Page 1 Repair Manual RRE140/160/180/200/250 Valid from serial number: 6051502 Order number: 261828-040 Issued: 2008-08-21 ITS © BT...
Page 2 Publication Changes 2008-08-21 261828-040 Completely new issue. This manual covers following truck models: T-code Model Serial number RRE140, RRE140C, (RRE140CC), 6051502- RRE140E,RRE140EC, (RRE140ECC), RRE160, RRE160C, (RRE160CC) RRE160E, RRE160EC, (RRE160ECC) RRE180, RRE180C, (RRE180CC), 6051502- RRE180E, RRE180EC, (RRE180ECC), RRE200, RRE200C, (RRE200CC), RRE200E, RRE200EC, (RRE200ECC),...
Page 3: Table Of Contents
Disc brake on the drive motor (parking brake) ....4-12 General ................4-12 Design ................4-12 Steering system 4000 ..............4-13 4.5.1 General ................4-13 Design ................4-13 Operator compartment..............4-14 4.6.1 Truck control, overview ..........4-14 © BT Repair Manual RRE140/160/180/200/250 1 – 1...
Page 4: Contents
Height preselector, description of function ........4-54 4.9.1 Using the height preselector .......... 4-54 4.9.2 Symbols ................. 4-54 4.9.3 Buzzer ................4-54 4.9.4 Height preselector levels ..........4-55 4.9.5 Level selection ............... 4-55 4.9.6 Height programming ............4-56 1 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 5 Initial operation................5-2 5.2.1 Placing the battery ............5-2 5.2.2 Parameters on initial operation ........5-3 Battery ................5-3 Load indicator ..............5-3 Ergo cabin ............... 5-3 Cold store cabin ............... 5-4 © BT Repair Manual RRE140/160/180/200/250 1 – 3...
Page 6 Height measurement (option) .......... 5-4 Travel speed limitation, height-dependent ....... 5-4 Travel speed limitation, reach movement dependent ..5-4 Travel speed limitation, parameter-dependent ....5-5 Collision sensor (BT) ............5-5 5.2.4 Mast, fitting ..............5-5 6 – Maintenance ..................6-1 Introduction, maintenance..............
Page 7 Fitting the drive motor to the truck ......... 9-19 10 – Drive gear 2000 ................10-1 10.1 General ..................10-1 10.1.1 Leakage from the bottom cap ........10-1 10.1.2 Replacing the drive gear ..........10-2 Special tools ..............10-2 © BT Repair Manual RRE140/160/180/200/250 1 – 5...
Page 8 12.1.4 Replacing the wiring harness in the operating console . 12-3 12.1.5 Placing the operating console in the truck ..... 12-5 12.2 Steering reference sensor (4350) ..........12-6 General ................12-6 12.2.1 Replacing the reference sensor ........12-6 1 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 9 14.1.3 Removing the pump motor from the truck ..... 14-4 14.1.4 Replacing the hydraulic pump ........14-5 14.1.5 Fitting the pump motor in the truck ........ 14-6 14.2 Main valve (6210)................. 14-7 © BT Repair Manual RRE140/160/180/200/250 1 – 7...
Page 10 15.1.5 Placing the mast on the truck ........15-12 15.2 Main lift chain system (7120) ............. 15-16 15.2.1 General ................ 15-16 15.2.2 Inspecting the chain ............. 15-16 Noise ................15-16 Surface rust ..............15-16 Rusty links ..............15-16 1 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 11 Fitting instructions ............15-40 Initial operation of telescopic forks with integrated flow divid- ers ................15-40 15.9.3 Maintenance of telescopic forks ........15-41 15.9.4 Dismantling telescopic forks ........15-42 15.9.5 Assembling telescopic forks ........15-43 © BT Repair Manual RRE140/160/180/200/250 1 – 9...
Page 12 22 – Appendix “Service data and grease specifications” ....22-1 22.1 General tightening torques............22-1 22.1.1 Galvanised non-oiled bolts ..........22-1 22.1.2 Untreated oiled bolts ............22-2 22.2 Oil and grease specifications ............22-3 23 – Technical data ................23-1 1 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 13: General Introduction
The various de- scriptions are organised according to BT's C-code system. • Appendixes – The appendixes contain: - instructions for disposal...
Page 14: Warning Symbols
‘s’: key size, ‘n’: number of screws and, where applicable, recommend- ed torque. One example of another pictogram type is “Cut tie wrap”: The pictogram might have additional information below, saying how many ties to cut. 2 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 15: General Safety Rules
• heated paint gives off harmful gases. So use sanding or a paint strip- per to remove the paint at least 100 mm around an area where any welding/grinding is to take place. © BT Repair Manual RRE140/160/180/200/250 3 – 1...
Page 16: Electrical System
IMPORTANT Risk of short-circuiting that may damage electrical components. Do not break the warranty seal on the electronic cards. 3 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 17: Safe Lifting
• Ensure the area where you place the jack is clean and free of oil and grease. • Ensure there is no grease or oil on your hands or the jack lever. © BT Repair Manual RRE140/160/180/200/250 3 – 3...
Page 18 - so that the truck cannot roll. • Never place a support under the jack to increase the lifting height. • Never work under a lifted truck without appropriate supports. 3 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 19: Functions And Parameters
The tilt stops are located on the rear corner of the support arm and con- sist of stops (c), shims (b), bolts (d), and nuts (a) on the inside of the chassis. © BT Repair Manual RRE140/160/180/200/250 4 – 1...
Page 20: Overhead Guard
The casing can be supplemented by a guard of finer mesh (b) and a transparent top (a). The truck may be fitted out with a protective grating (d) between the cabin and the mast. 4 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 21: Motors 1000
There are two sizes of pump motor for the trucks. On RRE140—RRE160, TSA170-200-106 is used. On RRE180—RRE250, TSA170-180-072 is used. Design ©...
Page 22: Electric Steering Motor (1730)
There are two sizes of steering motor. On RRE140–RRE160, 247454-001 is used. On RRE180–RRE250, 208014-003 is used. Design The steering motor has the EPS electronics fitted directly on top of it (a).
Page 23: Fan Motor/Fan (1740)
There are two cooling fans in the truck's motor compartment. These are a radial fan (a) that cools the frequency converter of the motors, and an axial fan (b) that ventilates the entire motor compart- ment. © BT Repair Manual RRE140/160/180/200/250 4 – 5...
Page 24: Electric Drive Motor (1760)
There are two sizes of drive motor for the truck. RRE140–RRE160 uses TSA 170-200-073. RRE180–RRE250 uses TSA 280-180-100. Design 4 – 6...
Page 25: Drive Gear - 2000
The gear is a two-stage 90 degree gear and comes in two different siz- es, depending on the truck model. • RRE140–RRE160 has a GK25 gear and • RRE180–RRE 250 has a GK30 gear. The drive unit is fitted to the chassis by means of 6 bolts. The steering bearings and a gear rim for the steering motor are fitted in the top edge of the gear.
Page 26: Design
The output shaft has a hub for the wheel. The wheel bolts are stud bolts that can be replaced. The gear has two oil level plugs for checking/topping up the oil level. The oil in the gear should not normally be changed. Drive gear, cross-section view 4 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 27: Brake System 3100
The parking brake on the drive motor is the main emergency brake. Motor braking can operate during emergency braking provided there is a supply voltage. If there are support arm brakes on the truck, these are also engaged during emergency braking. © BT Repair Manual RRE140/160/180/200/250 4 – 9...
Page 28: Drive Motor Brake (Travel Brake)
The brake force for a change in direction of travel can be adjusted using a service parameter - see section "2 – Parameters". 4 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 29: Multiple Disc Brake, Support Arm (Travel Brake)
50 %. Design The brake is fitted in the support arm wheels on a hub with splines and a locking shoe (j) which takes up the braking force. © BT Repair Manual RRE140/160/180/200/250 4 – 11...
Page 30: Disc Brake On The Drive Motor (Parking Brake)
The brake acts as a parking brake, as well as an emer- gency and secondary travel brake at the end (final 10 %) of brake pedal travel. Design Item Component Magnet housing Brake disc Friction disc 4 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 31: Steering System 4000
The MCU monitors the EPS and CAN buses, so any electrical faults in the pulse generator, cables or electronic unit result in automatic shut- down of the truck drive function. © BT Repair Manual RRE140/160/180/200/250 4 – 13...
Page 32: Operator Compartment
The information display and keypad allow access to the truck. Right-hand control panel, multi-control This has the same functions as single control, but they are located dif- ferently. Emergency switch off 4 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 33: Steering Module
Indication on the Central Information Display when the emergency switch off is depressed and the truck is in logged-in mode. Steering module The steering module is used to steer the truck. © BT Repair Manual RRE140/160/180/200/250 4 – 15...
Page 34: Pedals
Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 Pedals The truck has three pedals: a – Accelerator, b – Brake pedal, c – Safety pedal for presence checks. 4 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 35: Single Control
- Selection of extra hydraulic function 3 (active as long as the func- tion is used and for 15 seconds afterwards) or switching detected by service parameter. - Operator cabin tilt. - Turn signal lights. h: Travel direction selector. j: Horn. © BT Repair Manual RRE140/160/180/200/250 4 – 17...
Page 36: Multi-Control
- Selection of extra hydraulic function 3 (active as long as the func- tion is used and for 15 seconds afterwards) or switching detected by service parameter. - Operator cabin tilt. - Turn signal lights. h: Travel direction selector. j: Horn. 4 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 37: Central Information Display - Cid
Comes on when a warning is active. g. Low battery. Battery capacity is low: flashing lamp when 10 % remaining, comes on permanently at 0 %. h. Extra. Comes on when an extra hydraulic function is selected. © BT Repair Manual RRE140/160/180/200/250 4 – 19...
Page 38: Cid Information Symbols In The Display Area
Login via ID unit code verified by or unit connected T.W.I.S. to the MCU Reading ID unit. Waits for identifi- cation via ID unit Height preselector. Height preselector Pick up Deposit active Delete height 4 – 20 Repair Manual RRE140/160/180/200/250 © BT...
Page 39: Cid Disable Indications In The Display Area
Travel speed is limited to 4 km/h. Cold store cabin – Door open. Driving disabled or lim- ited to 2.5 km/h. Controlled by parameter 116. © BT Repair Manual RRE140/160/180/200/250 4 – 21...
Page 40: Cid Service Symbols In The Display Area
PIN code Calibration Programming PIN Service function for cali- codes brating sensors, etc. Joystick Mast Calibration of joysticks Service function for operating the mast. 4 – 22 Repair Manual RRE140/160/180/200/250 © BT...
Page 41: Driver Parameter Symbols
Calibration of the fork load measurement. Driver parameter symbols Sym- Description Sym- Description Steer progressiveness Top speed – Drive wheel direction Top speed – Fork direc- Acceleration tion Auto brake Cabin tilt © BT Repair Manual RRE140/160/180/200/250 4 – 23...
Page 42: Navigation
When logging in without the CAN key or TruckCom, only a limited number of functions are accessible and only icons for accessible func- tions are displayed. 4 – 24 Repair Manual RRE140/160/180/200/250 © BT...
Page 43 User Driver info Error info Teach Overview of the functions that are accessible without the CAN key or TruckCom. a: Login procedure, d: Only read access e: Parameter-based access, j: Logged in © BT Repair Manual RRE140/160/180/200/250 4 – 25...
