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BT TOYOTA FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL – PDF DOWNLOAD
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BT TOYOTA FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL – PDF DOWNLOAD
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Description
BT TOYOTA FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
BT TOYOTA FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL – PDF DOWNLOAD
Language : English
Pages : 942
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
BT TOYOTA FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL – PDF DOWNLOAD
1 – Table of contents...............................................................................................0 2 – General introduction............................................................................................0 2.1 How to use this manual......................................................................................0 2.2 Warning symbols.............................................................................................0 2.3 Pictograms..................................................................................................0 3 – General safety rules............................................................................................0 3.1 Work safety.................................................................................................0 3.2 Electrical system...........................................................................................0 3.3 Safe lifting................................................................................................0 4 – Descriptions of functions.......................................................................................0 4.1 Chassis 0000................................................................................................0 4.1.1 Operator’s cabin (0500)...............................................................................0 Versions for cold-store cabs............................................................................0 Emergency exit from the cab.............................................................................0 4.1.2 Cab windows (0530)....................................................................................0 Electrically heated windows.............................................................................0 4.1.3 Operator's seat (0620)................................................................................0 Adjustment:.............................................................................................0 Button for seat heater..................................................................................0 4.1.4 Cab heating/ventilation (0630)........................................................................0 Climate control knobs...................................................................................0 Ventilation.............................................................................................0 Temperature.............................................................................................0 4.1.5 Operator protection (0840)............................................................................0 Studs...................................................................................................0 Protective overhead guard...............................................................................0 4.2 Motors 1000.................................................................................................0 4.2.1 General...............................................................................................0 4.2.2 Electric pump motor (1710)............................................................................0 General.................................................................................................0 Construction............................................................................................0 4.2.3 Electric steering motor (1730)........................................................................0 General.................................................................................................0 Construction............................................................................................0 4.2.4 Fan motor/fan (1740)..................................................................................0 4.2.5 Electric drive motor (1760)...........................................................................0 General.................................................................................................0 Construction............................................................................................0 4.3 Drive gear - 2000...........................................................................................0 4.3.1 General...............................................................................................0 4.3.2 Construction..........................................................................................0 4.4 Brake system 3100...........................................................................................0 4.4.1 General...............................................................................................0 Travel brake............................................................................................0 Parking brake...........................................................................................0 Emergency brake.........................................................................................0 4.4.2 Drive motor brake (travel brake)......................................................................0 Accelerator released....................................................................................0 Changing the direction of travel........................................................................0 4.4.3 Multiple disc brake, support arm (travel brake).......................................................0 General.................................................................................................0 Construction............................................................................................0 4.4.4 Disc brake in support arm wheels (travel brake).......................................................0 General.................................................................................................0 Construction............................................................................................0 4.4.5 Disc brake on the drive motor (parking brake).........................................................0 General.................................................................................................0 Construction............................................................................................0 4.5 Steering system 4000........................................................................................0 4.5.1 General...............................................................................................0 4.5.2 Construction..........................................................................................0 4.5.3 Sensor................................................................................................0 Steering reference sensor...............................................................................0 4.6 Operation area..............................................................................................0 4.6.1 Truck control, overview...............................................................................0 Right-hand control panel, single control................................................................0 Right-hand control panel, multi-control.................................................................0 Emergency switch off....................................................................................0 Steering wheel module...................................................................................0 Pedals..................................................................................................0 4.6.2 Single-function control...............................................................................0 4.6.3 Multi-function control................................................................................0 4.6.4 Central Information Display – CID.....................................................................0 Navigation..............................................................................................0 LED symbols.............................................................................................0 Information symbols.....................................................................................0 Driver parameter symbols – Overview.....................................................................0 Blocking symbols – Overview.............................................................................0 Service symbols – Overview..............................................................................0 Service functions.......................................................................................0 Calibration functions...................................................................................0 Configuration functions.................................................................................0 Other functions.........................................................................................0 4.6.5 Load Information Display – LID (option)...............................................................0 LED symbols.............................................................................................0 Symbols in the display part.............................................................................0 4.7 sensors and sensors (5800)..................................................................................0 4.7.1 Inductive sensors.....................................................................................0 4.7.2 Position sensor.......................................................................................0 4.7.3 Magnetic sensor.......................................................................................0 4.8 Operation and connection sequences..........................................................................0 4.9 Functions...................................................................................................0 4.9.1 General overview......................................................................................0 Terminology.............................................................................................0 Components..............................................................................................0 4.9.2 MCU – main control unit...............................................................................0 General.................................................................................................0 Downloading software....................................................................................0 System communication....................................................................................0 4.9.3 ACT/ACH regulators....................................................................................0 General.................................................................................................0 4.9.4 Start-up..............................................................................................0 4.9.5 Shutdown..............................................................................................0 4.9.6 Driving...............................................................................................0 Introduction............................................................................................0 Acceleration and speed reduction........................................................................0 Reversing...............................................................................................0 Brakes..................................................................................................0 Travel speed............................................................................................0 4.9.7 OTP...................................................................................................0 Travel speed reduction - steering angle.................................................................0 Travel speed reduction - extension of reach carriage....................................................0 Speed reduction - main lift range.......................................................................0 Prevention of lifting/lowering the forks................................................................0 