BT Reach Truck RRE120M RRE140M RRE160M Repair Manual SN 6111575 – PDF DOWNLOAD
FILE DETAILS:
BT Reach Truck RRE120M RRE140M RRE160M Repair Manual SN 6111575 – PDF DOWNLOAD
Size : 44.6 MB
Format : PDF
Language : English
Brand: BT
Type of machine: Forklift-Reach Truck
Type of document: Repair Manual
Model: BT RRE120M RRE140M RRE160M Reach Truck
Date: 24/10/2016
Number of Pages: 662 Pages
Serial Number: 6111575
Part Number: 7519087-040
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
BT Reach Truck RRE120M RRE140M RRE160M Repair Manual SN 6111575 – PDF DOWNLOAD
1- Table of contents0
2- General introduction0
21 How to use this manual0
22 Warning levels and symbols0
23 Pictograms0
3- General safety rules0
31 Work safety0
32 Electrical system0
33 Safe lifting0
34 Truck modifications0
4- Installation0
41 Transporting the truck0
42 Transporting the mast0
43 Safe lifting0
5- Technical data 10
51 General tightening torques0
511 Galvanised, non-oiled screws0
512 Untreated, oiled screws0
6- Technical data 20
61 General tightening torques0
611 Galvanised, non-oiled screws0
612 Untreated, oiled screws0
7- Introduction, maintenance0
71 Safety precautions for maintenance work0
72 Cleaning and washing0
721 Cleaning the exterior0
722 Cleaning the motor compartment0
723 Electric components0
73 Safe lifting0
8- Preventive maintenance0
81 Maintenance schedule0
9- Oil and grease specifications0
10- Tools0
101 Super Seal contact0
1011 AMP connectors0
1012 AMP micro timer0
1013 Other tools0
11- Operator protection – 08400
111 General0
112 Studs0
1121 Inspection and Adjustment0
1122 Removing the tilt stops0
12- Electric pump motor – 17100
121 General0
122 Disassembled pump motor0
1221 Connection0
123 Disassembly and assembly of the pump motor0
1231 Dismantling0
1232 Fitting0
124 Replacing the ball bearing0
1241 Disassembly (D side)0
1242 Fitting0
1243 Disassembly (N side)0
1244 Assembly (N side)0
1245 Carbon brushes and carbon brush- rocker0
New carbon brushes should always be ground in0
Commutator0
Truing the commutator0
13- Electric steering motor – 17300
131 General0
132 Replacing the steering motor0
1321 Dismantling0
1322 Fitting0
133 Disassembly and assembly of the carbon brushes0
14- Electric drive motor – 176010
141 General0
142 Disassembled drive motor0
143 Disassembly and assembly of the drive motor0
1431 Removing the drive motor0
Remove the gear wheel0
Disassemble the brake0
1432 Fitting the drive motor0
Fit the brake0
Assemble the gear wheel0
1433 Restore the truck0
144 Replacing the ball bearing0
1441 Dismantling0
N side0
D side0
1442 Fitting0
N side0
D side0
145 Installation instructions for the external temperature sensor0
15- Electric drive motor – 176020
R212, R214, R2160
151 General0
152 Remove and install drive motor0
1521 Remove the drive motor from the truck0
1522 Remove the brake0
1523 Removing the drive motor0
1524 Fitting the drive motor0
1525 Replacing the ball bearing0
1526 Cleaning0
1527 Refit the brake0
1528 Fit the drive motor back in the truck0
1529 Restore the truck0
153 Replacing the rotational speed sensor0
Remove the rotational speed sensor0
Fitting the rotational speed sensor0
16- Drive unit/gear – 255010
161 General0
162 Components/data for the drive assembly/transmission0
1621 Component location0
1622 Technical data0
1623 Disassembling the gear0
163 Replacing the drive motor/drive gear0
1631 Removing the drive motor0
Remove the gear wheel0
1632 Removing the drive gear0
1633 Fitting the drive gear0
1634 Installing the drive motor0
Fit the gear wheel0
1635 Restore the truck0
164 Oil level check/change0