Page 44 Teach Error info Error info Overview of the functions that are accessible with the CAN key or TruckCom. a: Login procedure, j: Logged in, h: Also accessible with special PIN code 4 – 26 Repair Manual RRE140/160/180/200/250 © BT...
Page 45: Load Information Display - Lid (Option)
Not used. c. Sideshift in initial position (green). 4. Tilt in initial position (green). e. Aux (yellow). Not used. When the truck is operated in emergency driving mode, all the symbols flash simultaneously. © BT Repair Manual RRE140/160/180/200/250 4 – 27...
Page 46: Lid Symbols In The Display Area
T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 LID symbols in the display area 1125 kg: Load weight, 10.89 m: Load height, Right-hand half: Height preselector (option). 4 – 28 Repair Manual RRE140/160/180/200/250 © BT...
Page 47: Operation And Connection Sequences
The battery [G1] is connected [X3] or, with battery replacement cables, [X1] Contributing factors Main contactor [Q10] off Key relay [K20] off Fuse [F60] “+48 VDC ESO Circuit” OK Resulting conditions Login possible. Login method controlled by parameter 503. © BT Repair Manual RRE140/160/180/200/250 4 – 29...
Page 48 “Central Information Display (CID)” displays a status image for approximately 2 seconds: Main contactor [Q10] on Key relay [K20] on Login rejected: “Central Information Display (CID)” displays: Main contactor [Q10] off Key relay [K20] off 4 – 30 Repair Manual RRE140/160/180/200/250 © BT...
Page 49 “Central Information Display (CID)” displays a status image for approximately 2 seconds: Main contactor [Q10] on Key relay [K20] on Login rejected: “Central Information Display (CID)” displays: Main contactor [Q10] off Key relay [K20] off © BT Repair Manual RRE140/160/180/200/250 4 – 31...
Page 50 “Central Information Display (CID)” displays a status image for approximately 2 seconds: Main contactor [Q10] on Key relay [K20] on Login rejected: “Central Information Display (CID)” displays: Main contactor [Q10] off Key relay [K20] off 4 – 32 Repair Manual RRE140/160/180/200/250 © BT...
Page 51 On the information screen, select: and then press the green button Contributing factors – Resulting conditions “Central Information Display (CID)” displays a status image for approximately 2 seconds: Main contactor [Q10] on Key relay [K20] on © BT Repair Manual RRE140/160/180/200/250 4 – 33...
Page 52 It is possible to drive the truck, 2a, 2b & 2c, according to the parame- ters for the current operator profile and emergency driving, 2d, with greatly reduced speed for all functions. 4 – 34 Repair Manual RRE140/160/180/200/250 © BT...
Page 53 The accelerator [B32] is released and this has an effect on input A5- X130:17. Contributing factors Operator parameter 5: Automatic braking. Resulting conditions The frequency of the drive motor three-phase voltage is reduced. © BT Repair Manual RRE140/160/180/200/250 4 – 35...
Page 54 In terms of the support arm brake: When the pedal is depressed 50 - 90 % of its possible travel, PWM out- puts A5-X131:39 and A5-X131:12. are modulated so that the brakes [Q16] and [Q17] are released. 4 – 36 Repair Manual RRE140/160/180/200/250 © BT...
Page 55 The pump motor is supplied with three-phase voltage from the transis- tor regulator [T2]. Output A5:OUT.(PWM) REACH IN lowers the voltage Current flows through the proportional valve [Q6] The proportional valve [Q6] is opened in proportion to the current that flows through. © BT Repair Manual RRE140/160/180/200/250 4 – 37...
Page 56 Output A5-131:26 “OUT(PWM) MAIN MAST LIFT” reduces the voltage. Output T2-K1:10 “OUT.(PWM) INITIAL MAST LIFT” retains the full volt- age. The proportional valve [Q2] is opened in proportion to the current that flows through. Proportional valve [Q3] closed. 4 – 38 Repair Manual RRE140/160/180/200/250 © BT...
Page 57 Output T2-K1:2 “OUT.(PWM) INITIAL MAST LOWER” reduces the volt- age. Output A5-131:40 “OUT(PWM) MAIN MAST LOWER” retains the full voltage. The proportional valve [Q5] is opened in proportion to the current that flows through. Proportional valve [Q4] closed. © BT Repair Manual RRE140/160/180/200/250 4 – 39...
Page 58 The tilt cylinder is drained to the tank. On sideshift, or some other optional function: the following also applies: Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” remains high. No current flows through the coil [Q18]. 4 – 40 Repair Manual RRE140/160/180/200/250 © BT...
Page 59 Output A5-X131:11 “OUT.AUX DIRECTION B” reduces the voltage. Current flows through the coil [Q8]. Output A5-X131:38 “OUT.TILT/SIDESHIFT/AUX 1” reduces the volt- age. Current flows through the coil [Q18]. The piston rod end of the sideshift cylinder is pressurised. © BT Repair Manual RRE140/160/180/200/250 4 – 41...
Page 60 Action(s) The operator presses the red button. Contributing factors – Resulting conditions The login screen is displayed and login is possible. The screen to be displayed is determined by service parameter 503. 4 – 42 Repair Manual RRE140/160/180/200/250 © BT...
Page 61: Functions
EPS, ACT and ACH use the second. In its closed position, the main contactor [Q10] supplies the power stage of the truck, e.g. ACT and ACH. In its closed position, the key contactor [K20] supplies other electronic units © BT Repair Manual RRE140/160/180/200/250 4 – 43...
Page 62: Mcu - Main Control Unit
CAN1 is used for communication between the MCU and the various displays (CID and LID). CAN2 is used for communication between the MCU, the steering servo (EPS), and the transistor regulators (ACT and ACH). 4.8.3 ACT/ACH transistor regulators 4 – 44 Repair Manual RRE140/160/180/200/250 © BT...
Page 63: General
If the contactor is open, the voltage is slightly reduced and the condition for shutting down the electronics and opening the key contactor is met. © BT Repair Manual RRE140/160/180/200/250 4 – 45...
Page 64: Driving
Acceleration is reduced when battery voltage is low, as well as in emer- gency driving mode. Retardation is reduced in emergency driving mode. Speed is monitored so that actual speed is reduced when retardation is requested. 4 – 46 Repair Manual RRE140/160/180/200/250 © BT...
Page 65: Reversing
If an error is detected on the support arm brakes, the travel speed is reduced to the speed that applies for a truck without support arm brakes. © BT Repair Manual RRE140/160/180/200/250 4 – 47...
Page 66: Travel Speed
Other speeds are also possible depending on the limitations, warnings and errors that are specified. There are three digital inputs that can generate special speeds; these are parameter-based, provided as special options. 4 – 48 Repair Manual RRE140/160/180/200/250 © BT...
Page 67: Steering
In the case of a low steering value, the speed must be under a given speed, otherwise an error code is output. When the steering servo is deactivated, the actual steering speed must be 0, otherwise an error code is output. © BT Repair Manual RRE140/160/180/200/250 4 – 49...
Page 68: Steering Reference
The compass card indicates that the truck will be moving in the direc- tion of the drive wheel. 4 – 50 Repair Manual RRE140/160/180/200/250 © BT...
Page 69: Hydraulic System
• The lift control is checked to ensure it is within 0.3 – 4.7 V. • The electrical circuits of the lift and lowering valves are monitored for short circuits and breaks in the cabling. © BT Repair Manual RRE140/160/180/200/250...
Page 70: Reach Movement
The maximum lift height is set by a factory parameter. Once the forks reach this level, the movement is stopped and lift continuation is pre- vented. The cancel button for lift height limitation cannot be used to override this limit. 4 – 52 Repair Manual RRE140/160/180/200/250 © BT...
Page 71: Auxiliary/Extra Functions (Option)
If a sensor is connected to measure the mid position, a LED icon in the LID (option) comes on once the mid position is reached. Forkspread and telescopic forks The telescopic forks use the third auxiliary output and forkspread uses the fourth auxiliary output. © BT Repair Manual RRE140/160/180/200/250 4 – 53...
Page 72: Height Preselector, Description Of Function
The CID buzzer is used to warn of an error, for instance if a level that has been entered is not programmed, or if the entered level does not exist. The buzzer is also used to inform the operator when a target has been achieved. 4 – 54 Repair Manual RRE140/160/180/200/250 © BT...
Page 73: Height Preselector Levels
Press the number 1 --:-- Press the number 4 (within 0.5 s) --:-- Press the green button (I) (within 0.5 14:-- Press the number 9 14:-- Wait 0.5 s until level 9 is selected 14:9 © BT Repair Manual RRE140/160/180/200/250 4 – 55...
Page 74: Height Programming
378. If the height is outside this interval, it will not be saved and the buzzer emits a warning sound. To leave the programming screen, press the C-button. 4 – 56 Repair Manual RRE140/160/180/200/250 © BT...
Page 75: Height Preselector And Truckcom
If the measured stop height differs from the target height by more than the maximum error, defined byparameter 377, Max. StopHeight Error, a warning code is displayed at the same time as the CID emits a warning sound. © BT Repair Manual RRE140/160/180/200/250 4 – 57...
Page 76: Hydraulic System 6000
In the cold store version, the dehumidification filter is used in combina- tion with a special return filter with a specially adapted breather filter connection for connecting to the dehumidification filter. 4 – 58 Repair Manual RRE140/160/180/200/250 © BT...
Page 77: Hydraulic Pump
The valve block comes supplied with the pressure limiter DV1 set at 25 MPa (250 bar). For the reach movement and (where applicable) cabin tilt, there are also pressure reducing valves DV2 and DV3, set at 15 MPa (150 bar). © BT Repair Manual RRE140/160/180/200/250 4 – 59...
Page 78: Other Valve Blocks
Apart from these valve blocks there is the option of an additional one or two extra hydraulic functions using an extra valve block in one of two versions - for one or two hose reels. 4 – 60 Repair Manual RRE140/160/180/200/250 © BT...
Page 79: Cylinders
The free lift cylinder is a single-action sealed piston cylinder. Cylinders for the reach movement, cabin tilt, side- shift and fork tilt For the reach movement, cabin tilt, sideshift and fork tilt, double-action cylinders with piston seal are used. © BT Repair Manual RRE140/160/180/200/250 4 – 61...
Page 80: Lift And Lowering Function
The pressure limiter DV2 opens if the pressure exceeds 15 MPa (150 bar) on reach movement in the OUT direction. On reach movement in the IN direction, the pressure is limited by DV1 to 25 MPa (250 bar). 4 – 62 Repair Manual RRE140/160/180/200/250 © BT...
Page 81: Simultaneous Operation Of Mast Lift And Reach Movement
If Q2/Q3 is open, the flow travels to the main lift cylinders or the free lift cylinder, respectively; if Q2/Q3 is not open, the pressure increases and affects the pressure reducing valve, DV1, which opens the path to the tank. © BT Repair Manual RRE140/160/180/200/250 4 – 63...
Page 82: Cabin Tilt (Rre Ergo) During Servicing
On the magnetic tube to Q21 there is an allen screw, the emergency lowering screw, which allows opening of Q21 in the event of the electronics being out of action. 4 – 64 Repair Manual RRE140/160/180/200/250 © BT...
