake on the drive motor (parking brake)
4.5. Steering system 4000
4.5.1. General
4.5.2. Design
4.5.3. Sensor
4.6. Operator compartment
4.6.1. Truck control, overview
4.6.2. Single-function controls
4.6.3. Multi-function controls
4.6.4. Central Information Display – CID
4.6.5. Load Information Display – LID (option)
4.7. sensors and sensors (5800)
4.7.1. Inductive sensors
4.7.2. Position sensor
4.7.3. Magnetic sensor
4.8. Operation and connection sequences
4.9. Functions
4.9.1. General overview
4.9.2. MCU – main control unit
4.9.3. ACT/ACH transistor regulators
4.9.4. Start-up
4.9.5. Shutdown
4.9.6. Driving
4.9.7. OTP
4.9.8. Guide
4.9.9. Hydraulic system
4.10. Height preselector, description of function
4.10.1. Using the height preselector
4.10.2. Symbols
4.10.3. Buzzer
4.10.4. Height preselector levels
4.10.5. Level selection
4.10.6. Height programming
4.10.7. Height preselector and TruckCom
4.10.8. Lifting/lowering movement
4.10.9. Parameter settings braking at height preselector
4.11. Hydraulic system 6000
4.11.1. General
4.11.2. Tank
4.11.3. Filter
4.11.4. Hydraulic pump
4.11.5. Valve unit
4.11.6. Cylinders
4.11.7. Lift and lowering function
4.11.8. Extra functions
4.11.9. Cabin tilt (RRE Ergo)
4.12. Mast 7000
4.12.1. Mast and reach carriage
4.13. Lifting devices
4.13.1. Fork extensions
4.13.2. Telescopic forks
4.14. Accessories 9000
4.14.1. Radio equipment
4.14.2. Extra lighting
4.14.3. Extra warning lights/alarm
4.14.4. Turn signal lights
4.14.5. Movement alarm
4.14.6. Positioning/TV equipment
4.14.7. Extra electrical equipment
4.14.8. Other extra equipment
5. Parameters
5.1. General
5.2. Displaying/changing parameters
5.3. Operator parameters
5.3.1. Overview
5.3.2. Connection to logged-in operator
5.3.3. Description
5.4. General service parameters
5.4.1. Overview
5.4.2. Description
5.4.3. Service parameters, travel functions
5.4.4. Overview
5.4.5. Description
5.5. Service parameters, hydraulics
5.5.1. Overview
5.5.2. Description
5.6. Service parameters, CID
5.6.1. Overview
5.6.2. Description
5.7. Service parameters, General Function Unit GFU
5.8. General factory parameters
5.8.1. Overview
5.8.2. Description
5.9. Factory parameters, activation of options
5.9.1. Parameter 1115 (Steering angle)
5.9.2. Parameter 1116 (Extended mast)
5.9.3. Parameter 1117 (Weight of load and fork height)
5.9.4. Parameter 1118 (Main lift range)
5.10. Factory parameters, calibration
6. Installation
6.1. Transporting the truck
6.1.1. Method 1
6.1.2. Method 2
6.2. Initial operation
6.2.1. Tool
6.2.2. Battery
6.2.3. Mast, fitting
6.2.4. Parameters on initial operation
6.2.5. Parameters for optional equipment
6.2.6. Test driving
7. Maintenance
7.1. Introduction, maintenance
7.2. Safety precautions for maintenance work
7.3. Checks for cracks
7.3.1. Visual inspection
7.3.2. Crack detection
7.4. Periodic maintenance
7.4.1. Every 500 B-hours/180 days
7.4.2. Every 1000 B-hours/360 days
7.4.3. Every 2000 B-hours/720 days
7.4.4. Every 3000 B-hours/1080 days
7.4.5. Every 5000 B-hours/1800 days
7.4.6. Annual status inspection
7.5. Maintenance instructions
7.5.1. Cleaning and washing
8. Troubleshooting
8.1. Abbreviations used in this section
8.2. Truck help functions
8.2.1. Error log menu
8.2.2. Error information menu
8.2.3. Diagnostic screens
8.3. Initial troubleshooting
8.4. Troubleshooting using catch symbol
8.5. Troubleshooting using error codes
8.5.1. CID, warnings and errors
8.5.2. MCU and other warnings and errors
8.5.3. Drive system error
8.5.4. Hydraulic system error
8.5.5. Steering system, warnings and errors
8.5.6. GFU, warnings and errors
8.6. Troubleshooting without indications
8.6.1. Mechanical brake (3000)