Reduced extension speed.................................................................................0 4.9.8 Steering..............................................................................................0 Steering position control...............................................................................0 Steering speed..........................................................................................0 Steering reference......................................................................................0 Travel speed limitation.................................................................................0 Compass rose............................................................................................0 4.9.9 Hydraulic system......................................................................................0 Definitions.............................................................................................0 Controls................................................................................................0 Lift....................................................................................................0 Reach movement..........................................................................................0 Lift height limitation..................................................................................0 Maximum height limitation...............................................................................0 Auxiliary/Extra functions (option)......................................................................0 4.10 Height preselector, description of function................................................................0 4.10.1 Using the height preselector.........................................................................0 4.10.2 Symbols..............................................................................................0 4.10.3 Travel warning.......................................................................................0 4.10.4 Height preselector levels............................................................................0 4.10.5 Level selection......................................................................................0 4.10.6 Height programming...................................................................................0 4.10.7 Height preselector and TruckCom......................................................................0 4.10.8 Lift/lowering movement...............................................................................0 4.10.9 Parameter settings braking at height preselector.....................................................0 4.11 Hydraulic system 6000......................................................................................0 4.11.1 General..............................................................................................0 4.11.2 Tank.................................................................................................0 4.11.3 Filter...............................................................................................0 Return filter...........................................................................................0 Dehumidification filter.................................................................................0 4.11.4 Hydraulic pump.......................................................................................0 4.11.5 Valve unit...........................................................................................0 Main valve block........................................................................................0 Second valve block......................................................................................0 4.11.6 Cylinders............................................................................................0 Main lift cylinders.....................................................................................0 Free-lift cylinder......................................................................................0 Cylinders for the reach movement, cabin tilt, sideshift and fork tilt...................................0 4.11.7 Lift and lowering function...........................................................................0 Lifting and lowering of free lift.......................................................................0 Transition from free lift to main lift..................................................................0 Lifting and lowering of main lift.......................................................................0 Reach movement, in and out..............................................................................0 Simultaneous operation of Mast lift and Reach movement..................................................0 4.11.8 Extra functions......................................................................................0 4.11.9 Cabin tilt (RRE Ergo)................................................................................0 Hydraulic priority system...............................................................................0 Cabin tilt (RRE Ergo) during servicing..................................................................0 Cabin tilt in the event of hydraulic or electrical power loss...........................................0 4.12 Mast 7000..................................................................................................0 4.12.1 Mast and reach carriage..............................................................................0 4.13 Lifting devices............................................................................................0 4.13.1 Fork extensions......................................................................................0 4.13.2 Telescopic forks.....................................................................................0 4.14 Accessories 9000...........................................................................................0 4.14.1 Radio equipment......................................................................................0 4.14.2 Extra lighting.......................................................................................0 4.14.3 Extra warning lights/alarm...........................................................................0 4.14.4 Turn signal lights...................................................................................0 4.14.5 Movement alarm.......................................................................................0 4.14.6 Positioning-/TV equipment............................................................................0 4.14.7 Extra electrical equipment...........................................................................0 4.14.8 Other extra equipment................................................................................0 Fork spacers............................................................................................0 Load support............................................................................................0 E-bar...................................................................................................0 Fire extinguisher.......................................................................................0 5 – Parameters......................................................................................................0 5.1 General.....................................................................................................0 5.2 Displaying/changing parameters..............................................................................0 5.3 Operator parameters.........................................................................................0 5.3.1 Overview..............................................................................................0 5.3.2 Connection to logged-in operator......................................................................0 5.3.3 Description...........................................................................................0 Parameter 1 – Steering..................................................................................0 Parameter 2, 3 – Maximum travel speed...................................................................0 Parameters 4 and 5 – Acceleration/Deceleration..........................................................0 Parameter 6 – Cab tilt..................................................................................0 5.4 General service parameters..................................................................................0 5.4.1 Overview..............................................................................................0 5.4.2 Description...........................................................................................0 Parameter 101/104 – Service/Log-out.....................................................................0 Parameter 105/106/114/115/117 (Travel alarms 1 and 2)...................................................0 Parameter 107/108 – Battery.............................................................................0 Parameter 109/110/111/112 – Collision sensor............................................................0 Parameter 113 (shunt value).............................................................................0 Parameter 116 (Door on cold store cabs).................................................................0 5.5 Service parameters, travel functions........................................................................0 5.5.1 Overview..............................................................................................0 5.5.2 Description...........................................................................................0 Parameter 201 – Retardation when reversing..............................................................0 Parameters 202/203/204 – Adjusting erroneous, maximum travel speeds.....................................0 Parameters 205/206/207 – Adjusting function-related, maximum travel speeds..............................0 Parameter 208 - Creep speed in travel direction control.................................................0 Parameter 209/210 – Reduced maximum travel speed above a certain lift height............................0 Parameter 211/212 – Reduced maximum travel speed with a certain reach length............................0 Parameter 213 – Permanently reduced maximum travel speed................................................0 Parameter 214 – Adjusting the maximum travel speed in main lift range...................................0 Parameter 215/216/217 – Adjusting OTP speed and starting and finishing angles...........................0 5.6 Service parameters, hydraulics..............................................................................0 5.6.1 Overview..............................................................................................0 5.6.2 Description...........................................................................................0 Parameters 301/302/303/304/333 – Extra valve function...................................................0 Parameters 305/306/307/308/334 – Maximum oil pressure through valve Q8..................................0 Parameters 313/314/315/316/336 – Closing time...........................................................0 Parameters 317/318/319/320/337 – Maximum oil flow through valve Q8......................................0 Parameters 321/322/323/324/338 – Maximum oil flow through valve Q9......................................0 Parameters 325/326/327/328/339 – Opening/closing time for valve Q8......................................0 Parameters 329/330/331/332/340 – Opening/closing time for valve Q9......................................0 Parameters 333/334 Setting of additional security hydraulic function....................................0 Parameter 341/342 – Reducing the lifting/lowering speed.................................................0 Parameter 343 – Reduction of reach speed................................................................0 Parameter 344 - Reduction of fork lowering speed before floor level.....................................0 Parameter 345- Lift/lower sensitivity...................................................................0 Parameter 346- Ramping for hydraulic functions Lifting, Lowering and Reach in/out.......................0 Parameter 347/348 – Prevent the lifting/lowering of forks...............................................0 Parameter 349 - Fork weight.............................................................................0 Parameter 350 – Multi-function..........................................................................0 Parameters 351/352 Setting of button for additional security hydraulic function.........................0 Parameters 353/354/400 Soft