Page 83: Mast 7000
When ordering a replacement mast, TMHE Technical Support should be contacted to identify the right mast for the truck in question. © BT Repair Manual RRE140/160/180/200/250 4 – 65...
Page 84: Lifting Devices
(see the Maintenance section). The international stand- ard must be applied when checking the forks, with the exception of those sections that refer to “fork blades and shafts”, as the inner fork must not be subjected to wear. 4 – 66 Repair Manual RRE140/160/180/200/250 © BT...
Page 85 Along the rear of the fork holder there is a distribution valve. The maximum fluid pressure for the telescopic forks is 20 MPa (200 bar). © BT Repair Manual RRE140/160/180/200/250 4 – 67...
Page 86: Parameters
The service parameters can be changed once a suitable CAN service key or PDA/PC has been connected to the truck. Factory parameters can ONLY be changed once a specially configured PDA/PC has been connected to the truck. 4 – 68 Repair Manual RRE140/160/180/200/250 © BT...
Page 87: Displaying/Changing Parameters
10 % Acceleration 10 % Automatic brake 10 000 1000 Height above free lift once the Ergo cabin starts tilting. Operator Parameter number 1–10 11–20 21–30 31–40 41–50 51–60 61–70 71–80 81–90 91–100 © BT Repair Manual RRE140/160/180/200/250 4 – 69...
Page 88: Service Parameters, Overview
Door open action (cold store cabin) 0 = Disable operation 1 = Speed limited to 2.5 km/h Driving parameters Reversing speed Creep speed Half speed Safety speed Speed limitation 1 Speed limitation 2 Speed limitation 3 4 – 70 Repair Manual RRE140/160/180/200/250 © BT...
Page 89 Extra (Aux) max. flow, direction A1 Extra (Aux) max. flow, direction A2 Extra (Aux) max. flow, direction A3 Extra (Aux) max. flow, direction A4 Extra (Aux) max. flow, direction B1 Extra (Aux) max. flow, direction B2 © BT Repair Manual RRE140/160/180/200/250 4 – 71...
Page 90 Height preselector, max. variation in stop heighit Height preselector, p+d height, difference Height preselector,automatic load detection limit 15000 Lift height limitation 1 15000 Lift height limitation 2 15000 Lift height limitation 3 4 – 72 Repair Manual RRE140/160/180/200/250 © BT...
Page 91 3, 4 = Keypad using 100 PIN codes 5, 6 = Keypad using DHU 7, 8 = ID unit Odd number = Access to operator parameter Even number = No access to operator parameter © BT Repair Manual RRE140/160/180/200/250 4 – 73...
Page 92 6 = 2 + 4 7 = 1 + 2 + 4 Height preselector available Height preselector, number of rows Truck type RRE = 0 Date format 0 = yyyy-mm-dd 1 = dd-mm-yyyy 4 – 74 Repair Manual RRE140/160/180/200/250 © BT...
Page 93: Factory Parameters, Overview
Max. Increm Default Unit Description General parameters 1001 Truck type 0 = Unknown truck type 1 = RRE140 2 = RRE160 3 = RRE180 4 = RRE200 5 = RRE250 1002 Drive motor 0 = Small 1 = Large 1003...
Page 94 Support arm brakes 1102 Reverse steering 1103 HPS, height preselector 1104 Cabin tilt activated (Ergo) 1105 Cold store cabin 1106 1107 Height limitation 1108 Travel alarm available 1109 Travel direction indicators (flashers) availa- 4 – 76 Repair Manual RRE140/160/180/200/250 © BT...
Page 95: Calibration Parameters, Overview
–200 Calibration of free lift lowering speed. 1270 –200 Calibration of main lift lowering speed. 1271 9000 Free lift, height reference 1272 Main lift, height reference 1273 6000 3000 Free lift height © BT Repair Manual RRE140/160/180/200/250 4 – 77...
Page 96 Functions and parameters Parameters T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 4 – 78 Repair Manual RRE140/160/180/200/250 © BT...
Page 97: Installation
2100 mast Insert the forks under the support arms and lift as illustrated. Method 2 To move the truck over short distances, you can use an extension cable from an adjacent battery. © BT Repair Manual RRE140/160/180/200/250 5 – 1...
Page 98: Initial Operation
When replacing a battery, there is a danger of it slipping and falling. Always use an approved lifting device to lift the battery and use a bat- tery yoke that suits the battery. 5 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 99: Parameters On Initial Operation
Full calibration of the functions is described in section “13.3 Parameter settings”. Battery The size (capacity) of the battery fitted in the truck must be specified using parameter 107 Parameter RRE140 RRE160 RRE180 RRE200 RRE250 So as not to run the battery down completely, a limit is set beyond which...
Page 100: Cold Store Cabin
Limits travel speed when the mast is extended beyond a given predetermined millimetre limit. Speed reduction for a selectable Parameter no. reach movement length Reach movement length for speed limita- – tion Speed limitation beyond a selected limit – km/h 5 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 101: Travel Speed Limitation, Parameter-Dependent
Activated 1-99 1-1500 1-99 1-1500 1-99 1500 Collision sensor (BT) The values in parameters 110 and 111 must be adapted to match the truck application. Collision sensor, functional opera- Parameter no. tion Deactivated – Activated, restart of truck without collision 1–99...
Page 102 Installation Initial operation T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank. 5 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 103: Maintenance
At each service, checks must be made that the truck functions as usual and is safe. These checks are to be performed in accordance with the instructions for daily care that are in the operator's manual. © BT Repair Manual RRE140/160/180/200/250...
Page 104: Periodic Maintenance
Periodic maintenance T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 6.2 Periodic maintenance 6.2.1 Every 500 B-hours/180 days Estimated duration: 39.5 min. 7120.1 7120.2 7120.3 5110.1 5110.2 5110.3 6 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 105 7120.2 Mast Inspection Adjustment of lifting chains, check the tightening torque of the lock nuts and inspect the cotter pins 7120.3 Mast Lubrication Lifting chains © BT Repair Manual RRE140/160/180/200/250 6 – 3...
Page 106: Every 1000 B-Hours/360 Days
6.2.2 Every 1000 B-hours/360 days Estimated duration: 124.3 min. <TBD>: Not 0390.5, 0390.6, 0390.9, 0390.10, 4310.1 0340.1 0620.1 0350.2 0350.1 3370.1 0340.2 3180.1 3180.2 3180.3 2550.1 3180.4 0840.1 0390.5 0390.2 0390.4 0390.9 0390.1 0390.10 0390.6 6 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 107 3180.3 Wheel brake Inspection Braking force 3180.4 Wheel brake Check on Locking screw of the wheel tightening brake in the supporting arm (34 torque 3370.1 Parking brake Inspection Play in un-braked position © BT Repair Manual RRE140/160/180/200/250 6 – 5...
Page 108 Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 7110.1 4310.1 5590.2 5590.3 6600.2 7400.1 5430.1 5430.2 3550.2 7190.2 7190.1 5000.4 3530.1 3530.2 6120.2 3530.3 7190.4 7190.7 7190.5 7190.8 6 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 109 7190.4 Reach carriage Adjustment Play of guide rollers 7190.5 Reach carriage Lubrication Guide rollers 7190.7 Reach carriage Adjustment Eccentric rollers 7190.8 Reach carriage Lubrication Eccentric rollers 7400.1 Forks Inspection Cracks © BT Repair Manual RRE140/160/180/200/250 6 – 7...
Page 110 Maintenance Periodic maintenance T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 0000.2 5000.3 3370.2 0390.12 5110.7 5110.8 5110.9 3550.1 0390.11 7190.3 0390.7 2550.2 0390.3 5000.2 6 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 111: Every 2000 B-Hours/720 Days
Drive gear Check on tightening The gear's mounting bolts in the torque chassis 3370.2 Parking Inspection Braking force brake 5000.3 Electrical Check on tightening Power cables on transistor regula- system torque tors © BT Repair Manual RRE140/160/180/200/250 6 – 9...
Page 112 Maintenance Periodic maintenance T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 5200.1 0640.1 5110.4 5110.5 5110.6 6140.1 1700.1 5390.1 5590.1 5000.1 6 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 113: Every 5000 B-Hours/1800 Days
Wear and damage to the truck displays system 5390.1 Electrical Inspection Wiring harness wear system 5590.1 Electrical Inspection Wear and damage to wiring harness, system including protective covering, in the reach carriage © BT Repair Manual RRE140/160/180/200/250 6 – 11...
Page 114: Maintenance Instructions
• Rinse off loose dirt with tepid water. IMPORTANT! Jamming, corrosion. Mechanical parts can be damaged. After washing the truck it should be lubricated as set out in the main- tenance instructions. 6 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 115: Cleaning The Chain
• Clean electrical panels, PCBs, contactors, contacts, solenoid valves, etc., with a moist cloth and a cleaning agent. IMPORTANT! Risk of short-circuiting. The electrical components may become damaged. Do not break the warranty seal on the PCBs. © BT Repair Manual RRE140/160/180/200/250 6 – 13...
Page 116 Maintenance Maintenance instructions T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 6 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 117: Troubleshooting
(080409) and time (12:57) when the error occurred. The window also contains logged information relating to the error. Only five values are displayed at a time; to obtain more values, the arrow keys must be used. © BT Repair Manual RRE140/160/180/200/250 7 – 1...
Page 118: Service Diagnostics Menu
Toggle between the numbered diagnostics states using the plus/minus buttons, and select a state using the green button (I). You can also use the numerical keys to access a given diagnostics state directly. 7 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 119: Diagnostics States
The value is displayed in volts to 2 decimal places. CID signal X505:2 Lift/lowering lever X505:11 Reach movement lever X505:17 Tilt lever X505:3 Sideshift lever X505:12 Forkspread lever X505:4 Travel direction selector X505:6 – X505:15 – 9–10 Not used © BT Repair Manual RRE140/160/180/200/250 7 – 3...
Page 120: State 2 - Digital Signals From Truck Controls To Mcu
Cabin tilt DI13 X503:5 Free DI14 X503:11 Free DI15 X504:10 Flashers, left DI16 X504:1 Flashers, right DI17 X505:14 (Multi/Single Keying) DI18 X503:12 Free ESOIN X504:16 Emergency stop (ESO) KEYIN X504:7 Key signal 7 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 121: State 3 - Voltages To Mcu
Fork tilt indicator X130:30 Hydraulic pressure, main lift X130:3 Hydraulic pressure, free lift X130:17 Accelerator X130:31 Safety pedal X130:4 Brake pedal 1 X130:18 Brake pedal 2 X130:32 Power consumption X130:5 Battery voltage + © BT Repair Manual RRE140/160/180/200/250 7 – 5...
Page 122: State 4 - Digital Input Signals To Mcu
Speed limitation 2 DI19 X131:4 Speed limitation 3 DI20 X131:18 Sideshift, left DI21 X131:32 Sideshift, right DI22 X131:5 Emergency stop (ESO) DI23 X131:19 Key (option) DI24 X131:33 (production test) DI25 X131:6 Key signal in 7 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 123: State 5 - Digital Output Signals From Mcu
Extra (Aux) hydraulic function valve 4 DO14 X131:38 Extra (Aux) hydraulic function valve 1 DO15 X131:11 Extra (Aux), direction B DO16 X131:25 Horn DO17 X131:39 Support arm brake, left DO18 X131:12 Support arm brake, right © BT Repair Manual RRE140/160/180/200/250 7 – 7...
