BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040

BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040 - Image 2

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BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040 - Image 5

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bt rpe140 rpe160 rpe180 rpe200 rpe250 repair manual 7510399 040 3

BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040

$30.00

Type Of Manual: Repair Manual
Manual ID: 7510399-040
: Service Manual PDF
Number of Pages: 728
Size: 55.2MB
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. Function descriptions
4.1. Chassis 0000
4.1.1. Operators cabin (0500)
4.1.2. Cab windows (0530)
4.1.3. Drivers seat (0620)
4.1.4. Cab heating/ventilation (0630)
4.1.5. Driver 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. Sensors
4.6. Operator compartment
4.6.1. Truck control, overview
4.6.2. Single control
4.6.3. Multi-control
4.6.4. Central Information Display – CID
4.6.5. Load Information Display – LID (option)
4.7. Transducers 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. Steering
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. Lift/lowering movement
4.10.9. Parameter settings, braking at height preselection
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 block
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 work lights
4.14.3. Extra warning light/alarm
4.14.4. Direction indicators
4.14.5. Travel alarm
4.14.6. Positioning/TV equipment
4.14.7. Extra electrical equipment
4.14.8. Extra equipment, miscellaneous
5. Parameters
5.1. General
5.2. Displaying/changing parameters
5.3. Operator parameters
5.3.1. Overview
5.3.2. Coupling 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. General factory parameters
5.7.1. Overview
5.7.2. Description
5.8. Factory parameters, activation of options
5.9. 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 regulations during maintenance work
7.3. Periodic maintenance
7.3.1. Every 500 B-hours/180 days
7.3.2. Every 1,000 B-hours/360 days
7.3.3. Every 2,000 B-hours/720 days
7.3.4. Every 3,000 B-hours/1,080 days
7.3.5. Every 5,000 B-hours/1,800 days
7.3.6. Annual status inspection
7.4. Maintenance instructions
7.4.1. 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 code
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-in normal but one or more 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. Repairs/servicing
11.3. Actions
11.3.1. Checking the oil level
11.3.2. Changing the oil
11.3.3. Leakage from the bottom cover
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. Replacement of LID
14.2.2. Replacement of LID cold store cab
14.3. Replacing pedals
14.3.1. Replacing/repairing 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. Remove 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. Placing 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. Changing cabling
14.10. Main computer unit MCU (A5)
14.10.1. Installing a new card in the truck.
14.10.2. Voltage feed
14.10.3. Battery minus
14.10.4. Internal status monitoring
14.10.5. Resetting the battery indicator
15. Hydraulic system 6000
15.1. Hydraulic hygiene
15.1.1. Cleaning
15.1.2. Packaging
15.1.3. Handling
15.1.4. Storage
15.1.5. Procedure
15.2. Hydraulic unit (6100)
15.2.1. Emptying the hydraulic tank
15.2.2. Hydraulic system, bleeding
15.2.3. Remove the pump motor from the truck
15.2.4. Replacing the hydraulic pump
15.2.5. 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 Q4 valve
15.3.4. Adjusting the maximum opening pressure
15.4. Hydraulic couplings (6230)
15.4.1. Hydraulic couplings, tightening torques
15.4.2. Quick coupling
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. Remove the lift 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 the cylinder in the mast
15.7. Free lift cylinder (6620)
15.7.1. General
15.7.2. Removing the free lift cylinder from the truck
15.7.3. Replacing the hose rupture valve, free lift cylinder
15.7.4. Fitting the free lift cylinder in the truck
15.8. Reach cylinder (6650)
15.8.1. General
15.8.2. Remove 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. Dismantling 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. Dismantling 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 complete mast
16.1.2. Removing the mast from the truck
16.1.3. Adjusting mast play
16.1.4. Replacing the masts damper plates
16.1.5. Fitting the mast on the truck
16.2. Main lift chain system (7120)
16.2.1. General
16.2.2. Inspecting the chain
16.2.3. Lubricating the chain
16.2.4. Main lift chain system, adjusting the fork-to-floor distance
16.3. Reach carriage (7190)
16.3.1. Adjusting radial play in the reach carriage
16.3.2. Adjusting axial play in the reach carriage
16.4. Lifting devices (7400)
16.4.1. Forks
16.4.2. Forks, repairs and testing
16.5. Fork carriage
16.5.1. Checking the fork carriages wear strip
16.5.2. Lubricating the fork carriage

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