lift........................................................................0 Parameters 356/357 Active draining......................................................................0 Parameters 358/359/360 – Deactivation of hydraulic functions............................................0 Parameters 361/362/363/364/365 /366 – Function related, maximum lifting/lowering speeds.................0 Parameter 367/368 – Fork limit for deactivating the extension of the fork carriage and for sideshift....0 Parameter 369 through 379 – Height preselector..........................................................0 Parameter 380/381 – Lift height limitations.............................................................0 Parameters 387/388 – Configuring lift height limitations................................................0 Parameters 395/396/397 – Function-related, maximum lift heights.........................................0 Parameters 398/399 – Operator profile dependent, maximum lift heights...................................0 5.7 Service parameters, CID.....................................................................................0 5.7.1 Overview..............................................................................................0 5.7.2 Description...........................................................................................0 Parameter 503 – Login method............................................................................0 Parameters 504/505/506/507 – Smart Access...............................................................0 Parameter 508/509/512/513/514 – CID configuration.......................................................0 Parameters 510/511 – Height pre-selection...............................................................0 5.8 General factory parameters..................................................................................0 5.8.1 Overview..............................................................................................0 5.8.2 Description...........................................................................................0 Parameter 1001 - Truck type.............................................................................0 Parameter 1002 - (Drive motor)..........................................................................0 Parameter 1003 – Pedal type.............................................................................0 Parameter 1004 - Steering servo.........................................................................0 Parameter 1005 - Pump motor.............................................................................0 Parameter 1006 – Hydraulic pump.........................................................................0 Parameter 1007 – Activation of hydraulic levers.........................................................0 Parameter 1008 – Mast type..............................................................................0 Parameter 1009 – Height indication......................................................................0 Parameter 1010 - Weight indication......................................................................0 5.9 Factory parameters, activation of options...................................................................0 5.9.1 Overview..............................................................................................0 Parameter 1115 (Steering angle).........................................................................0 Parameter 1116 (Extended mast)..........................................................................0 Parameter 1117 (Weight of load and fork height).........................................................0 Parameter 1118 (Main lift range)........................................................................0 Parameter 1131 – Adjusting the maximum travel speed in main lift range..................................0 5.9.2 Description...........................................................................................0 5.10 Factory parameters, calibration............................................................................0 6 – Installation....................................................................................................0 6.1 Transporting the truck......................................................................................0 6.2 Transporting the mast.......................................................................................0 6.3 Transporting the truck......................................................................................0 Method 1....................................................................................................0 Method 2....................................................................................................0 6.4 Commissioning...............................................................................................0 6.4.1 Tools.................................................................................................0 6.4.2 Battery...............................................................................................0 Placing the battery.....................................................................................0 Battery parameters......................................................................................0 6.4.3 Mast, fitting.........................................................................................0 6.5 Bleeding the air from the hydraulic system..................................................................0 6.5.1 Parameters on initial operation.......................................................................0 Load indicator..........................................................................................0 Ergo cab................................................................................................0 Cold store cabin........................................................................................0 6.5.2 Parameters for optional equipment.....................................................................0 Height measurement (option).............................................................................0 Travel speed limitation, height-dependent...............................................................0 Travel speed limitation, reach movement dependent.......................................................0 Travel speed limitation, parameter-dependent............................................................0 Collision sensor........................................................................................0 7 – Maintenance.....................................................................................................0 7.1 Introduction, maintenance...................................................................................0 7.2 Safety precautions for maintenance work.....................................................................0 7.3 Maintenance instructions....................................................................................0 7.3.1 Cleaning and washing..................................................................................0 7.3.2 High-pressure washers.................................................................................0 7.3.3 Degreasing agents.....................................................................................0 7.3.4 Cleaning the exterior.................................................................................0 7.3.5 Cleaning the chain....................................................................................0 7.3.6 Cleaning the motor compartment........................................................................0 7.3.7 Electric components...................................................................................0 7.4 Checks for cracks...........................................................................................0 7.4.1 Visual inspection.....................................................................................0 7.4.2 Crack detection.......................................................................................0 Crack detection with liquid penetrant...................................................................0 Crack detection with magnetic yoke......................................................................0 7.5 Periodic maintenance........................................................................................0 7.5.1 Every 500 operating hours/180 days....................................................................0 7.5.2 Every 1000 operating hours/360 days...................................................................0 7.5.3 Every 2000 operating hours/720 days...................................................................0 7.5.4 Every 3000 operating hours/1080 days..................................................................0 7.5.5 Every 5000 operating hours/1800 days..................................................................0 7.5.6 Annual status inspection..............................................................................0 7.6 Maintenance instructions....................................................................................0 7.6.1 Cleaning and washing..................................................................................0 High-pressure washers...................................................................................0 Degreasing agents.......................................................................................0 Cleaning the exterior...................................................................................0 Cleaning the chain......................................................................................0 Cleaning the motor compartment..........................................................................0 Electric components.....................................................................................0 8 – Troubleshooting.................................................................................................0 8.1 Abbreviations used in this section..........................................................................0 8.2 Truck help functions........................................................................................0 8.2.1 Error log menu........................................................................................0 Description.............................................................................................0 Access..................................................................................................0 8.2.2 Error information menu................................................................................0 Description.............................................................................................0 Access..................................................................................................0 8.2.3 Diagnostic screens....................................................................................0 Access..................................................................................................0 State 1 – Voltage from the control console levers.......................................................0 State 2 – Digital signals from the truck control to CID.................................................0 State 3 – Voltage from control/sensor to MCU............................................................0 State 4 – Digital input signals to MCU..................................................................0 State 5 – Digital output signals from MCU...............................................................0 State 6 – PWM output signals from MCU...................................................................0 State 7 – FCU (not used)................................................................................0 State 8 – FCU (not used)................................................................................0 State 9 – GFU (not used)................................................................................0 State 10 – GFU (not used)...............................................................................0 State 11 – Temperature signals..........................................................................0 State 12 – Voltage levels...............................................................................0 State 13 – Travel information...........................................................................0 State 14 – Steering information.........................................................................0 State 15 – Lift/lowering information....................................................................0 Stage 16 – Reach movement information...................................................................0 Stage 17 – Hydraulic