Page 124: State 6 - Pwm Outputs From Mcu
Cabin tilt, up PWM2 K1:2 Cabin tilt, down State 7 – FCU (not used) State 8 – FCU (not used) State 9 – GFU (not used) State 10 – GFU (not used) 7 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 125: State 11 - Temperature Signals
2 decimal places. Voltage MCU battery voltage 15 V external voltage 5 V external voltage ACH battery voltage ACT battery voltage EPS battery voltage 7–10 Free © BT Repair Manual RRE140/160/180/200/250 7 – 9...
Page 126: State 13 - Travel Information
State 13 displays travel information. Unit Travel speed, target Travel speed, actual Accelerator Brake pedal Brake pedal Main contactor ACT power stage enabled Safety pedal/door switch Seat switch Parking brake enabled 6–8 Not used 7 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 127: State 14 Steering Information
° Steering speed, target V/min Steering speed, actual V/min Steering command Steering command MCU reference sensor EPS reference sensor Target drive wheel direction Target fork direction Steering command reversed 6–8 Not used © BT Repair Manual RRE140/160/180/200/250 7 – 11...
Page 128: State 15 - Lift/Lowering Information
ACH power stage enabled Forks near to mast top Full height indication (parameter 1009 = 1) Mast lowered pos. A Mast lowered pos. B ACH power stage enabled Free lift, height reference 7 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 129: State 16 - Reach Movement
State 16 displays reach movement information. Unit Actual reach movement length Parameter 1265, maximum reach movement length Reach movement lever Requested hydraulic pump speed Reach carriage sensor 1 Reach carriage sensor 2 Not used © BT Repair Manual RRE140/160/180/200/250 7 – 13...
Page 130: State 17 - Hydraulic Information
Lever aux 1 Lever aux 2 Lever aux 3 Requested hydraulic pump speed Ergo cabin, upper position Not used Sideshift sensor, left-hand side Sideshift sensor, right-hand side Ergo cabin, lowered position Not used 7 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 131: Warning And Error Codes
All codes start with a main group, 1–7, depending on the system they belong to. Group number, error codes Group: Description 1:nnn 2:nnn 3:nnn Traction force system 4:nnn Hydraulic system 5:nnn Steering system 6:nnn Wire guidance (does not apply to RRE trucks) 7:nnn © BT Repair Manual RRE140/160/180/200/250 7 – 15...
Page 132 CAN-related error codes. n:n20–n39 Error codes related to specific units. n:n40–n59 Error codes for short-circuited output data. n:n60–n79 Error codes for output data from open electrical circuits. n:n80–n99 Faulty signals from sensors. 7 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 133: Error Codes
Look for the latest software, replace the MCU. 1:503 Emergency mode error The MCU and CID display different status if the truck is in emergency driving mode. Restart the truck. © BT Repair Manual RRE140/160/180/200/250 7 – 17...
Page 134 3. Replace the MCU. 1:581 Key contactor off 1. Check that the wiring harness and contacts are intact and correctly fitted. 2. Check the operation of the key contactor. 3. Replace the MCU. 7 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 135 Lift height limiting is activated but no height measurement is activated. 2:106 Collision locking Collision value registered over the level determined by the service parameter, a collision has been registered. Travel speed reduced © BT Repair Manual RRE140/160/180/200/250 7 – 19...
Page 136 110 to deactivate the impact sensor. 2. Check the power supply, contacts and wiring harness. 2:401 Internal program error Error in the MCU program. Program software error, report to BT. 2:403 Read A/D time-out A/D reading is taking too long. 2:420 Incorrect battery voltage The battery voltage is below 33.6 V.
Page 137 The check sum is not correct. 2:502 General internal program Program error in the MCU program. error in MCU Report to BT. 2:504 Emergency mode error The MCU and CID display different status if the truck is in emergency driving mode.
Page 138 Output signal for main contactor has been short-circuited. nal 3 1. Check the magnetic coils, the electrical supply, contacts and wiring harness with regard to a short circuit. 2. Check that the main contactor works. 3. Replace the MCU. 7 – 22 Repair Manual RRE140/160/180/200/250 © BT...
Page 139 Check the magnetic coil, electrical supply, contacts and wir- ing harness. Check the output signal X131:12. 3:180 Safety pedal Safety pedal signal is outside the permitted value; 1.5– 3.5 V Check the output signal X131:31. © BT Repair Manual RRE140/160/180/200/250 7 – 23...
Page 140 Check the electrical supply to the ACT. 3:333 Internal + 15 V error. The internal 15 V supply in the ACT is under the permitted voltage range. See 3:305. Check the electrical supply to the ACT. 7 – 24 Repair Manual RRE140/160/180/200/250 © BT...
Page 141 3:500 Unexpected error Unknown drive error. Check that the same versions of the software are being used in the MCU and ACT. Update to the latest version. Report to BT. 3:520 Start-up error 3:540 Error on digital output sig- Output signal for parking brake short-circuited.
Page 142 1010. Lift/lowering speed reduced Activate the reference sensors by lifting and lowering the forks. If the error remains, check all height-related parame- ters. 7 – 26 Repair Manual RRE140/160/180/200/250 © BT...
Page 143 Unknown drive error. Deactivated hydraulics Check that the same versions of the software are being used in the MCU and ACH. Update to the latest version. Report to BT. 4:205 Temperature error Pump motor temperature is over 180 °C. Deactivated hydraulics 1.
Page 144 Error on digital output sig- Short circuit in output signal for AUX 3. nal 12. Aux (extra function) deacti- Check the magnetic coil, electrical supply, contacts and wir- vated. ing harness. Check the output signal (X131:10). 7 – 28 Repair Manual RRE140/160/180/200/250 © BT...
Page 145 Error on the free lift valve Interrupted circuit in the free lift valve output signal Lift deactivated. Check the magnetic coil, electrical supply, contacts and wir- ing harness. Check the output signal (K1:10). © BT Repair Manual RRE140/160/180/200/250 7 – 29...
Page 146 Error on MCU output signal Interrupted circuit in output signal for mast reach valve. Reach movement deacti- Check the magnetic coil, electrical supply, contacts and wir- vated ing harness. Check the output signal (X131:41). 7 – 30 Repair Manual RRE140/160/180/200/250 © BT...
Page 147 Error on the free lowering Interrupted circuit in output signal for the free lowering valve. valve. Check the magnetic coil, electrical supply, contacts and wir- ing harness. Check the output signal (K1:2). © BT Repair Manual RRE140/160/180/200/250 7 – 31...
Page 148 This problem can occur if the operator continues to steer when the truck has stopped or is stationary. 5:326 Temperature error The temperature on the EPS power stage is outside the permitted range, –40 to +85 °C. See 5:300. 7 – 32 Repair Manual RRE140/160/180/200/250 © BT...
Page 149 Unknown steering error. Check that the same versions of the software are being used in the MCU and EPS. Update to the latest version. Report to BT. 5:509 Unwanted steering move- The steered wheel turns in spite of no steering command ment being transmitted.
Page 150: Act/Ach Transistor Regulators
12 V, 1 kOhm phase 2 – CAN2 L 0–5 V In/Out Battery + 48 V Battery - Motor winding U 0–33 V Motor winding V 0–33 V Motor winding W 0–33 V 7 – 34 Repair Manual RRE140/160/180/200/250 © BT...
Page 151 2 CAN2 H 0–5 V In/Out CAN L 0–5 V In/Out Battery + 48 V Battery – Motor winding U 0–33 V Motor winding V 0–33 V Motor winding W 0–33 V © BT Repair Manual RRE140/160/180/200/250 7 – 35...
Page 152 15 V X130:38 Reach carriage - sensor 1 48 V X130:39 Height reference - forks below free lift 48 V X130:40 Height sensor - forks, upper free lift, pulse A 48 V 7 – 36 Repair Manual RRE140/160/180/200/250 © BT...
Page 153 0–24 V PWM Out X131:42 CAN1 low 0,5–2,5 V In/Out a."Mast near to lowered position" when height measurement is not used. b."Forks near top of mast" when height measurement is not used. © BT Repair Manual RRE140/160/180/200/250 7 – 37...
Page 154: Symptom Tables
Grease on the friction surfaces Replace the friction disc and readjust the play. Uneven brak- Voltage too low. Check the truck battery. Charge if nec- essary. ing effect 7 – 38 Repair Manual RRE140/160/180/200/250 © BT...
Page 155: Telescopic Forks
Too great a tolerance The outer forks are worn or have been Replace the outer forks overloaded, resulting in the underside between the inner of the outer forks becoming perma- and outer fork nently deformed © BT Repair Manual RRE140/160/180/200/250 7 – 39...
Page 156 Troubleshooting Symptom tables T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 7 – 40 Repair Manual RRE140/160/180/200/250 © BT...
Page 157: Frame/Chassis 0000
• Loosen the screw (8 mm allen screw) beside the operator seat and swing the door out. To close the motor compartment: • Close the door by swinging it in and tighten the screw. © BT Repair Manual RRE140/160/180/200/250 8 – 1...
Page 158: Operator Cabin (0500)
Ensure nobody is present in the motor compartment when tilting. 1. Shift the fork lift hydraulic lever forwards until the cabin stops in its normal position. 8 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 159: Operator Compartment (0600)
This panel is also fixed in place with a snap fastener (c). Remove the entire panel. 3. The remaining panels can now be removed one by one in se- quence, without the use of tools. 4. Refit in reverse order. © BT Repair Manual RRE140/160/180/200/250 8 – 3...
Page 160: Safety Equipment (0800)
2. Check the following for cracks and secure mounting: - The casing (c) - The finer mesh guard (b) (option) - The transparent top (a) (option) - The protective grating (d) (option). 8 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 161: Adjusting The Tilt Stops (0840)
6. Re-shim the stop so that the distance between it and the floor is as close to 15 mm as possible. The distance may not exceed 15 mm. 7. Refit in reverse order. Max. 15 mm © BT Repair Manual RRE140/160/180/200/250 8 – 5...
Page 162 Frame/Chassis 0000 Safety equipment (0800) T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 8 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 163: Motors 1000
2. Scrape the surface clean where the new temperature sensor is to be mounted. 3. Place the temperature sensor as shown in the illustration. © BT Repair Manual RRE140/160/180/200/250 9 – 1...
Page 164: Replacing The Motor Speed Sensor
3. Loosen the cable connection of the sensor (c) from the motor by pushing in the locking pin on the rear of the contact. 4. Reassemble in reverse order. Tightening torque 6 Nm. 9 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 165: Pump Motor (1710)
This section contains instructions for bearing replacement and shaft seals. For removal of the pump motor from the truck, removal of the hydraulic pump, and refitting of these, see the section "Hydraulic unit (6100)". The pump motor dismantled © BT Repair Manual RRE140/160/180/200/250 9 – 3...
Page 166: Replacing The Bearing On The Pump Motor
4. Remove the pulse transducer (d) (5 mm allen screw) from the N- shield and loosen the cable clamp (f) (3 mm allen screw) 5. Lift out the N-shield (e) and spring washer (j). 9 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 167 8. Remove the D-shield (a) from the stator. 9. Remove the locking ring (o) and support ring (p). 10. Remove the bearings (s, q) from the rotor and the D-shield with a puller. © BT Repair Manual RRE140/160/180/200/250 9 – 5...