1641 Checking/refilling oil0
1642 Oil change0
165 Repairs0
1651 Replacing the drive shaft sealing ring0
Removing0
Fitting0
1652 Leakage from the upper cover0
1653 Leakage from the lower cover0
1654 Replacing the wheel bolt0
17- Drive unit/gear – 255020
R212, R214, R2160
171 General0
172 Components/data for the drive assembly/gear0
1721 Component location0
1722 Technical data0
173 Replacing the drive motor/drive gear0
1731 Remove the drive motor0
1732 Removing the drive gear0
1733 Fitting the drive gear0
1734 Fitting the drive motor0
174 Replacing the steering bearing0
1741 Removing the steering bearing0
1742 Fitting the steering bearing0
175 Restore the truck0
176 Oil level check/change0
1761 Checking/refilling oil0
1762 Oil change0
1763 Leakage from the lower cover0
177 Replacing the wheel bolt0
178 Replacing the gear wheel0
1781 Installing the gear wheel0
1782 Installing the ball bearing0
1783 Fitting the seal0
1784 Fitting the gear wheel0
179 Installing the bearing on the wheel axle0
1791 Determining the required shim thickness to achieve the correct preload0
Calculation of shim required0
1792 Installing the bearing in the cover0
18- Service brake system – 310010
181 General0
182 Function description0
1821 Releasing the accelerator0
1822 Travel direction selector0
1823 Pressing down the brake pedal0
1824 Parking brake0
1825 Emergency brake0
183 Electro-mechanical disc brake, drive motor0
184 Dismantling0
185 Inspection0
186 Fitting0
187 Maintenance0
1871 Adjusting clearance0
1872 Wear0
1873 Check of braking force0
19- Service brake system – 310020
R212, R214, R2160
191 General0
192 Function description0
1921 Releasing the accelerator0
1922 Travel direction selector0
1923 Pressing down the brake pedal0
1924 Parking brake0
1925 Emergency brake0
193 Electro-mechanical disc brake, drive motor0
194 Dismantling0
195 Inspection0
196 Fitting0
197 Maintenance0
1971 Adjusting clearance0
1972 Wear0
1973 Check of braking force0
20- Drive wheel – 35300
201 General0
202 Dismantling the drive wheel0
203 Assembling the drive wheel0
21- Fork/support arm wheel – 35500
211 General0
212 Dismantling the wheel0
213 Fitting the support arm wheel0
214 Dismantling the wheel bearings0
215 Assembling the wheel bearings0
22- Mechanical steering system – 41000
221 General0
222 Replacing the steering generator0
2221 Dismantling0
2222 Fitting0
2223 Adjusting the steering system screws0
23- Steering angle sensor – 43500
231 General0
232 Procedure0
2321 Adjusting the direction sensor0
2322 Adjusting the steering angle sensor0
24- Electrical system – 500010
241 General0
2411 Electric panel0
242 Symbol list and electric wiring diagram0
2421 List of symbols0
2422 Wiring diagram0
2423 Component List0
2424 Figure 10
2425 Figure 20
2426 Figure 30
2427 Figure 40
2428 Figure 50
2429 Figure 60
24210 Figure 70
24211 Figure 80
243 Description of operation0
2431 Key in Position 00
2432 Key in Position I0
2433 Choice of travel direction0
On the operating console0
On the accelerator0
2434 Driving0
2435 Steering0
2436 Steering wheel indicator0
2437 Braking0
Auto brake0
Motor braking (electric)0
Foot brake0
Parking brake0
2438 Fork lifting0
2439 Maximum height0
24310 Maximum height0
24311 Fork lowering0
24312 Mast out/in0
24313 Fork tilt up/down0
24314 Hydraulic function 40
24315 Hydraulic function 50
24316 Height indication0
24317 Height pre-selection0
24318 Operator identification0
Without pin code0
With pin code0
25- Electrical System – 50000
R212, R214, R2160
251 Electric panel:0
252 Symbol list and electric wiring diagram0
2521 List of symbols0