information........................................................................0 State 18 – VNA (not used)...............................................................................0 State 19 – Pressure sensor for free and main lifts......................................................0 8.3 Initial troubleshooting.....................................................................................0 8.4 Troubleshooting using blocking symbol.......................................................................0 8.5 Troubleshooting using error codes...........................................................................0 8.5.1 CID, warnings and errors..............................................................................0 8.5.2 MCU and other warnings and errors.....................................................................0 8.5.3 Drive system error....................................................................................0 8.5.4 Hydraulic system error................................................................................0 8.5.5 Steering system, warnings and errors..................................................................0 8.5.6 External systems......................................................................................0 8.6 Troubleshooting without indications.........................................................................0 8.6.1 Mechanical brake (3000)...............................................................................0 8.6.2 Steering (4000).......................................................................................0 8.6.3 Telescopic forks......................................................................................0 8.6.4 Log on was normal, but one or several functions cannot be used........................................0 9 – Frame/Chassis 0000..............................................................................................0 9.1 General.....................................................................................................0 9.2 Motor hood (0340)...........................................................................................0 9.2.1 Opening the motor compartment.........................................................................0 RRE 140-RRE 250.........................................................................................0 Replacing the motor cover...............................................................................0 Adjusting the motor cover...............................................................................0 Method..................................................................................................0 9.3 Battery compartment components (0390).......................................................................0 9.3.1 Adjusting the battery tray............................................................................0 9.3.2 Adjusting the battery tray from serial number 6229952-................................................0 9.4 Operator’s cabin (0500).....................................................................................0 9.4.1 Tilting the cab RRE 140 – 250 Ergo....................................................................0 9.4.2 Ergoled...............................................................................................0 Disassembly.............................................................................................0 9.5 Assembly....................................................................................................0 9.5.1 Cab windows (0530)....................................................................................0 Fitting a window........................................................................................0 9.5.2 Cab door (0550).......................................................................................0 Disassembly of the door lock............................................................................0 Method..................................................................................................0 9.6 Cab heating/ventilation C0630...............................................................................0 9.6.1 Replacing the air filter on the cold store cab........................................................0 9.6.2 Replacement of wiring harness with potentiometer......................................................0 9.6.3 Replacing the air outlet..............................................................................0 9.6.4 Climate control knobs.................................................................................0 Disassembly of the lock device..........................................................................0 Method..................................................................................................0 9.7 Operator's compartment (0600)...............................................................................0 9.7.1 Adjusting the seat:...................................................................................0 Seat heater button (Option).............................................................................0 9.7.2 Replacing the seat assembly...........................................................................0 Method..................................................................................................0 9.7.3 Replacing the seat assembly, Basic....................................................................0 Removing the operator’s seat (Basic)....................................................................0 Fitting the operator’s seat (Basic).....................................................................0 9.7.4 Replacing the seat switch.............................................................................0 Method..................................................................................................0 9.7.5 Replacing the back rest...............................................................................0 Method..................................................................................................0 9.7.6 Replacing the chair seat..............................................................................0 Method..................................................................................................0 9.7.7 Replacing the seat heater switch......................................................................0 Method..................................................................................................0 9.7.8 Installing the safety belt/armrest (Option)...........................................................0 Method..................................................................................................0 9.7.9 Cab heating/ventilation (0630)........................................................................0 Replacing the air filter on the cold store cabin:.......................................................0 Removing the fan and heater.............................................................................0 Replacing the potentiometers............................................................................0 9.7.10 Internal fittings (0680).............................................................................0 9.7.11 Disassembly/assembly of floor plate, B version 0680..................................................0 9.8 Operator controls (mechanical) C0640........................................................................0 9.8.1 Replacing pedals......................................................................................0 Method..................................................................................................0 9.9 Overhead guard/roof C0810...................................................................................0 9.9.1 Overview..............................................................................................0 9.9.2 Removing the overhead guard...........................................................................0 Method..................................................................................................0 9.9.3 Fastening the overhead guard..........................................................................0 Method..................................................................................................0 9.9.4 Removing the roof cassette............................................................................0 Method..................................................................................................0 9.9.5 Fastening the roof cassette...........................................................................0 Method..................................................................................................0 9.10 Finger/foot guards C0820...................................................................................0 9.10.1 Replacing a figure guard.............................................................................0 Method..................................................................................................0 9.11 Operator protection C0840..................................................................................0 9.11.1 Replacing the fender.................................................................................0 Method..................................................................................................0 9.12 Safety equipment (0800)....................................................................................0 9.12.1 Checking the overhead guard (0810)...................................................................0 9.12.2 Adjusting the support lugs (0840)....................................................................0 10 – Motors 1000....................................................................................................0 10.1 Motor sensors..............................................................................................0 10.1.1 Temperature sensor...................................................................................0 Retrofitting of external temperature sensor.............................................................0 10.1.2 Replacing the rotational speed sensor................................................................0 10.2 Pump motor (1710)..........................................................................................0 10.2.1 General..............................................................................................0 Disassembled pump motor.................................................................................0 10.2.2 Replacing the bearing on the pump motor..............................................................0 Dismantling the pump motor..............................................................................0 Assembling the pump motor...............................................................................0 10.3 Steering motor and steering unit (1730)....................................................................0 10.3.1 General..............................................................................................0 10.3.2 Layout of the flange holes...........................................................................0 10.3.3 Removing the steering motor from the truck...........................................................0 10.3.4 Mounting a steering motor in the truck...............................................................0 10.4 Fan motor/fan (1740).......................................................................................0 10.4.1 General..............................................................................................0 10.4.2 Replacing the frequency converter cooling fan........................................................0 Standard truck:.........................................................................................0 Ergotruck...............................................................................................0 10.4.3 Replacing the motor compartment cooling fan..........................................................0 10.5 Drive motor (1760).........................................................................................0 10.5.1 General..............................................................................................0 Disassembled drive motor................................................................................0 10.5.2 Removing the drive motor from the truck..............................................................0 10.5.3 Dismantling the drive motor..........................................................................0 10.5.4 Cleaning.............................................................................................0 10.5.5 Assembling the