Page 168: Assembling The Pump Motor
10. Place the four long screws (c) - tightening torque 15 Nm. 11. Place the pulse transducer (d) in the N-shield and attach the cable clamp (f). 12. Attach the pulse transducer's connector unit in the bracket under the power terminal block. 9 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 169: Steering Motor And Steering Unit (1730)
The steering motor can turn the drive unit through 360°. This section contains instructions for steering motor replacement. 9.3.2 Layout of the flange holes View from the steering motor underside. a: Mounting, b: Steering, c: Threaded M10 holes © BT Repair Manual RRE140/160/180/200/250 9 – 7...
Page 170: Removing The Steering Motor From The Truck
1. Clean the guide pin hole in the motor bracket and place the motor. Tightening torque 45 Nm. 2. Connect the connector unit for the steering motor and press the locking catch in. 9 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 171: Fan Motor/Fan (1740)
2. The top cover (a) can be lifted off without any tools (snap fastener). 3. The cover at the fan exhaust is screwed on with three screws (b) (12 mm allen screws). © BT Repair Manual RRE140/160/180/200/250 9 – 9...
Page 172 (e) in the cool- ing block. Standard model Ergo model 8. Screw the cooling fan in place. 9. Connect the harness. 10. Refit any covers or the floor. 9 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 173: Replacing The Motor Compartment Cooling Fan
4. Remove the cooling fan from the air duct - 4 slot-head screws (b). 5. Place the new cooling fan. 6. Screw the cooling fan in place. 7. Connect the harness. © BT Repair Manual RRE140/160/180/200/250 9 – 11...
Page 174: Drive Motor (1760)
The drive motor is integrated with the drive gear to form a complete drive unit that can be steered through 360°. This section contains instructions for drive motor replacement, disman- tling/assembly of the drive motor, and bearing replacement. The drive motor dismantled 9 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 175: Removing The Drive Motor From The Truck
2. Disconnect the power cables from the drive motor. × 3 13 mm 3. Undo the connector unit for the temperature sensor and pulse transducer. 4. Undo the brake cable connector unit. © BT Repair Manual RRE140/160/180/200/250 9 – 13...
Page 176 The motor weighs approximately 40 kg. IMPORTANT! Risk of spline damage. The splines on the end of the motor are easily damaged. Be careful when lifting out the motor. 9 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 177: Dismantling The Drive Motor
4. Unscrew the four screws (h) that hold the power terminal block (j) in the N-shield. 5. Remove the two locking rings (e) from the motor shaft. 6. Remove the long screws (c). 7. Lift the N-shield and the rotor (k) from the stator. © BT Repair Manual RRE140/160/180/200/250 9 – 15...
Page 178: Cleaning
The motor should be cleaned dry, preferably by vacuuming it. Do not wash the motor in water. The insulation resistance on a cleaned and dry motor should be in excess of 1 G ohm under cool conditions. 9 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 179: Assembling The Drive Motor
4. Insert the rotor shaft in the bearing and place the locking rings (e) on the rotor shaft. 5. Insert the rotor (k) with the N-shield in the stator. © BT Repair Manual RRE140/160/180/200/250 9 – 17...
Page 180 8. Refit the speed sensor (d) along with its harness (g). 9. Replace the contact in the holder under the power cables. 10. Fit the parking brake - see the section "Fitting the parking brake to the truck". 9 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 181: Fitting The Drive Motor To The Truck
5. Connect the power cables of the motor – tightening torque 20 Nm. 6. Connect up the connector unit for the sensor and brake. 7. Place the cap in the centre of the parking brake (2.5 mm allen screws). © BT Repair Manual RRE140/160/180/200/250 9 – 19...
Page 182 Motors 1000 Drive motor (1760) T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 9 – 20 Repair Manual RRE140/160/180/200/250 © BT...
Page 183: Drive Gear 2000
6. Fill the gearbox up with new oil as far as the upper oil level plug (a). 7. Change the seal on the oil level plug (a) and fit it. © BT Repair Manual RRE140/160/180/200/250 10 – 1...
Page 184: Replacing The Drive Gear
Removing a drive motor from the truck See the section "Removing the drive motor from the truck". Removing a steering motor from the truck See the section "Removing the steering motor from the truck". 10 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 185: Removing The Drive Gear From The Truck
5. Undo the six gear screws. 6. Place a block of wood, approximately 70×70 mm, under the gear. 7. Lower the truck so that the gear is resting on the block of wood. © BT Repair Manual RRE140/160/180/200/250 10 – 3...
Page 186 9. Raise the truck by 21 cm and chock up the truck. 10. Lower the gear onto the floor. 11. Extract the gear in a lying down position. The gear weighs approxi- mately 60 kg. 10 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 187: Replacing The Pinion Gear, Input Shaft
- Loosen the nut on the puller to release the pinion gear. 4. Pull the bearing (c) off the pinion gear with a claw puller. a. Seal b. Locking ring c. Bearing d. Pinion gear e. Sealing ring © BT Repair Manual RRE140/160/180/200/250 10 – 5...
Page 188: Placing A New Ball Bearing
® 4. Apply grease sparingly to the seal. Apply LOCTITE 574 to the out- er edge of the seal. 5. Use tool 257414 to push the seal in until it makes contact. 10 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 189: Placing The Drive Gear In The Truck
7. Raise the truck and place the drive wheel. Hand tighten the nuts as tight as possible. 8. Lower the truck onto the wheel. 9. Tighten the drive wheel nuts to a torque of 130 Nm. © BT Repair Manual RRE140/160/180/200/250 10 – 7...
Page 190: Placing The Steering Motor In The Truck
10.1.5 Refitting 1. Refit the floor and pedals. Join the connector unit for the pedal har- ness. 2. Refit the fender behind the drive wheel and step. 3. Function test the truck. 10 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 191: Brake And Wheel 3000
Make a note of the number of shims (f) on each spacer (g). 5. Lift off the pressure plate (c) and the disc unit which consists of 4 outer discs (a) and three inner discs (b). 6. Remove the brass plate (h). © BT Repair Manual RRE140/160/180/200/250 11 – 1...
Page 192: Inspection
Check play at two points simultaneously, with 180° between the points. 3. Maximum permitted play = 2.25 mm. 4. Nominal play on a newly adjusted brake should be 1.0 - 1.25 mm. 5. To adjust, remove the aluminium end plate. 11 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 193: Assembling The Multiple Disc Brake
Make sure that the locking shoe (j) is seated correctly in its recess in the support arm. 5. Connect the brake cable harness (k) and check the braking func- tion by pressing the brake pedal fully down. © BT Repair Manual RRE140/160/180/200/250 11 – 3...
Page 194: Parking Brake (3300)
The brake is a safety component. Do not interfere with the brake compo- nents. a. Fixing screws b. Magnet housing c. Pressure plate d. Adjusting screws e. Friction disc Pressure place (fixed) g. Mounting screws h. Hub 11 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 195: Emergency Release Of The Parking Brake
6. The braking force is too low if the brake is released before the torque wrench starts to slip. 7. Adjust brake play to the correct value – see the section "Adjusting play". Check the brake force once more using the torque wrench. © BT Repair Manual RRE140/160/180/200/250 11 – 5...
Page 196: Removing The Parking Brake From The Truck
2. Undo the 3 mounting screws (g) (locked with thread locker). 3. The brake unit can now be dismantled for inspection of its compo- nent parts. 4. Measure the thickness of the friction disc (e). Min. thickness: 10.5 mm Min 10,5 11 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 197: Assembling The Parking Brake
7. Check play again once the screws have been tightened. 8. Repeat the adjustment stage until play is correct. 9. Check play all the way around the pressure plate. The maximum permitted deviation from the play setting is 0.075 mm. © BT Repair Manual RRE140/160/180/200/250 11 – 7...
Page 198: Placing The Parking Brake In The Truck
IMPORTANT! Do not hammer the friction disc onto the motor shaft, as cracks may occur on the brake disc resulting in it breaking. Push the friction disc onto the motor shaft instead. 11 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 199: Drive Wheel (3530)
5. Insert the plank with the wheel so that the wheel finds its proper po- sition. 6. Fit the washers and nuts. 7. Tighten the wheel nuts - tightening torque 130 Nm. 8. Refit the fender by the drive wheel. © BT Repair Manual RRE140/160/180/200/250 11 – 9...
Page 200: Wheel Bolt (3530)
Place the new wheel bolt using the stud bolt tool. Tightening torque: 80 Nm. 5. Place the drive wheel - see the section "Placing the drive wheel on the truck". 6. Insert the battery cut-out connector. 11 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 201: Support Arm Wheel (3550)
5. Remove the screw (e) and screw an M16 screw into the axle (d) and extract this from the support arm. 6. Remove the support arm wheel. © BT Repair Manual RRE140/160/180/200/250 11 – 11...
Page 202: Replacing A Wheel Bearing - Braked Wheel (A)
4. Insert the locking ring (k) in the wheel. 5. Insert the bearing and axle in the wheel. 6. Fit the other locking ring (g). 7. Insert the spacer rings (n) and (m) in the wheel. 11 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 203: Replacing A Wheel Bearing - Unbraked Wheel (B)
6. Place the bearing and axle in the wheel. 7. Place the other bearing (q) in the wheel and place the locking ring (s) on the axle. 8. Place the washers (o, t) on the wheel. © BT Repair Manual RRE140/160/180/200/250 11 – 13...
Page 204: Placing The Support Arm Wheel In The Truck
Replace the protective cover (b) on top of the cable. 5. Replace any guards (a, b) on top of the support arm wheel. 6. Let the support arm down and function test the truck. 11 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 205: Steering System 4000
5. Remove the steering wheel (e) and the spacer (f). 6. Undo the connector unit for the pulse transducer. 7. Remove the three screws (g) (torx 20) that hold the pulse transduc- er (h) in place. 8. Reassemble in reverse order. © BT Repair Manual RRE140/160/180/200/250 12 – 1...
Page 206: Removing The Operating Console From The Truck
3. Undo the connector unit (c) by the wall. 4. Remove the three screws (d) (torx 30) that hold the operating con- sole in place and remove the operating console from the truck. 12 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 207: Replacing The Wiring Harness In The Operating Console
6. Remove the screws (torx 25) and sleeve (g) by the steering wheel module joint. 7. Unscrew the adjusting screw (f) all the way so that the steering wheel module is free of the operating console. © BT Repair Manual RRE140/160/180/200/250 12 – 3...
Page 208 13. Note how the cable is fixed in the operating console and then re- move the cable. 14. Place a new cable and reassemble in reverse order. 12 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 209: Placing The Operating Console In The Truck
2. Tighten the three screws (d) (torx 30) that hold the operating con- sole in place. 3. Connect the connector unit (c) by the wall. 4. Refit the panels around the operating console. © BT Repair Manual RRE140/160/180/200/250 12 – 5...