253 General wiring diagram0
254 Wiring diagram0
2541 Component List0
255 Description of the function0
2551 Truck not switched on0
2552 Truck started up0
2553 Choice of travel direction0
On the operating console0
On the accelerator0
2554 Driving0
2555 Steering0
2556 Steering wheel indicator0
2557 Braking0
Auto brake0
Motor braking (electric)0
Foot brake0
Parking brake0
2558 Fork lifting0
2559 Maximum height0
25510 Maximum height0
25511 Fork lowering0
25512 Mast out/in0
25513 Fork tilt up/down0
25514 Hydraulic function 40
25515 Hydraulic function 50
25516 Height indication0
25517 Height pre-selection0
25518 Operator identification0
Without pin code0
With pin code0
256 Display and programming0
2561 Keyboard and display0
2562 Clock, display (C)0
2563 Parameters0
2564 Operator parameters 1-70
2565 Serial numbers software0
2566 Operating Time0
2567 Error codes0
2568 Warning codes0
257 Parameters0
2571 Parameter 190
2572 Parameter 210
258 Operating Time0
2581 Installing a new card in the truck0
259 Warning codes0
2510 Error codes0
25101 Error mode0
25102 Safety logics0
2511 Warning code without recording0
25111 Error codes with registration0
2512 Keypad0
25121 General0
25122 Display0
25123 Description of the keyboard symbols0
25124 Function0
25125 Function 00
25126 Function 10
25127 Function 20
25128 Function 30
25129 Programming0
251210 LED status0
251211 Operator codes0
26- Battery – 51100
261 Battery dimensions0
262 Setting battery parameters with Hawker Evolution gel batteries0
2621 General0
2622 Battery recommendation0
2623 Battery installation0
2624 Parameter setting recommendation for valve-regulated batteries (VRLA)0
Instructions for verifying the parameter setting0
27- Transistor panel – 54600
271 Frequency converter0
2711 General description0
2712 Connection terminal and terminal pillars0
2713 Technical data0
2714 Programming0
28- Power electronic panel – 56600
281 General description0
2811 Connection terminal and terminal pillars0
2812 Technical data0
2813 Installing a new transistor panel0
282 Diagnostics and troubleshooting0
2821 Displaying errors codes and error logging0
2822 Error codes, troubleshooting0
2823 Resetting errors0
283 Maintenance0
2831 Safety0
2832 Cleaning0
29- Logic card 57100
291 General description0
292 Connection terminals and voltages on A50
2921 10X0
2922 20X0
2923 30X0
2924 40X0
2925 50X0
2926 60X0
2927 70X0
2928 80X0
2929 90X0
293 Adjusting the lowering speed0
294 Display0
295 Programming0
2951 Clock0
2952 Operator parameters (1–7)0
296 Warning codes0
297 Error codes0
2971 Error mode0
2972 Safety logics0
2973 Warning code without recording0
298 Warning codes with registration0
299 Error codes0
2991 Error codes with registration0
2910 Operating Time0
2911 Setting all0
29111 Parameter 10
29112 Parameter 20
29113 Parameter 30
29114 Parameter 40
29115 Parameter 50
29116 Parameter 100
29117 Parameter 110
29118 Parameter 120
29119 Parameters 13 to 140
291110 Parameters 15 and 160
291111 Parameters 17 and 180
291112 Parameter 190
291113 Parameter 200
291114 Parameter 210
291115 Parameter 230
291116 Parameter 240
291117 Parameter 250
291118 Parameter 260
291119 Parameter 270
291120 Parameter 280
291121 Parameter 290
291122 Parameter 380
291123 Parameter 390
291124 Parameters 40 to 420
291125 Miscellaneous parameters0
291126 Installing a new card in the truck0
30- Hydraulics – 60000
301 General0
302 Symbols0
3021 Hydraulics diagram 1 (3)0
3022 Hydraulics diagram 2 (3)0
3023 Hydraulics diagram 3 (3)0
303 List of symbols0
3031 Component placement 1 (2)0
3032 Component placement 2 (2)0