drive motor...........................................................................0 10.5.6 Mounting the drive motor in the truck................................................................0 11 – Drive gear 2000................................................................................................0 11.1 General....................................................................................................0 11.2 Repair- and serviceability.................................................................................0 11.3 Measures...................................................................................................0 11.3.1 Checking the oil level...............................................................................0 11.3.2 Oil change...........................................................................................0 Oil refill table........................................................................................0 11.3.3 Leakage from the bottom cover........................................................................0 11.3.4 Replacing the drive gear.............................................................................0 Special tools...........................................................................................0 Exposing the drive gear.................................................................................0 Removing a drive motor from the truck...................................................................0 Removing a steering motor from the truck................................................................0 Removing the drive gear from the truck..................................................................0 Fit the drive gear back in the truck....................................................................0 Placing the steering motor in the truck.................................................................0 Placing the drive motor in the truck....................................................................0 Concluding work.........................................................................................0 12 – Brake and wheel 3000...........................................................................................0 12.1 Travel brake system (3100).................................................................................0 12.1.1 Removing the support arm's multiple disc brake.......................................................0 12.1.2 Dismantling the multiple disc brake..................................................................0 Inspection..............................................................................................0 Adjusting clearance.....................................................................................0 Assembling the multiple disc brake......................................................................0 12.1.3 Installing the multiple disc brake in the truck......................................................0 12.2 Single disk brake support arm..............................................................................0 12.2.1 Removing the brake disc from the wheel...............................................................0 12.2.2 Fitting the brake disc in the wheel..................................................................0 12.2.3 Install the support arm electro- magnetic brake......................................................0 12.2.4 Removing the brake, RRE160R..........................................................................0 12.2.5 Removing the brake disc from the hub, RRE160R........................................................0 12.2.6 Fitting a new brake disc on the hub, RRE160R.........................................................0 12.2.7 Fitting the brake in the support arm, RRE160R........................................................0 12.2.8 Checking the wheel brake's brake force...............................................................0 12.3 Parking brake (3300).......................................................................................0 12.3.1 General..............................................................................................0 12.3.2 Emergency release of the parking brake...............................................................0 12.3.3 Check of braking force...............................................................................0 Up to and including serial number 6308394...............................................................0 From and including serial number 6308395................................................................0 12.3.4 Removing the parking brake from the truck............................................................0 Disassembly and inspection of wear......................................................................0 Method..................................................................................................0 Adjusting the air gap...................................................................................0 Method..................................................................................................0 12.3.5 Installing the parking brake in the truck............................................................0 12.4 Drive wheel (3530).........................................................................................0 12.4.1 General..............................................................................................0 12.4.2 Removing the drive wheel from the truck..............................................................0 12.4.3 Installing the drive wheel on the truck..............................................................0 12.5 Wheel studs (3530).........................................................................................0 General.....................................................................................................0 12.5.1 Wheel stud replacement...............................................................................0 12.6 Support arm wheel (3550)...................................................................................0 12.6.1 Removing the support arm wheel from the truck........................................................0 12.6.2 Removing the support arm wheel, RRE160R..............................................................0 12.6.3 Replacing wheel bearings, RRE160R....................................................................0 12.6.4 Fitting a support arm wheel to the truck, RRE160R....................................................0 12.6.5 Replacing a wheel bearing - braked wheel (A).........................................................0 Version with disc brake.................................................................................0 12.6.6 Replacing a wheel bearing - unbraked wheel (B).......................................................0 12.6.7 Fitting a support arm wheel to the truck.............................................................0 12.6.8 Support arm wheel, (280mm wheel with 1050mm support arm width).......................................0 General.................................................................................................0 12.6.9 Dismantling the wheel................................................................................0 12.6.10 Fitting the support arm wheel.......................................................................0 12.6.11 Dismantling the wheel bearings......................................................................0 12.6.12 Assembling the wheel bearings.......................................................................0 12.6.13 Wheel wear..........................................................................................0 13 – Steering system 4000...........................................................................................0 13.1 Electric steering wheel (4310).............................................................................0 13.1.1 General..............................................................................................0 13.1.2 Replacing the steering wheel.........................................................................0 13.1.3 Replacing the steering wheel knob....................................................................0 13.1.4 Replacing the pulse transducer on the steering wheel module..........................................0 13.1.5 Removing the steering console from the truck.........................................................0 13.1.6 Replacing the wiring harness in the steering console.................................................0 13.1.7 Fit the steering console in the truck................................................................0 13.2 Steering reference sensor (4350)...........................................................................0 General.....................................................................................................0 13.2.1 Replacing the reference sensor [B17].................................................................0 13.3 Steering bearings (4380)...................................................................................0 13.3.1 Steering bearing.....................................................................................0 Replacing the steering bearing..........................................................................0 Method..................................................................................................0 14 – Electrical system 5000.........................................................................................0 14.1 Battery (5110).............................................................................................0 14.1.1 Battery recommendation...............................................................................0 Exide gel batteries (e.g. Sonnenschein).................................................................0 Hawker Evolution gel batteries..........................................................................0 Lithium-ion batteries (Li-ion)..........................................................................0 14.1.2 Battery installation.................................................................................0 Replacement/installation of battery.....................................................................0 Procedure without battery changing table................................................................0 Procedure with battery changing table...................................................................0 14.1.3 Replacing/installing the lithium-ion battery.........................................................0 Battery replacement.....................................................................................0 14.1.4 Installation of electrolyte mixing, fixed battery....................................................0 14.1.5 Installation of electrolyte mixing, battery replacement..............................................0 14.2 LID (5200).................................................................................................0 14.2.1 Replacing the LID....................................................................................0 14.2.2 Replacing the LID cold store cab.....................................................................0 14.3 Replacing pedals (5300)....................................................................................0 14.3.1 Accelerator and brake pedal..........................................................................0 14.3.2 Safety pedal.........................................................................................0 14.4 Control console (5510).....................................................................................0 14.4.1 General..............................................................................................0 14.4.2 Replacement/installation of a control................................................................0 14.4.3 Replacing the multi-function control.................................................................0 Replacing the multi-function control's buttons..........................................................0 14.4.4 Removing the control console from the truck..........................................................0 14.4.5 Replacing the access card's circuit board............................................................0 14.4.6 Dismantling the control console......................................................................0 Installing an extra push button.........................................................................0 Replacing the travel direction selector with signal button..............................................0 Replacing the display...................................................................................0 