Page 210: Steering Reference Sensor (4350)
1. Remove the screw holding the old sensor (5 mm allen screw). 2. Undo the connector unit for the sensor. 3. Place the new sensor and screw it tight. 4. Connect the harness. 5. Refit the floor. 12 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 211: Steering Bearings (4380)
12.3.2 Placing a steering bearing on the drive gear 1. Apply Loctite 242 to the screws (a). 2. Using the screws (a), place the steering bearing (b) on the drive gear. Tightening torque 23 Nm. © BT Repair Manual RRE140/160/180/200/250 12 – 7...
Page 212 Steering system 4000 Steering bearings (4380) T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 12 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 213: Electrical System 5000
13.1 Battery (5110) 13.1.1 Battery recommendation Exide gel batteries (Sonnenschein, for example) In BT's tests with Exide gel batteries, no recommendations were obtained for parameter setting on any of BT's products. BT does not therefore recommend these batteries. Hawker Evolution gel batteries After carrying out trials and tests, there are recommended parameter settings for RRE with the Hawker Evolution gel battery.
Page 214: Battery Installation
13.1.3 Setting battery parameters Parameter settings for valve-controlled batteries (VRLA) BT recommends that when setting parameter 107in a Reflex truck with Hawker Evolution batteries, the recommended value for wet batteries should be reduced by six (6) units. DANGER! The battery's service life will be reduced if the value of parameter 107 is set to a value that is too high.
Page 215: Control Console (5510)
- Pull the top of the control upwards. - Press the new top tightly into place on the control. 7. Reassemble in reverse order. © BT Repair Manual RRE140/160/180/200/250 13 – 3...
Page 216: Removing The Control Console From The Truck
6. Release the control console by lifting it straight up. Take care that the catch does not break off. 7. Remove the control console with its attendant wiring harness; be careful with the connector units. 13 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 217: Replacing The Access Card's Circuit Board
1. Insert a screwdriver in the small hole to release the catch that locks the access card unit (a). 2. Undo the cable connection. Angle the access card unit slightly so as to draw it through the hole. 3. Connect the new card and refit. © BT Repair Manual RRE140/160/180/200/250 13 – 5...
Page 218: Dismantling The Control Console
2. Remove the cover (a). 3. Remove the three screws (c) (torx 20) on the bottom of the control console in order to release the lower cover (b). 13 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 219 7. Remove the 10 screws (j) (torx 20) from the bottom that hold the in- ner plate (g) against the bottom section (h). 8. Release the panel adjustment catch (k) from its retainer in the sled and lift the inner plate out (g). © BT Repair Manual RRE140/160/180/200/250 13 – 7...
Page 220: Installing An Extra Push Button
2. Remove the two screws (b) that hold the selector (a) in the panel. 3. Undo the cable connection and remove the selector from the panel. 4. Reassemble in reverse order. 13 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 221: Replacing The Display
Press together, and use the catch to pull the contact to- gether; then lock the catch in place on the contact. 4. Reassemble in reverse order. 13.2.6 Assembling the control console Reassemble in reverse order. © BT Repair Manual RRE140/160/180/200/250 13 – 9...
Page 222: Placing The Control Console In The Truck
4. Rotate the catch (f) so that it points to the side. 5. Connect the two contacts (c) under the armrest. 6. Place the cable clamp (d) (10 mm hex). 7. Replace the box (b) under the armrest, and the armrest (a). 13 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 223: Parameter Settings
The value is saved by pressing the green button (I). The parameter's default value can be selected by selecting the factory icon and pressing the green button (I). © BT Repair Manual RRE140/160/180/200/250 13 – 11...
Page 224: Driver Parameter Modification
The last driver parameter is the parameter for cabin tilt height. This parameter uses a special screen as shown below. The height is edited by pressing the + and - keys or using the numeric keys. 13 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 225: Pin Menu
A new PIN code is entered using the numerical buttons in the PIN box. The value is saved in the MCU by pressing the green button (I). © BT Repair Manual RRE140/160/180/200/250 13 – 13...
Page 226: Calibrations
5. At approximately 0.5–1 second intervals, press the minus button until the forks have very low constant speed (obtained by the pilot valve). 6. Calibration 2 (free lowering) is now complete. Repeat on valve 4 (main lowering). 13 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 227: Reach Movement Valve Calibration
25 mA at a time, until it starts to move on its own. 13. At approximately 0.5–1 second intervals, press the minus button until the reach carriage halts. 14. Calibration of valve 6 is complete. © BT Repair Manual RRE140/160/180/200/250 13 – 15...
Page 228: Joystick Calibration
11. Read off the weight on the CID screen. Use the plus/minus buttons to adjust the read value to the known weight of the load (± 5 kg). Repeat steps 1 to 8 as necessary. 13 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 229: Height Measurement/Reach Movement Length Calibration
3. Lift the forks until they halt; they will do this at max. free lift height. 4. Using the arrow keys, select the box along the bottom of the screen and press the green button (I). The correct value is read and saved automatically. © BT Repair Manual RRE140/160/180/200/250 13 – 17...
Page 230: Calibrating Reach Movement Length
5. Run out the mast until it stops (mechanical stop). 6. Using the arrow keys, select the box along the bottom of the screen and press the green button (I). The correct value is read and saved automatically. 13 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 231: Transition/Mast Separation Calibration
7. If the forks do not reach "main lift bottom" within a reasonable time (several metres into main lift), raise the value. 8. Repeat stages 5–7 until the downward transition is satisfactory. © BT Repair Manual RRE140/160/180/200/250 13 – 19...
Page 232 Electrical system 5000 Calibrations T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 13 – 20 Repair Manual RRE140/160/180/200/250 © BT...
Page 233 Hydraulic system 6000 Hydraulic unit (6100) Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 14 – Hydraulic system 6000 14.1 Hydraulic unit (6100) Item Function Tank Pump motor Pump © BT Repair Manual RRE140/160/180/200/250 14 – 1...
Page 234 The oil must not be reused and shall be sent for destruction accord- ing to normal procedures. Method b: Use suitable pump to drain the tank. The oil must not be reused and shall be sent for destruction accord- ing to normal procedures. 14 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 235 End with the mast in its fully lowered posi- tion. 8. Quit the truck program's service mode. 9. Check the oil level in the tank and top up as necessary to the right level. © BT Repair Manual RRE140/160/180/200/250 14 – 3...
Page 236 8. Remove the screws (a) (6 mm allen screws) that hold the pump motor mounting to the chassis. Mom 7: M12×1,75 9. Lift out the hydraulic motor with the hydraulic pump and place it on a clean surface. 14 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 237 5. Place a new O-ring on the pump between the pump and pump mo- tor. 6. Place the pump unit on the pump motor. 7. Tighten the screws. × n s mm Mom 7: s = 6, n = 2 23 ±6 Nm © BT Repair Manual RRE140/160/180/200/250 14 – 5...
Page 238 8. Check the oil level and if necessary top up the hydraulic oil in the tank. 9. Before any hydraulic function is initiated: Put the truck program in service mode and activate the service po- sition for bleeding. 14 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 239: Emergency Lowering Of Forks
The screw only needs opening 1½ turns to lower the forks. IMPORTANT! The slot-head screw next to the allen screw must NEVER be removed. 5. Once lowering is complete, tighten the screw to 2.5 Nm only. © BT Repair Manual RRE140/160/180/200/250 14 – 7...
Page 240: Replacing The Complete Main Valve Block
5. Undo the two screws (8 mm allen screws) that hold the protective plate over the main valve in the reach carriage, and remove the plate. 6. Remove all the hoses from the main valve. Mark them to facilitate assembly. 14 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 241 10. Reassemble in reverse order. 11. Before any hydraulic function is initiated: 12. Put the truck program in service mode and activate the service po- sition for bleeding. © BT Repair Manual RRE140/160/180/200/250 14 – 9...
Page 242: Adjustment Of Maximum Opening Point
Use a 3 mm hex-Allen key to change the valve setting: – CW decreases the lowering speed. – CCW increases the lowering speed. 7. Tighten the locking nut and repeat the procedure until correct mo- tion is reached. 14 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 243: Hydraulic Connections (6230)
Dimension Tightening torque [Nm] R 1/8 12-18 R 1/4 25-45 R 3/8 50-70 R 1/2 70-100 R 5/8 100-140 R 3/4 150-200 © BT Repair Manual RRE140/160/180/200/250 14 – 11...
Page 244: Pipe Coupling
GE 6-LM M 10x1 GE 6-LM-ed M 10x1 GE 6-LR R 1/8 GE 6-LR-ed R 1/8 GE 8-LM M 12x1.5 GE 8-LM-ed M 12x1.5 GE 8-LR R 1/4 GE 8-LR-ed R 1/4 14 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 245 R 1 1/4 ~392 GE 35-LR-ed R 1 1/4 ~235 GE 42-LM M 48x2 ~491 GE 42-LM-ed M 48x2 ~294 GE 42-LR R 1 1/2 ~491 GE 42-LR-ed R 1 1/2 ~294 © BT Repair Manual RRE140/160/180/200/250 14 – 13...
Page 246: Quick Change Connector
(2) runs freely in the groove. 2. Push the male fitting into the female fitting until the assembly stop makes contact with the female fitting. 3. The coupling is now made and locked. 14 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 247: Dismantling The Quick Change Connector
2. Push the male fitting all the way into the female fitting. 3. Pull the male fitting out of the female fitting. 4. Refit the assembly stop on the male fitting. 5. Place protective plugs on the valve and hose. © BT Repair Manual RRE140/160/180/200/250 14 – 15...
Page 248: Hydraulic System, Mast (6300)
The stated values apply as guideline values. Spring preloading (turns) Hose diameter Hose length (m) (mm) 1.5-2 The hose is only pulled out from the drum once the correct preloading value has been reached. 14 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 249: Checks After Fitting
The spring-loaded eye must face the direction in which the hose un- winds. Spare parts must conform to the technical specifications laid down by the manufacturer. This requirement is always met if original spare parts are used. © BT Repair Manual RRE140/160/180/200/250 14 – 17...
Page 250: Main Lift Cylinder (6610)
1. Remove the hydraulic hose from the quick change connector and plug it. 2. Unscrew the quick change connector from the cylinder. 3. Put a new quick change connector on. 14 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 251: Fitting The Cylinder To The Mast
9. Lower the forks to the bottom. 10. Fit the chain wheel and lifting chain. 11. Adjust the chain so that the mast does not pull to one side at the top. © BT Repair Manual RRE140/160/180/200/250 14 – 19...
Page 252: Free Lift Cylinder (6620)
16. Lower the free lift cylinder. 14.6.2 Replacing the hose rupture valve, free lift cylinder The hose rupture valve (lowering brake valve) is fitted in the hydraulic cylinder's pipe connection and can be replaced using standard tools. 14 – 20 Repair Manual RRE140/160/180/200/250 © BT...
Page 253: Placing The Free Lift Cylinder In The Truck
10. Place the twin hose and the cable on the free lift cylinder’s hose reels. 11. Take away the traverse. 12. Remove the plugs on the free lift cylinder. 13. Fit the feeder pipe to the free lift cylinder. © BT Repair Manual RRE140/160/180/200/250 14 – 21...
Page 254: Reach Cylinder (6650)
2. Put the locking rings in position on the pins. 3. Fit the hoses to the cylinder. 4. Fit the reach carriage graduated rule. This has a snap fastener at each end and is attached by gently pressing on it. 14 – 22 Repair Manual RRE140/160/180/200/250 © BT...