304 Adjusting fork lowering0
305 Adjusting the maximum lifting capacity0
31- Hydraulic pump – 61400
311 General0
312 Replacing the hydraulic pump0
3121 Dismantling0
3122 Mounting0
32- Hydraulic couplings – 62300
321 General0
322 Tightening torques for hydraulic connections0
3221 Tapered coupling with O-ring0
3222 Tredo seal0
3223 Pipe coupling0
3224 Coupling set in aluminium0
3225 Coupling set in steel0
Pressure class L0
33- Mast-mounted hose reel – 63700
331 General0
332 Fitting0
333 Checks after fitting0
34- Hydraulic cylinder – 66000
341 General0
342 Duplex mast0
3421 Dismantling the lift cylinders from the mast0
3422 Dismantling the cylinder0
3423 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder0
3424 Assembling the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder0
3425 Dismantling and assembling the lower brake valve0
3426 Assembling the cylinder0
3427 Assembling cylinder in the mast0
343 Triplex mast:0
3431 Dismantling the free lift cylinder from the mast0
3432 Dismantling the mast lift cylinders from the mast0
344 Cylinder seals0
345 Replacing wear parts in the cylinder0
3451 Securing0
3452 Dismantling the cylinder0
3453 Replacing the lower support ring0
3454 Replacing the O-ring on the top sleeve0
3455 Replacing the internal wear parts in the top sleeve0
3456 Assembling the cylinder0
3457 Assembling the free lift cylinder in the mast0
3458 Assembling the mast lift cylinder0
35- Main lift cylinder – 66100
351 General0
352 Tools0
353 Dismantling the lift cylinders from the mast0
354 Dismantling the cylinder0
3541 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder0
3542 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder0
3543 Dismantling and assembling the hose rupture valve0
355 Assembling the cylinder0
3551 Assembling cylinder in the mast0
36- Free lift cylinder – 66200
361 General0
362 Tools0
363 Dismantling0
3631 Dismantling the cylinder0
364 Dismantle the rod seal and support ring0
3641 Assembling the rod seal and support ring0
365 Dismantling the piston0
3651 Fitting the piston in the free lift cylinder0
366 Dismantling and assembling the hose rupture valve0
367 Assembling the cylinder0
368 Fitting0
37- Reach cylinder – 66500
371 General0
372 Assembling and dismantling the reach cylinder0
3721 Dismantling the cylinder0
3722 Removing the piston rod0
3723 Removing the top sleeve seals0
3724 Fitting the top sleeve0
3725 Fitting the piston seal0
3726 Mounting the piston rod0
3727 Assembling the cylinder0
373 Fitting0
38- Tilt cylinder – 666010
381 General0
382 Assembling and dismantling the tilt cylinder0
3821 Dismantling the cylinder0
3822 Removing the piston rod0
3823 Removing the piston seals0
3824 Removing the top sleeve seals0
3825 Assembling the top sleeve0
3826 Fitting the piston seal0
3827 Mounting the piston rod0
3828 Assembling the cylinder0
383 Fitting0
39- Tilt cylinder – 666020
391 General0
392 Mast with valve on the fork carriage0
3921 Disassembly of the fork carriage0
3922 Dismantling the cylinder0
3923 Dismantling the piston rod seal0
3924 Dismantling the piston0
3925 Fitting the piston0
3926 Fitting the piston rod seal0
3927 Assembling the cylinder0
3928 Fitting the fork carriage0
393 Mast without valve on the fork carriage0
3931 Disassembly of the fork carriage0
3932 Dismantling the cylinder0
3933 Dismantling the piston rod seal0
3934 Dismantling the piston0
3935 Fitting the piston0
3936 Fitting the piston rod seal0
3937 Assembling the cylinder0
3938 Fitting the fork carriage0
40- Main mast/mast – 710010
401 General0
402 Tool list0
403 Transporting the truck0