14.4.7 Assembling the control console.......................................................................0 14.4.8 Placing the control console in the truck.............................................................0 14.5 Magnetic sensor (5850).....................................................................................0 General.....................................................................................................0 14.5.1 Replacing the magnetic sensor [B47]..................................................................0 14.5.2 Reference magnet.....................................................................................0 14.6 Parameter settings.........................................................................................0 14.6.1 Configuration menu...................................................................................0 Calendar/hour counter menu..............................................................................0 Parameter menu (PAR)....................................................................................0 Setting driver parameters...............................................................................0 14.7 PIN menu...................................................................................................0 14.7.1 Activate PIN block menu..............................................................................0 14.7.2 Menu for programming a PIN (P).......................................................................0 14.8 Calibrations...............................................................................................0 14.8.1 Calibrating the hydraulic function control...........................................................0 14.8.2 Height measurement/reach movement length calibration.................................................0 Calibrating height measurement (option).................................................................0 14.8.3 Valve calibration....................................................................................0 Lift valve calibration..................................................................................0 Lowering valve calibration with height indication.......................................................0 Lowering calibration without height indication..........................................................0 Reach movement valve calibration........................................................................0 Calibration of the Ergo cabin...........................................................................0 14.8.4 Weight calibration...................................................................................0 Calibrating the weight indicator........................................................................0 14.9 Replacing the wiring harness...............................................................................0 14.10 main computer unit MCU (A5)...............................................................................0 14.10.1 Installing a new card in the truck..................................................................0 14.10.2 Power supply........................................................................................0 14.10.3 Battery negative....................................................................................0 14.10.4 Internal status monitoring..........................................................................0 14.10.5 Resetting the battery indicator.....................................................................0 15 – Hydraulic system 6000..........................................................................................0 15.1 Hydraulic hygiene..........................................................................................0 15.1.1 Washing..............................................................................................0 15.1.2 Packaging............................................................................................0 15.1.3 Handling.............................................................................................0 15.1.4 Storage..............................................................................................0 15.1.5 Work procedures......................................................................................0 15.2 Hydraulic unit (6100)......................................................................................0 15.2.1 Hydraulic tank, emptying.............................................................................0 15.2.2 Hydraulic system, bleeding...........................................................................0 15.2.3 Filter...............................................................................................0 Overview................................................................................................0 Filter replacement (for air and oil)....................................................................0 Method..................................................................................................0 15.2.4 Removing the pump motor from the truck...............................................................0 15.2.5 Replacing the hydraulic pump or the O- Ring..........................................................0 15.2.6 Fitting the pump motor in the truck..................................................................0 15.3 Main valve (6210)..........................................................................................0 15.3.1 Emergency lowering of the forks......................................................................0 15.3.2 Replacing the main valve block.......................................................................0 15.3.3 Replacing the lifting/lowering valves................................................................0 Overview................................................................................................0 Method..................................................................................................0 15.3.4 Adjusting the maximum opening pressure...............................................................0 15.4 Hydraulic connections (6230)...............................................................................0 15.4.1 Tightening torques for hydraulic connections.........................................................0 Tapered coupling with O-ring............................................................................0 Tredo seal..............................................................................................0 Pipe coupling...........................................................................................0 15.4.2 Quick change connectors..............................................................................0 Overview................................................................................................0 Assembly................................................................................................0 Disassembly.............................................................................................0 15.5 Hydraulic system, mast (6300)..............................................................................0 15.5.1 Mast-mounted hose reel (6370)........................................................................0 General.................................................................................................0 15.5.2 Fitting the hose reel................................................................................0 Spring preloading (turns)...............................................................................0 15.5.3 Checks after fitting.................................................................................0 15.6 Main lift cylinder 6610....................................................................................0 General.....................................................................................................0 15.6.1 Overview.............................................................................................0 Cylinder nomenclature...................................................................................0 Nomenclature for cylinder head..........................................................................0 Nomenclature for piston.................................................................................0 15.6.2 Removing the air cylinder from the mast..............................................................0 15.6.3 Replacing the hose rupture valve.....................................................................0 15.6.4 Dismantling the cylinder.............................................................................0 Method..................................................................................................0 15.6.5 Dismantling the piston...............................................................................0 Method..................................................................................................0 15.6.6 Dismantling the cylinder head........................................................................0 Method..................................................................................................0 15.6.7 Fitting the cylinder head seals......................................................................0 Method..................................................................................................0 15.6.8 Fitting the piston seals.............................................................................0 Method..................................................................................................0 15.6.9 Assembling the cylinder..............................................................................0 Method..................................................................................................0 15.6.10 Assembling a mast cylinder..........................................................................0 15.7 Free lift cylinder (6620)..................................................................................0 General.....................................................................................................0 15.7.1 Overview.............................................................................................0 Cylinder nomenclature...................................................................................0 Nomenclature for cylinder head..........................................................................0 Nomenclature for piston.................................................................................0 15.7.2 Removing the free lift cylinder from the truck.......................................................0 15.7.3 Replacing the hose rupture valve, free lift cylinder.................................................0 15.7.4 Dismantling the cylinder.............................................................................0 Method..................................................................................................0 15.7.5 Dismantling the piston...............................................................................0 Method..................................................................................................0 15.7.6 Dismantling the cylinder head........................................................................0 Method..................................................................................................0 15.7.7 Fitting the cylinder head seals......................................................................0 Method..................................................................................................0 15.7.8 Fitting the piston seals.............................................................................0 Method..................................................................................................0 15.7.9 Assembling the cylinder..............................................................................0 Method..................................................................................................0 15.7.10 Assembling the free lift cylinder in the mast.......................................................0 15.8 Reach cylinder (6650)......................................................................................0 15.8.1 General..............................................................................................0 15.8.2 Removing the reach cylinder from the truck...........................................................0 15.8.3 Fitting the reach cylinder in the truck..............................................................0 15.9 Fork tilt cylinder (6660)..................................................................................0 15.9.1 