8.6.2. Steering (4000)
8.6.3. Telescopic forks
8.6.4. Log on was normal, but one or several functions cannot be used
9. Frame/Chassis 0000
9.1. General
9.2. Motor hood (0340)
9.2.1. Opening the motor compartment
9.3. Battery compartment components (0390)
9.3.1. Adjusting the battery bed
9.4. Operators cab (0500)
9.4.1. Cab tilting RRE 140 – 250 Ergo
9.4.2. Cab windows (0530)
9.4.3. Cab door (0550)
9.5. Operator compartment (0600)
9.5.1. Operators seat (0620)
9.5.2. Cab heating/ventilation (0630)
9.5.3. Internal fittings (0680)
9.5.4. Disassembling/assembling the floor plate, B version 0680
9.6. Safety equipment (0800)
9.6.1. Checking the overhead guard (0810)
9.6.2. Adjusting the tilt stops (0840)
10. Motors 1000
10.1. Motor sensors
10.1.1. Temperature sensor
10.1.2. Replacing the motor speed sensor
10.2. Pump motor (1710)
10.2.1. General
10.2.2. Replacing the bearing on the pump motor
10.3. Steering motor and steering unit (1730)
10.3.1. General
10.3.2. Layout of the flange holes
10.3.3. Removing the steering motor from the truck
10.3.4. Fitting the steering motor in the truck
10.4. Fan motor/fan (1740)
10.4.1. General
10.4.2. Replacing the frequency converter cooling fan
10.4.3. Replacing the motor compartment cooling fan
10.5. Drive motor (1760)
10.5.1. General
10.5.2. Removing the drive motor from the truck
10.5.3. Dismantling the drive motor
10.5.4. Cleaning
10.5.5. Assembling the drive motor
10.5.6. Fitting the drive motor in the truck
11. Drive gear 2000
11.1. General
11.2. Repair- and serviceability
11.3. Measures
11.3.1. Checking the oil level.
11.3.2. Oil change
11.3.3. Leakage from the bottom cap
11.3.4. Replacing the drive gear
12. Brake and wheel 3000
12.1. Travel brake system (3100)
12.1.1. Removing the support arms multiple disc brake
12.1.2. Dismantling the multiple disc brake
12.1.3. Installing the multiple disc brake in the truck
12.1.4. Checking the wheel brakes brake force
12.2. Parking brake (3300)
12.2.1. General
12.2.2. Emergency release of the parking brake
12.2.3. Checking the brake force
12.2.4. Removing the parking brake from the truck
12.2.5. Installing the parking brake in the truck
12.3. Drive wheel (3530)
12.3.1. General
12.3.2. Removing the drive wheel from the truck
12.3.3. Installing the drive wheel on the truck
12.4. Wheel bolt (3530)
12.4.1. General
12.4.2. Replacing wheel bolts
12.5. Support arm wheel (3550)
12.5.1. Removing the support arm wheel from the truck
12.5.2. Replacing a wheel bearing – braked wheel (A)
12.5.3. Replacing a wheel bearing – unbraked wheel (B)
12.5.4. Fitting the support arm wheel to the truck
12.5.5. Wheel wear and tear
13. Steering system 4000
13.1. Electric steering wheel (4310)
13.1.1. General
13.1.2. Replacing the pulse transducer on the steering wheel module
13.1.3. Removing the operating console from the truck
13.1.4. Replacing the wiring harness in the operating console
13.1.5. Fitting the operating console in the truck
13.2. Steering reference sensor (4350)
13.2.1. General
13.2.2. Replacing the reference transducer B17
13.3. Steering bearings (4380)
13.3.1. Removing a steering bearing from the drive gear
13.3.2. Fitting a steering bearing on the drive gear
14. Electrical system 5000
14.1. Battery (5110)
14.1.1. Battery recommendation
14.1.2. Battery installation
14.2. LID (5200)
14.2.1. Replacing the LID
14.2.2. Replacing the LID cold store cab
14.3. Replacing pedals (5300)
14.3.1. Accelerator and brake pedal
14.3.2. Safety pedal
14.4. Control console (5510)
14.4.1. General
14.4.2. Replacement/installation of a control
14.4.3. Replacing the multi-function control
14.4.4. Removing the control console from the truck
