BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040
BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040 - Image 2
BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040 - Image 3
BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040 - Image 4
BT RPE140, RPE160, RPE180, RPE200, RPE250 Repair Manual 7510399-040 - Image 5

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:

Product details

  • 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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