General..............................................................................................0 15.9.2 Dismantling the tilting cylinder.....................................................................0 Mast with valve on the fork carriage....................................................................0 Method..................................................................................................0 15.9.3 Removing a tilt cylinder from truck number 6395129-..................................................0 Mast with valve on the fork carriage....................................................................0 Mast without valve on the fork carriage:................................................................0 Method..................................................................................................0 15.9.4 Mounting the tilting cylinder........................................................................0 Mast with valve on the fork carriage....................................................................0 Method..................................................................................................0 Mast without valve on the fork carriage:................................................................0 Method..................................................................................................0 15.9.5 Mounting a tilt cylinder, from truck number 6395129-.................................................0 Mast with valve on the fork carriage....................................................................0 15.10 Cab tilt cylinder (6660)..................................................................................0 15.10.1 General.............................................................................................0 15.10.2 Overview............................................................................................0 Cylinder nomenclature...................................................................................0 Nomenclature for cylinder head..........................................................................0 Nomenclature for piston.................................................................................0 15.10.3 Dismantling the cylinder............................................................................0 Method..................................................................................................0 15.10.4 Removing the piston rod.............................................................................0 Method..................................................................................................0 15.10.5 Dismantling the cylinder head.......................................................................0 Method..................................................................................................0 15.10.6 Fitting the cylinder head seals.....................................................................0 Method..................................................................................................0 15.10.7 Mounting the piston rod.............................................................................0 Method..................................................................................................0 15.10.8 Assembling the cylinder.............................................................................0 Method..................................................................................................0 15.11 Sideshift cylinder (6670).................................................................................0 15.11.1 General.............................................................................................0 15.11.2 Overview............................................................................................0 Cylinder nomenclature...................................................................................0 Nomenclature for cylinder head..........................................................................0 Nomenclature for piston.................................................................................0 15.11.3 Dismantling the cylinder from the truck.............................................................0 Method..................................................................................................0 15.11.4 Dismantling the cylinder............................................................................0 Method..................................................................................................0 15.11.5 Removing the piston rod.............................................................................0 Method..................................................................................................0 15.11.6 Dismantling the cylinder head.......................................................................0 Method..................................................................................................0 15.11.7 Fitting the cylinder head seals.....................................................................0 Method..................................................................................................0 15.11.8 Mounting the piston rod.............................................................................0 Method..................................................................................................0 15.11.9 Assembling the cylinder.............................................................................0 Method..................................................................................................0 15.11.10 Refitting the cylinder in the truck................................................................0 16 – Mast/Lift system 7000..........................................................................................0 16.1 General....................................................................................................0 16.2 Checking the chain.........................................................................................0 16.2.1 Noise................................................................................................0 16.2.2 Surface rust.........................................................................................0 16.2.3 Rusty links..........................................................................................0 16.2.4 Stiff links..........................................................................................0 16.2.5 Bolt rotation........................................................................................0 16.2.6 Loose bolts..........................................................................................0 16.2.7 Outline wear.........................................................................................0 16.2.8 Stretching...........................................................................................0 16.2.9 Damage...............................................................................................0 16.2.10 Damaged plates......................................................................................0 16.2.11 Damaged bolts.......................................................................................0 16.2.12 Dirty chain.........................................................................................0 16.3 Lubricating the chain......................................................................................0 16.4 Adjustment.................................................................................................0 16.5 Main mast 1.6-2.5 t (7100).................................................................................0 16.5.1 Replacing the full mast..............................................................................0 16.5.2 Remove the mast from the truck.......................................................................0 16.5.3 Adjusting mast clearance.............................................................................0 General.................................................................................................0 Preparations............................................................................................0 Adjusting lateral clearance.............................................................................0 Adjustment of radial clearance..........................................................................0 Adjusting the damper parts..............................................................................0 Adjusting the damper plate..............................................................................0 Refitting the mast......................................................................................0 16.5.4 Replacing the mast damper plates.....................................................................0 16.5.5 Replacing the free lift chain........................................................................0 Removing the free lift chain............................................................................0 Fitting the free lift chain.............................................................................0 Checking the chain bolt angle...........................................................................0 16.5.6 Assembly of frame on truck...........................................................................0 16.6 Main lift chain system (7120)..............................................................................0 16.6.1 Main lift chain system, adjusting the fork- to-floor distance........................................0 16.7 Reach carriage (7190)......................................................................................0 Overview:...................................................................................................0 16.7.1 Adjusting the radial clearance in the reach carriage.................................................0 16.7.2 Adjusting the axial clearance in the reach carriage..................................................0 16.8 Lifting devices (7400).....................................................................................0 16.8.1 Forks................................................................................................0 General.................................................................................................0 Inspection..............................................................................................0 Inspection intervals....................................................................................0 Surface cracks..........................................................................................0 Difference in height between the fork tips..............................................................0 Position lock...........................................................................................0 Readability of the markings.............................................................................0 Fork blades and back of fork carriage...................................................................0 Mounting fixtures on the fork...........................................................................0 16.8.2 Forks, repairs and testing...........................................................................0 Repairs.................................................................................................0 Testing the yield point.................................................................................0 Fork....................................................................................................0 16.9 Fork carriage..............................................................................................0 16.9.1 Checking the fork carriage’s wear strip..............................................................0 16.9.2 Lubricating the fork carriage........................................................................0 16.10 Fork spread unit..........................................................................................0 16.10.1 Servicing the fork spread unit......................................................................0 Replacing the bearing...................................................................................0 Roller replacement......................................................................................0 16.11 Fork extensions with adjustable fork length...............................................................0 16.12 Manual shuttle forks......................................................................................0 16.12.1 Assembly............................................................................................0 16.12.2 Maintenance.........................................................................................0 