14.4.5. Replacing the access cards circuit board
14.4.6. Dismantling the control console
14.4.7. Assembling the control console
14.4.8. Fitting the control console in the truck
14.5. Magnetic sensor (5850)
14.5.1. General
14.5.2. Replacing the magnetic sensor B47
14.5.3. Reference magnet
14.6. Parameter settings
14.6.1. Configuration menu
14.7. PIN menu
14.7.1. Menu for activating a PIN block
14.7.2. Menu for programming a PIN (P)
14.8. Calibrations
14.8.1. Calibrating the hydraulic function control
14.8.2. Height measurement/reach movement length calibration
14.8.3. Valve calibration
14.8.4. Weight calibration
14.9. Replacing the wiring harness
14.10. main computer unit MCU (A5)
14.10.1. Installing a new card in the truck
14.10.2. Voltage supply
14.10.3. Battery negative
14.10.4. Internal status monitoring
14.10.5. Resetting the battery indicator
15. Hydraulic system 6000
15.1. Hydraulic hygiene
15.1.1. Washing
15.1.2. Packaging
15.1.3. Handling
15.1.4. Storage
15.1.5. Work procedures
15.2. Hydraulic unit (6100)
15.2.1. Hydraulic tank, emptying
15.2.2. Hydraulic system, bleeding
15.2.3. Filter
15.2.4. Remove the pump motor from the truck
15.2.5. Replacing the hydraulic pump
15.2.6. Fitting the pump motor in the truck
15.3. Main valve (6210)
15.3.1. Emergency lowering of forks
15.3.2. Replacing the main valve block
15.3.3. Replacing the lifting/lowering valves
15.3.4. Adjusting the maximum opening pressure
15.4. Hydraulic connections (6230)
15.4.1. Tightening torques for hydraulic connections
15.4.2. Quick change connector
15.5. Hydraulic system, mast (6300)
15.5.1. Mast-mounted hose reel (6370)
15.5.2. Fitting the hose reel
15.5.3. Checks after fitting
15.6. Main lift cylinder 6610
15.6.1. General
15.6.2. Overview
15.6.3. Removing the air cylinder from the mast
15.6.4. Replacing the hose rupture valve
15.6.5. Dismantling the cylinder
15.6.6. Dismantling the piston.
15.6.7. Dismantling the cylinder head
15.6.8. Fitting the cylinder head seals.
15.6.9. Fitting the piston seals
15.6.10. Assembling the cylinder
15.6.11. Assembling cylinder in the mast
15.7. Free lift cylinder (6620)
15.7.1. General
15.7.2. Overview
15.7.3. Removing the free lift cylinder from the truck
15.7.4. Replacing the hose rupture valve, free lift cylinder
15.7.5. Dismantling the cylinder
15.7.6. Dismantling the piston
15.7.7. Dismantling the cylinder head
15.7.8. Fitting the cylinder head seals.
15.7.9. Fitting the piston seals
15.7.10. Assembling the cylinder
15.7.11. Assembling the free lift cylinder in the mast
15.8. Reach cylinder (6650)
15.8.1. General
15.8.2. Removing the reach cylinder from the truck
15.8.3. Fitting the reach cylinder in the truck
15.9. Fork tilt cylinder (6660)
15.9.1. General
15.9.2. Remove the tilt cylinder from the truck
15.9.3. Fit the tilt cylinder in the truck
15.10. Cab tilt cylinder (6660)
15.10.1. General
15.10.2. Overview
15.10.3. Dismantling the cylinder
15.10.4. Dismantling the piston rod
15.10.5. Dismantling the cylinder head
15.10.6. Fitting the cylinder head seals.
15.10.7. Mounting the piston rod
15.10.8. Assembling the cylinder
15.11. Sideshift cylinder (6670)
15.11.1. General
15.11.2. Overview
15.11.3. Dismantling the cylinder from the truck
15.11.4. Dismantling the cylinder
15.11.5. Dismantling the piston rod
15.11.6. Dismantling the cylinder head
15.11.7. Fitting the cylinder head seals.
15.11.8. Mounting the piston rod
15.11.9. Assembling the cylinder
15.11.10. Refitting the cylinder in the truck
16. Mast/Lift system 7000
16.1. Main mast 1.6-2.5 t (7100)
16.1.1. Replacing the full mast
16.1.2. Removing the mast from the truck

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