404 Assembling the mast0
405 Disassembling the mast0
4051 Chains, cylinders and hoses0
4052 Dismantling the runner0
4053 Inner guide0
406 Assembling Duplex mast0
4061 Assembly – shimming of lateral play0
4062 Inner guide0
4063 Chains, cylinders and hoses0
4064 Fork carriage:0
4065 Docking the mast in the truck0
407 Assembling the Triplex mast0
4071 Assembly-shimming the side play0
4072 Inner guide0
4073 Chains, cylinders and hoses0
4074 Fork carriage:0
408 Problem with mast rollers0
409 Adjusting the fork-to-floor distance0
41- Main mast/mast – 710020
411 General0
412 Tool list0
413 Transporting the truck0
414 Assembling the mast0
415 Disassembling the mast0
416 Adjusting the play0
4161 Adjusting the mast play0
Lateral play0
4162 Radial play0
417 Fitting0
418 Problem with mast rollers0
419 Adjusting the fork-to-floor distance0
42- Main lift chain system – 71200
421 General0
422 Checking the chain setting0
423 Checking the chain0
4231 Noise0
4232 Surface rust0
4233 Rusty links0
4234 Stiff links0
4235 Bolt rotation0
4236 Loose bolts0
4237 Outline wear0
4238 Stretching0
4239 Damage0
42310 Damaged plates0
42311 Damaged bolts0
42312 Dirty chain0
424 Cleaning0
425 Adjustment0
426 Lubrication0
43- Lifting devices – 74000
431 General0
4311 Inspection intervals0
4312 Inspection0
4313 Surface cracks0
4314 Difference in height between the fork tips0
4315 Position lock0
4316 Marking legibility0
4317 Fork blade and shaft0
4318 Mounting fixtures on the fork0
4319 Repairs and testing0
Repairs0
Testing the yield point0
Fork0
Fork extension0
432 Checking the fork carriage wear strip (Applies to T-codes 657, 658, 793, 794)0
433 Fork spread unit (Applies to T-codes 657, 658, 793, 794)0
4331 Servicing the fork spread unit0
Replacing bearings0
44- Battery charger – 83400
441 General0
442 Installation0
443 Function description0
4431 Display functions0
4432 Charging process0
4433 Shutdown conditions0
4434 Delayed power on and charging0
4435 Extra charging0
4436 Equalising charging0
4437 Current and voltage characteristics0
4438 Safety shutdowns0
4439 Display and keyboard0
Reading of analogue measurement values0
Error indication and error messages0
Reading statistics from the previous charge0
Reading of long term statistics0
Storing parameters0
Reading parameters0
Battery specific parameters0
Charger specific parameters0
Mains voltage codes0
Other functions0
Changing parameters0
44310 Acid circulation0
General0
BTM with acid circulation0
Pump type APE, VPM0
Pump type API0
444 Service and Maintenance0
4441 Basic programming, code 300
4442 Resetting the statistics, code 310
4443 Calibrating the measurement value0
Calibrating the battery voltage measurement value code 200
Calibrating the current’s zero value and temperatures, code 210
Calibrating the charging current, code 250
Calibrating the mains voltage display, code 260
4444 Calibrating and programming API0
Calibrating zero pressure0
Calibrating the pressure0
Programming the alarm limits0
Programming the API function0
4445 Adjusting the charging characteristics0
4446 Troubleshooting0
Error message, analysis and action0
Errors without indication0
4447 Trouble shooting acid circulation0
4448 Service measures0
Switching to the timer charger0
Replacing the display card0
Replacing the computer board0
Replacing the mother board0
Replacing the diodes0
4449 Preventive maintenance0
45- Extra Lighting– 93600
46- Extra warning light/alarm – 93700
461 General0
47- Positioning/TV equipment – 93900
471 General0
472 Height indication0
473 Function0
474 Display0
475 Height pre-selection0