16.13 Hydraulic shuttle forks...................................................................................0 16.13.1 Shuttle forks with separate flow dividers...........................................................0 Fitting instructions....................................................................................0 Initial operation of shuttle forks with separate flow dividers..........................................0 16.13.2 Shuttle forks with integrated flow dividers.........................................................0 Fitting instructions....................................................................................0 Initial operation of shuttle forks with integrated flow dividers........................................0 16.13.3 Maintenance of shuttle forks........................................................................0 16.13.4 Wear................................................................................................0 16.13.5 Wear plate welding information......................................................................0 16.13.6 Dismantling shuttle forks...........................................................................0 16.13.7 Shuttle fork assembly...............................................................................0 17 – Peripherals - 8000.............................................................................................0 17.1 Introduction...............................................................................................0 18 – Optional equipment - 9000......................................................................................0 18.1 Smart Access 2 (SA2).......................................................................................0 18.1.1 Replacing SA 2.......................................................................................0 Removing SA 2...........................................................................................0 Mounting the SA 2.......................................................................................0 18.2 Pre-Op Check...............................................................................................0 18.2.1 Replacing the Pre-Op Check...........................................................................0 Removing the Pre-Op Check...............................................................................0 Mounting the Pre-Op Check...............................................................................0 19 – Appendix “Destruction instructions”............................................................................0 19.1 General....................................................................................................0 19.2 Marking of plastics........................................................................................0 19.2.1 General marking of products and packaging............................................................0 19.2.2 Marking according to Standard........................................................................0 Abbreviations...........................................................................................0 Marking examples........................................................................................0 19.3 Pressure vessels...........................................................................................0 19.3.1 Gas struts...........................................................................................0 19.4 Sorting categories.........................................................................................0 20 – Wiring diagram.................................................................................................0 20.1 Components.................................................................................................0 20.2 Component location.........................................................................................0 Figure 1 (Fork carriage)....................................................................................0 Figure 2 (Chassis wiring harness)...........................................................................0 Figure 3 (Chassis wiring harness)...........................................................................0 Figure 4 (Support leg brake)................................................................................0 Figure 5 (Pedals)...........................................................................................0 Figure 6 (Motor wiring harness).............................................................................0 Figure 7 (Reach carriage wiring harness)....................................................................0 Figure 8 (Level/position meter).............................................................................0 Figure 9 (seat).............................................................................................0 Figure 10 (DC/DC)...........................................................................................0 Figure 11 (Driver position wiring harness)..................................................................0 Figure 12 (Extra hydraulic function(s)).....................................................................0 Figure 13 (Travel alarm)....................................................................................0 Figure 14 (Roof wiring harness).............................................................................0 Figure 15 (Roof)............................................................................................0 Figure 16 (Sound system)....................................................................................0 Figure 17 (Forks camera)....................................................................................0 Figure 18 (Battery harness).................................................................................0 Figure 19 (Fuse box)........................................................................................0 Figure 20 (LID).............................................................................................0 Figure 21 (Mast wiring harness).............................................................................0 Figure 22 (Fork carriage wiring harness)....................................................................0 Figure 23 (Reach carriage wiring harness options)...........................................................0 Figure 24 (Working light wiring harness)....................................................................0 Figure 25 (Extra outlet DC).................................................................................0 Figure 26 (T.W.I.S.)........................................................................................0 Figure 27 (Shock Switch / Impact Manager)...................................................................0 Figure 28 (Heated windows CC)...............................................................................0 Figure 29 (Cabling driver position CC)......................................................................0 Figure 30 (Heater CC).......................................................................................0 Figure 31 (Cab heater wiring harness CC)....................................................................0 Figure 32 (Safety switch for door CC).......................................................................0 Figure 33 (Cab tilt wiring harness).........................................................................0 Figure 34 (Control panel)...................................................................................0 Figure 35 (Control panel)...................................................................................0 Figure 36 (Steering arm)....................................................................................0 Figure 37 (MCU).............................................................................................0 Figure 38 (Control motor)...................................................................................0 Figure 39 (Main valve block)................................................................................0 Figure 40 (Li-ion wiring harness)...........................................................................0 20.3 Cable connections and terminal posts.......................................................................0 20.3.1 ACT/ACH transistor regulators........................................................................0 20.3.2 Connections to CID...................................................................................0 20.3.3 Connections on the MCU...............................................................................0 20.4 Fuse box A9................................................................................................0 20.5 Overview...................................................................................................0 20.6 Details up to and including serial no. 6206800.............................................................0 20.7 Detailed diagram cold-store cab............................................................................0 21 – Hydraulics schematics..........................................................................................0 21.1 Main valve unit............................................................................................0 21.1.1 RRE Std..............................................................................................0 21.1.2 RRE Ergo.............................................................................................0 21.2 Hydraulic diagrams.........................................................................................0 21.2.1 Schematics designations..............................................................................0 21.2.2 List of symbols......................................................................................0 21.2.3 Wiring diagrams RRE/RRE Ergo.........................................................................0 22 – Tools..........................................................................................................0 22.1 AMP connectors.............................................................................................0 22.2 MQS connectors.............................................................................................0 22.3 CPC contacts...............................................................................................0 22.4 Other tools................................................................................................0 23 – Appendix “Service data and grease specifications”..............................................................0 23.1 General tightening torques.................................................................................0 23.1.1 Galvanised, non-oiled screws.........................................................................0 23.1.2 Untreated, oiled screws..............................................................................0 23.2 Lubricants specification...................................................................................0 24 – Technical data.................................................................................................0 Mast, maximum weight and maximum height.........................................................................0
DESCRIPTION:
BT TOYOTA FORKLIFT RRE140/160/180/200/250 REPAIR MANUAL – PDF DOWNLOAD
How to use this manual
The repair manual is divided into chapters containing the following information:
• Safety regulations – This chapter includes general safety regulations regaring working with the truck.
• Function – This chapter provides a basic description of the main functions of the truck.
• Parameters – This chapter contains a basic description of the steering system’s parameters.
• Installation – This chapter describes the work that needs to be done before the truck is used for the first time.
• Maintenance – the chapter contains a general periodic maintenance schedule and a detailed description of the maintenance to be carried out.
• Troubleshooting – The troubleshooting chapter describes the error codes that are displayed when the truck is partially or completely disabled. It also describes the cause of the problem together with suggested remedies.
• Actions chapter – This chapter describes the various parts of the truck, what the parts look like and the service actions that need to be carried out. The various chapters are organised according to C-code system.
• Appendices – The appendices include:
– Instructions for disposal
– Information about electrical components and wiring diagrams
– Hydraulics diagram
– List of required tools
– Information about general tightening torques
– Oil and grease specifications
– Technical data.
S.S 05/01/2025