Page 255: Fork Tilt Cylinder (6660)
7. Remove and plug the hydraulic lines to the tilt cylinder (e). 8. Remove the tilt cylinder (e). 9. Placing the tilt cylinder in the fork carriage 10. Refit in reverse order. © BT Repair Manual RRE140/160/180/200/250 14 – 23...
Page 256 Hydraulic system 6000 Fork tilt cylinder (6660) T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 14 – 24 Repair Manual RRE140/160/180/200/250 © BT...
Page 257: Mast/Lift System 7000
815, 816 15 – Mast/Lift system 7000 15.1 Main mast 1.6-2.5 t (7100) 15.1.1 Replacing the full mast When ordering a replacement mast, TMHE Technical Support should be contacted to identify the mast. © BT Repair Manual RRE140/160/180/200/250 15 – 1...
Page 258: Replacing The Mast Damper Plates
5. If the plate is not worn out, the play in relation to the mast can be adjusted using plate shims behind the plate. The shims are availa- ble in two thicknesses: 0.5 mm and 1 mm. 15 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 259: Removing The Mast From The Truck
11. If the truck is fitted with extra hydraulic functions, loosen the hy- draulic hoses from the valve block on the reach carriage. Fit protec- tive plugs on hoses and valve block. © BT Repair Manual RRE140/160/180/200/250 15 – 3...
Page 260 16. Turn the eccentric cams (e) (60 mm hexagonal screw) so that the large level surfaces (f) are facing downwards. 18. Lift out the mast. 15 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 261 + 2 metres safety distance. Always stand to the side of the mast at a safe distance, as far away as the controls of the traverse will allow. 21. Wipe or wash off any oil spillage on the truck. © BT Repair Manual RRE140/160/180/200/250 15 – 5...
Page 262: Adjusting Mast Play
Leaking oil. Risk of valve or cylinder failure if dirt enters the hydraulic connec- tions. Plug all hydraulic connections. 2. Place the mast horizontally on a number of pallets or similar items. 15 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 263 - The twin hose (c) from the mast, but leave it in the outer runner. - The feeder hoses (d) for the main lift cylinders. - The feeder hose brackets (e) and the hose (f) for the free lift cylin- der from the inner runner. © BT Repair Manual RRE140/160/180/200/250 15 – 7...
Page 264 - The main lift cylinders (h). - The main lift chains (j), but leave them in the outer runner. - The main chain rollers (k) and the twin hose reel (m) at the bottom of the mast. 15 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 265: Adjusting Lateral Play
5. Remove: - The fork carriage (n) from the mast. - The inner runner (o) from the mast using the BT lifting yoke (see the section "Tools"). - Pull out the inner runner to its full travel length and lift out the run- ner.
Page 266: Adjustment Of Radial Play
The end position dampers are adjusted using washers so that the damper stops the runners simultaneously on both sides, and the ends of the beams are level at the end position - see the diagram. 15 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 267: Adjusting The Damper Plate
The twin hose is liable to separate. Risk of the twin hose breaking. Make sure the twin hose rollers are in line. Fit the mast to the truck - see the section "Placing the mast on the truck". © BT Repair Manual RRE140/160/180/200/250 15 – 11...
Page 268: Placing The Mast On The Truck
3. Turn the eccentric cams (e) so that the largest level surfaces attain a horizontal position facing downwards. 4. Lubricate the cups on the mast attachment (k) in the reach carriage with MoS2 grease. 15 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 269 7. If necessary, the mast and reach carriage are centred using the ad- justing screws (h) by alternately moving the adjusting screw on one side and loosening on the other. Refit the locking screw (b). © BT Repair Manual RRE140/160/180/200/250...
Page 270 13. Check the incline to the rear (90° ± 10‘) once more, and add shims as needed. 15 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 271 20. Connect the hydraulic hoses to the tilt cylinder (A1 and B2). 21. Connect any electric cables for extra functions on the mast. 22. Bleed the hydraulic system - see the section "Hydraulic system, bleeding". © BT Repair Manual RRE140/160/180/200/250 15 – 15...
Page 272: Main Lift Chain System (7120)
The chain should be replaced. Rusty links Fretting corrosion results in a reddish brown powder being visible near the outer plates. The chain can also appear to bleed when lubricated. The chain should be replaced. 15 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 273: Stiff Links
Loose bolts If a bolt is loose it will protrude from the side of the chain, and this is due to a stiff link or bolt rotation. The chain should be replaced. © BT Repair Manual RRE140/160/180/200/250 15 – 17...
Page 274: Plate Wear
The nominal and minimum plate heights for the relevant lift chain are specified in the table in the section "Elongation". 15 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 275: Elongation
One cause of chain elongation is wear on the bolts and around the holes in the plates. The chain must be replaced if elongation exceeds Damage If there is any other damage, the chain should be replaced. © BT Repair Manual RRE140/160/180/200/250 15 – 19...
Page 276: Damaged Plates
Do not use a special rust protective agent to prevent rust attack on the lift chains. These agents impair lubrication of the chains. Regular lubrication is the best way of preventing rust attack. 15 – 20 Repair Manual RRE140/160/180/200/250 © BT...
Page 277: Main Lift Chain System, Adjusting The Fork-To-Floor Distance
Then the forks are adjusted so that the fork holes are 10-15 mm from the floor. 10-15 mm IMPORTANT! The forks should be tilted into their horizontal position. © BT Repair Manual RRE140/160/180/200/250 15 – 21...
Page 278: Reach Carriage (7190)
6. Slowly run the reach movement fully in and out again; do this care- fully so that the load holds the rear runners against the top beam flanges for the entire time. 15 – 22 Repair Manual RRE140/160/180/200/250 © BT...
Page 279 11. Withdraw the feeler gauge. (If the feeler gauge has got stuck, give the tool in the eccentric axle a slight tap in the opposite direction so that the feeler gauge comes loose). 12. Reset the truck for normal operation. © BT Repair Manual RRE140/160/180/200/250 15 – 23...
Page 280: Adjusting Axial Play In The Reach Carriage
9. If necessary, adjust the stop on the side the roller strikes first by sanding it down until both rollers strike the stop simultaneously. 15 – 24 Repair Manual RRE140/160/180/200/250 © BT...
Page 281: Lifting Devices (7400)
(c, d), including their attachments to the shaft (b). The fork must be taken out of service if surface cracks are discovered. © BT Repair Manual RRE140/160/180/200/250 15 – 25...
Page 282: Difference In Height Between The Fork Tips
Perform sim- ilar checks on other types of mounting fixings. 15 – 26 Repair Manual RRE140/160/180/200/250 © BT...
Page 283: Forks, Repairs And Testing
Specified capacity for fork Test load F t m ≤5000 2.5 m m >5000 2.1 m Fork a. Fork b. Bracket c. Tension pin d. Washer e. Spring Lock © BT Repair Manual RRE140/160/180/200/250 15 – 27...
Page 284: Fork Carriage
Tighten the four screws to 45 ±11 Nm. 4. The gap can be adjusted with the screws on the stop lug (see the screws marked with arrows). Max tilt angle a: Maximum tilt angle 15 – 28 Repair Manual RRE140/160/180/200/250 © BT...
Page 285: Lubricating The Fork Carriage
The following locations should be lubricated once a year: • Between the ball beam and the wear strip of the side shift unit (a) • Between the yoke and the friction plate (b) © BT Repair Manual RRE140/160/180/200/250 15 – 29...
Page 286: Fork Spread Unit
• Check the forks. The thickness of the blade or shaft should be at least 90% of the original thickness in accordance with ISO 5057. • Check the screws and nuts. If necessary, tighten as normal. 15 – 30 Repair Manual RRE140/160/180/200/250 © BT...
Page 287: Replacing Bearings
1. Remove the tension pin (g) from the fork lug. 2. Push the axle (f) out. 3. Remove the roller (h). 4. Place a new roller in position. 5. Push the axle in. 6. Fit the tension pin. © BT Repair Manual RRE140/160/180/200/250 15 – 31...
Page 288: Fork Extensions With Adjustable Fork Length
• Check the function and safety of the locking pin. To fit the forks, use the following locking pin: Check that the fork extension is firmly attached; pull on the fork exten- sion to check it is secure. 15 – 32 Repair Manual RRE140/160/180/200/250 © BT...
Page 289 Fork extensions with adjustable fork length Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 a. Fork extension b. Fork, main segment c. Fork, extension d. Fork, extension e. Pin Lock © BT Repair Manual RRE140/160/180/200/250 15 – 33...
Page 290: Manual Telescopic Forks
The stop screw (c) must be screwed into the extended section and se- cured using Loctite 242, for example. It may only be removed to allow replacement of the extended section. It must then be screwed back in and secured. 15 – 34 Repair Manual RRE140/160/180/200/250 © BT...
Page 291: Maintenance
• Check for wear to the extended section (t=>3 mm) • Check the extended section for deformation and cracks • Check the locking bolt and its function IMPORTANT! Always replace the forks in pairs. © BT Repair Manual RRE140/160/180/200/250 15 – 35...
Page 292: Hydraulic Telescopic Forks
15.9 Hydraulic telescopic forks The KOOI forks can be extended hydraulically. They come in two types: telescopic forks with separate flow dividers and telescopic forks with an integrated system for flow distribution. 15 – 36 Repair Manual RRE140/160/180/200/250 © BT...
Page 293: Telescopic Forks With Separate Flow Dividers
Support ring Piston rod Complete cylinder head Attachment screw Washer Plastic plug Washer Serial number on inner M10 special bolt fork Piston with seals Sealing strip, inner fork Cylinder head with seals © BT Repair Manual RRE140/160/180/200/250 15 – 37...
Page 294: Fitting Instructions
2. Move the mast from its front to rear position several times. 3. Run the forks in and out ten times. 4. Check that the hoses can move freely. 5. Check the system for oil leaks. 15 – 38 Repair Manual RRE140/160/180/200/250 © BT...
Page 295: Telescopic Forks With Integrated Flow Dividers
T-code 261828-040 2008-08-21 6051502 815, 816 15.9.2 Telescopic forks with integrated flow dividers a. Telescopic forks, pair of forks b. Piston c. Cylinder head d. Friction plate e. Outer fork Piston rod © BT Repair Manual RRE140/160/180/200/250 15 – 39...
Page 296: Fitting Instructions
3. Move the forks in and out a number of times. 4. Check that the hoses are not blocked and that the system is not leaking oil. 15 – 40 Repair Manual RRE140/160/180/200/250 © BT...
Page 297: Maintenance Of Telescopic Forks
6. Once the outer fork has been removed you can easily check the cylinder head. (e) © BT Repair Manual RRE140/160/180/200/250 15 – 41...
Page 298: Dismantling Telescopic Forks
11. Replace the parts. 12. Remove all Loctite from the piston rod thread. 13. Clean the piston rod and thread with Loctite 7063. 14. The cylinder head can now be reinstalled on the piston rod. 15 – 42 Repair Manual RRE140/160/180/200/250 © BT...
Page 299: Assembling Telescopic Forks
For forks with separate flow dividers, the forks must be extended and retracted several times. © BT Repair Manual RRE140/160/180/200/250 15 – 43...
Page 300 Mast/Lift system 7000 Hydraulic telescopic forks T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 15 – 44 Repair Manual RRE140/160/180/200/250 © BT...