476 Function0
477 Display0
4771 Description of the display symbols0
478 Assembly of height pre-set0
479 Programming0
4791 Programming a level0
Collect level0
Leave level0
4792 Deleting programmed levels0
4710 Automatic driving0
47101 Collect load0
47102 Deposit load0
47103 Checking0
4711 Parameters0
47111 Parameter 10
47112 Parameter 20
47113 Parameter 30
47114 Parameter 40
47115 Parameter 50
47116 Parameter 70
47117 Parameter 80
47118 Parameter 90
4712 Programming parameters0
4713 Error codes0
48- Truck log system, code lock – 942010
481 General0
TLS – Truck Log System0
482 EV 1 and S 16 keyboard version0
4821 Logging in with a code (5 digits)0
4822 Logout0
4823 Log-in with fault reporting (5+1 digit)0
Only applies to S 160
Logging in0
4824 Log-in with extra code (5+3 digits)0
Only applies to S 160
4825 Log-in with extra code and fault reporting (5+3+1 digits)0
Only applies to S 160
4826 Changing the three-digit personal code0
Only applies to S 160
483 EV 1 and S 16 code card version0
4831 Logging in0
4832 Logout0
4833 Wiring diagram0
484 Collision sensor0
Only applies to S 160
4841 Wiring diagram0
485 Troubleshooting0
4851 EV 10
4852 S 160
486 Truck log system, code lock – 942020
R212, R214, R2160
4861 General0
4862 SD 160
4863 Logging in with a code (5 digits)0
4864 Logout0
4865 Components0
If the truck does not start:0
487 I/O module0
49- Extra equipment – 95000
491 Dry powder extinguisher0
In the event of fire, the powder extinguisher should be employed as follows:0
4911 Regular checks of the powder extinguisher – truck driver0
4912 Inspection of powder extinguisher in service inspection of the truck0
50- Disposal instructions0
501 General0
502 Procedure0
503 Abbreviations0
504 Sorting0
505 Frame/chassis (0300)0
5051 Dismantling0
5052 Material handling0
506 Seat, cushions (0620)0
5061 Dismantling0
5062 Material handling0
507 Operator controls (0640)0
5071 Dismantling0
5072 Material handling0
508 Internal fittings (0680)0
5081 Dismantling0
5082 Material handling0
509 Rollover guard/overhead guard (0810)0
5091 Dismantling0
5092 Material handling0
5010 Finger guards (0820)0
50101 Dismantling0
50102 Material handling0
5011 Electric motors (1700)0
50111 Dismantling0
50112 Material handling0
5012 Electric fan motor (1740)0
50121 Dismantling0
50122 Material handling0
5013 Drive unit, final gear (2500)0
50131 Dismantling0
50132 Material handling0
5014 Wheels (3500)0
50141 Dismantling0
50142 Material handling0
5015 Electric steering system (4300)0
50151 Dismantling0
50152 Material handling0
5016 General electronic equipment (5100)0
50161 Dismantling0
50162 Material handling0
5017 Power system, drive function (5400)0
50171 Dismantling0
50172 Material handling0
5018 Control system, working function (5500)0
50181 Dismantling0
50182 Material handling0
5019 Steering/protective electronics (5700)0
50191 Dismantling0
50192 Material handling0
5020 Hydraulic unit (6100)0
50201 Dismantling0
50202 Material handling0
5021 Hydraulic system, fitted on the chassis (6200)0
50211 Dismantling0
50212 Material handling0
5022 Hydraulic system, mast mounted (6300)0
50221 Dismantling0
50222 Material handling0
5023 Hydraulic cylinders (6600)0
50231 Dismantling0
50232 Material handling0
5024 Main mast and mast (7100)0
50241 Dismantling0
50242 Material handling0
5025 Lift fork (7410)0
50251 Dismantling0
50252 Material handling0
5026 Optional electric equipment (9300)0
50261 Dismantling0
50262 Material handling0
5027 Optional electric equipment (9400)0
50271 Dismantling0
50272 Material handling0
VIDEO PREVIEW OF THE MANUAL:
S.V 08/24