Page 301: External Equipment 8000
External Equipment 8000 Introduction Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 16 – External Equipment 8000 16.1 Introduction This section is reserved for future use. © BT Repair Manual RRE140/160/180/200/250 16 – 1...
Page 302 External Equipment 8000 Introduction T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 16 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 303: Options 9000
Options 9000 Introduction Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 17 – Options 9000 17.1 Introduction This section is reserved for future use. © BT Repair Manual RRE140/160/180/200/250 17 – 1...
Page 304 Options 9000 Introduction T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 17 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 305: Appendix "Destruction Instructions
• 02: PE-HD – Polyethylene with High Density • 03: PVC – Polyvinyl chloride • 04: PE-LD – Polyethylene with Low Density • 05: PP - Polypropylene • 06: PS – Polystyrene • 07: O – Others © BT Repair Manual RRE140/160/180/200/250 18 – 1...
Page 306: Marking According To Our Standard
Products made from a single substance ABS (acrylonitrile/butadiene/polystyrene): >ABS< Polyurethane: >PUR< Plastic compounds A compound based on acrylonitrile/butadiene/polystyrene and carbon- ate plastic: >ABS+PC< Filled or reinforced materials Polypropylene with 30% mineral powder: >PP-MD30< 18 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 307: Pressure Vessels
20 mm 1: Drill or cut a hole in the cylinders, approximately 20 mm from the bot- tom. 2: Drill or cut a hole in the cavity at the piston rod end. © BT Repair Manual RRE140/160/180/200/250 18 – 3...
Page 308: Sorting Categories
• Hydraulic hoses: Oil polluted mate- Carefully drain all oil. rial Any accumulators should • Oil tank: >PP< be emptied of gas and if possible opened. • Motor, valves: Electronic parts • Pump: Iron/steel • Accumulator: Iron/steel 18 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 309 • Hydraulic hoses: Oil-polluted () • Cables • Sensors/switches: Electronic parts • Plastic components: According to marking or as combustible waste Chargers and connec- • Electronic parts tors • Cables © BT Repair Manual RRE140/160/180/200/250 18 – 5...
Page 310 Appendix “Destruction instructions” Sorting categories T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 18 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 311 Position for reach carriage, Inductive sensor Distance: 0-6.5 mm sensor 1 Position for reach carriage, Inductive sensor sensor 2 B28* Cabin tilt in lowest position Inductive sensor B29* Cabin tilt in highest position Inductive sensor © BT Repair Manual RRE140/160/180/200/250 19 – 1...
Page 312 Lamp Working light Lamp Working light Lamp Working light Lamp E10* Seat heater Resistor Fuse for [T1] Fuse 160 A/200 A Fuse for [T2] Fuse 250 A/325 A Fuse for relays Fuse 19 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 313 Pump motor 3 phase AC motor Steering servo motor Step motor Horn Horn Warning lamp LEDs Flashing: ~2 Hz Nominal current: 70 mA Load Information Display PCB with display (LID) Vehicle alarm Horn © BT Repair Manual RRE140/160/180/200/250 19 – 3...
Page 314 Power relay Q32* Relay for defroster Power relay Heater element Heater element 4x400 W Heater element Heater element 4x400 W Speed control Resistor Speed control Resistor Temperature control Potentiometer Temperature control Potentiometer 19 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 315 Connection for General Contact Function Unit (GFU) Connection for service key CAN contact Socket 48 V DC Contact X43* Socket 12 V DC Contact X44* Socket 24 V DC Contact * option © BT Repair Manual RRE140/160/180/200/250 19 – 5...
Page 316: Overview
Wiring diagrams Overview T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19.2 Overview 19 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 317: Wiring Diagrams
Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 19.3 Wiring diagrams © BT Repair Manual RRE140/160/180/200/250 19 – 7...
Page 318 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 319 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 9...
Page 320 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 321 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 11...
Page 322 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 12 Repair Manual RRE140/160/180/200/250 © BT...
Page 323 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 13...
Page 324 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 14 Repair Manual RRE140/160/180/200/250 © BT...
Page 325 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 15...
Page 326 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 16 Repair Manual RRE140/160/180/200/250 © BT...
Page 327 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 17...
Page 328 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 18 Repair Manual RRE140/160/180/200/250 © BT...
Page 329 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 19...
Page 330 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 20 Repair Manual RRE140/160/180/200/250 © BT...
Page 331 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 21...
Page 332 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 22 Repair Manual RRE140/160/180/200/250 © BT...
Page 333 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 23...
Page 334 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 24 Repair Manual RRE140/160/180/200/250 © BT...
Page 335 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 25...
Page 336 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 19 – 26 Repair Manual RRE140/160/180/200/250 © BT...
Page 337 Wiring diagrams Wiring diagrams Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 19 – 27...
Page 338 Wiring diagrams Wiring diagrams T-code Valid from serial number Date Publication No.815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 19 – 28 Repair Manual RRE140/160/180/200/250 © BT...
Page 339: Hydraulics Schematics
Free lift (initial lift) Reach carriage - Out Main lift Extra function, pump pressure for A1 Main lift Extra function, pump pressure for B1 Pressure sensor H1 Tank connection Measuring point H2-H3 © BT Repair Manual RRE140/160/180/200/250 20 – 1...
Page 340: Rre Ergo
Free lift (initial lift) Extra function, pump pressure for B1 Main lift Cabin tilt - up Main lift Cabin tilt - down - and emergency Pressure sensor H1 lowering Measuring point H2-H3 Tank connection 20 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 341: Schematics Designations
Reach carriage - out Magnetic valve Extra function, direction A Magnetic valve Extra function, direction B Magnetic valve Cabin tilt - upwards Magnetic valve Cabin tilt - downwards Magnetic valve Tank Tank © BT Repair Manual RRE140/160/180/200/250 20 – 3...
Page 342: List Of Symbols
Priority flow valve Counter balance valve Directional valve 4/3 (above centre valve) Directional valve 6/3 Proportional valve 4/3 Electric motor and pump Filter Tank Non-return valve Counter balance valve Directional valve 6/2 20 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 343: Wiring Diagrams Rre/Rre Ergo
Hydraulics schematics Hydraulics schematics Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 20.2.3 Wiring diagrams RRE/RRE Ergo © BT Repair Manual RRE140/160/180/200/250 20 – 5...
Page 344 Hydraulics schematics Hydraulics schematics T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 20 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 345 Hydraulics schematics Hydraulics schematics Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 20 – 7...
Page 346 Hydraulics schematics Hydraulics schematics T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 20 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 347 Hydraulics schematics Hydraulics schematics Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 © BT Repair Manual RRE140/160/180/200/250 20 – 9...
Page 348 Hydraulics schematics Hydraulics schematics T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 20 – 10 Repair Manual RRE140/160/180/200/250 © BT...
Page 349: Tool
Tool for removing pins/sleeves 213298 (MPT) Tool for removing pins/sleeves 1=163787 (JPT) Tool for fitting sleeves 2=163788 (JPT) 1=213336 (MPT) 2=213337 (MPT) 1=213336 (JPT) Tool for fitting pins 2=213549 (JPT) For 0.5–2.5 mm © BT Repair Manual RRE140/160/180/200/250 21 – 1...
Page 350: Amp Microtimer
Tool AMP microtimer T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 21.2 AMP microtimer Tool Number 141199 Tool for fitting pins/sleeves 650006 Tool for removing pins/sleeves 21 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 351: Mqs Contacts
25 jointing sleeves 0.5–1.5 mm 2 each of 2-, 3-, 4-, 6-, 8- and 12-pole connector pairs (male and female) with cables and jointing sleeves fitted. Used for replacing damaged connec- tors in the truck. © BT Repair Manual RRE140/160/180/200/250 21 – 3...
Page 352 MQS SWS 0.25–0.5 mm MQS SWS 0.5–0.75 mm MQS Std. & "clean body" 0.25–0.5 MQS Std. & "clean body" 0.5–0.75 Extraction tools for 2-, 3-, 4-, 6-, 8- and 12-pole male and female connectors. 21 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 353: Other Tools
T-code 261828-040 2008-08-21 6051502 815, 816 21.4 Other tools Tool Number 156263 Service instrument (CAN) Anti-static mat for electronic work 808-413 Socket for support arm wheel 808-4XX 219730 Pressure measurement for hydraulics © BT Repair Manual RRE140/160/180/200/250 21 – 5...
Page 354 1/2” — 254528 nector 1/4” — 254529 Plugs (female part) for hydrau- 3/8” — 254530 lic hoses with WEO type quick 1/2” — 254531 change connector 11-999-8 Lifting tool for battery 1,500 kg max. 21 – 6 Repair Manual RRE140/160/180/200/250 © BT...
Page 355 Other tools Publication No. Date Valid from serial number T-code 261828-040 2008-08-21 6051502 815, 816 Tool Number 11-1242 Lifting tool for mast 11-1091 Lifting tool for mast 11-1133/2 Lifting tool for mast © BT Repair Manual RRE140/160/180/200/250 21 – 7...
Page 356 Tool Other tools T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 Tool Number 11-1020 Lifting tool for mast runner 11-1021 Lifting tool for mast runner 21 – 8 Repair Manual RRE140/160/180/200/250 © BT...
Page 357: Appendix "Service Data And Grease Specifications
22.1 General tightening torques Millimetre threads M3 to M24. The tables apply under good conditions, e.g. steel against steel. 22.1.1 Galvanised non-oiled bolts Tightening torque (Nm) Strength class: 10.9 12.9 1075 © BT Repair Manual RRE140/160/180/200/250 22 – 1...
Page 358: Untreated Oiled Bolts
Do not tighten more than the values set out in the table otherwise the bolts may be destroyed. 22 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 359: Oil And Grease Specifications
< +45 °C Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette > +45 °C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication < +80 °C * Equivalent products from another manufacturer may be used © BT Repair Manual RRE140/160/180/200/250 22 – 3...
Page 360 Appendix “Service data and grease specifications” Oil and grease specifications T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank 22 – 4 Repair Manual RRE140/160/180/200/250 © BT...
Page 361: Technical Data
Support arm wheel, diameter x width, Maximum weight on support arm wheel without load/with load (kg) Maximum weight on drive wheel without load/with load (kg) Maximum wheel pressure, support arm (MPa) Maximum wheel pressure, drive (MPa) © BT Repair Manual RRE140/160/180/200/250 23 – 1...
Page 362 7.5 A F72, Steering motor EPS [M6] 30 A 30 A F73, Controls [T1], [A5] 7.5 A 7.5 A F74, Key relay [A1], [A5] F75, Working light (option) 10 A 10 A 23 – 2 Repair Manual RRE140/160/180/200/250 © BT...
Page 363 (km/h) With support arm brake, drive wheel direction, laden/unladen (km/h) With support arm brake, fork direction, Unladen: 10 Unladen: 10 laden/unladen (km/h) > 1000 kg: 8 > 1000 kg: 8 © BT Repair Manual RRE140/160/180/200/250 23 – 3...
Page 364 Technical data T-code Valid from serial number Date Publication No. 815, 816 6051502 2008-08-21 261828-040 This page is intentionally left blank. 23 – 4 Repair Manual RRE140/160/180/200/250 © BT...

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