Content SM BT Rre160

PICTURE HERE
Repair Manual en
RRE140/160/180/200/250
Valid from serial number: 6070557-
Order number: 7510399-040

Issued: 2009-12-22 ESP
© BT
Document revisions:
Issue date Order Changes

number
2009-06-22 7510399-040 Completely new issue.
2009-XX-XX Updated:
Chapter: 4.1.3, 4.14.4, 5, 8.2.2, 8.5.2, 8.5.4, 8.5.5, 8.6.4, 13.2,
14.8, 15.6, 15.10, 15.11, 16.1.2, 20.1, 22.4
New:
Chapter: 4.1.1, 4.1.2, 4.1.4, 4.5.3, 4.7, 4.9.7, 9.3, 9.4.2, 9.4.3,
14.5, 15.1, 15.3.3, 20.2, 20.7
This manual covers following truck models:
T-code Model Serial number

815 RRE140, RRE140C, RRE140CC,
RRE140E,RRE140EC, RRE140ECC,
RRE160, RRE160C, RRE160CC,
RRE160E, RRE160EC, RRE160ECC
816 RRE180, RRE180C, RRE180CC,
RRE180E, RRE180EC, RRE180ECC,
RRE200E, RRE200EC, RRE200ECC,
RRE250E, RRE250EC, RRE250ECC
© BT Repair Manual RRE140/160/180/200/250

Contents
Order number Date Valid from serial number T-code
7510399-040 2009-12-22 6070557- 815, 816
1 – Contents
2 – General introduction ......................................................................... 2-1
2.1 How to use the manual................................................................... 2-1
2.2 Warning symbols ........................................................................... 2-2
2.3 Pictogram....................................................................................... 2-2
3 – General safety rules .......................................................................... 3-1

3.1 Safety while working ...................................................................... 3-1
3.2 Electrical system ............................................................................ 3-2
3.3 Safe lifting ...................................................................................... 3-3
4 – Function descriptions ....................................................................... 4-1

4.1 Chassis 0000 ................................................................................. 4-1
4.1.1 Operator’s cabin (0500) ................................................... 4-1
Versions for cold-store cabs ............................................ 4-1
Emergency exit from the cab ........................................... 4-2
4.1.2 Cab windows (0530) ........................................................ 4-3
Electrically heated windows ............................................. 4-3
4.1.3 Driver's seat (0620) ......................................................... 4-4
Adjustment: ...................................................................... 4-4
Button for seat heater ...................................................... 4-4
4.1.4 Cab heating/ventilation (0630) ......................................... 4-5
Climate control knobs ...................................................... 4-5
Ventilation ........................................................................ 4-5
Temperature .................................................................... 4-5
4.1.5 Driver protection (0840) ................................................... 4-6
Tilt stops .......................................................................... 4-6
Overhead guard ............................................................... 4-8
4.2 Motors 1000 ................................................................................... 4-9
4.2.1 General ............................................................................ 4-9
4.2.2 Electric pump motor (1710) ............................................. 4-9
General ............................................................................ 4-9
Design ............................................................................. 4-9
4.2.3 Electric steering motor (1730) ....................................... 4-10
General .......................................................................... 4-10
Design ........................................................................... 4-10
4.2.4 Fan motor/fan (1740) ..................................................... 4-11
4.2.5 Electric drive motor (1760) ............................................ 4-12
General .......................................................................... 4-12
Design ........................................................................... 4-12
4.3 Drive gear - 2000 ......................................................................... 4-13
4.3.1 General .......................................................................... 4-13
4.3.2 Design ........................................................................... 4-14
4.4 Brake system 3100 ...................................................................... 4-15
4.4.1 General .......................................................................... 4-15
Travel brake ................................................................... 4-15
Parking brake ................................................................ 4-15
Emergency brake .......................................................... 4-15
4.4.2 Drive motor brake (travel brake) .................................... 4-16
Accelerator released ...................................................... 4-16
Changing the direction of travel ..................................... 4-16
© BT Repair Manual RRE140/160/180/200/250 1– 1

Contents
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-12-22 7510399-040
4.4.3 Multiple disc brake, support arm (travel brake) ............. 4-17
General .......................................................................... 4-17
Design ........................................................................... 4-17
4.4.4 Disc brake on the drive motor (parking brake) .............. 4-18
General .......................................................................... 4-18
Design ........................................................................... 4-18
4.5 Steering system 4000 .................................................................. 4-19
4.5.1 General .......................................................................... 4-19
4.5.2 Design ........................................................................... 4-19
4.5.3 Sensors ......................................................................... 4-20
Steering reference sensor ............................................. 4-20
4.6 Operator compartment................................................................. 4-21
4.6.1 Truck control, overview .................................................. 4-21
Right-hand control panel, single control ........................ 4-21
Right-hand control panel, multi-control .......................... 4-21
Emergency switch ......................................................... 4-22
Steering wheel module .................................................. 4-23
Pedals ............................................................................ 4-23
4.6.2 Single control ................................................................. 4-24
4.6.3 Multi-control ................................................................... 4-25
4.6.4 Central Information Display – CID ................................. 4-26
Navigation ...................................................................... 4-26
LED symbols ................................................................. 4-29
Information symbols ...................................................... 4-30
Driver parameter symbols – Overview .......................... 4-31
Catch symbols – Overview ............................................ 4-32
Service functions ........................................................... 4-34
Calibration functions ...................................................... 4-36
Configuration functions .................................................. 4-38
Other functions .............................................................. 4-41
4.6.5 Load Information Display – LID (option) ........................ 4-43
LED symbols ................................................................. 4-43
Symbols in the display part ............................................ 4-44
4.7 Transducers and sensors (5800) ................................................. 4-45
4.7.1 Inductive sensors ........................................................... 4-45
4.7.2 Position sensor .............................................................. 4-45
4.7.3 Magnetic sensor ............................................................ 4-46
4.8 Operation and connection sequences.......................................... 4-47
4.9 Functions ..................................................................................... 4-80
4.9.1 General overview ........................................................... 4-80
Key ................................................................................ 4-80
Components .................................................................. 4-80
4.9.2 MCU – main control unit ................................................ 4-81
General .......................................................................... 4-81
Downloading software ................................................... 4-81
System communication ................................................. 4-81
4.9.3 ACT/ACH transistor regulators ...................................... 4-82
General .......................................................................... 4-82
4.9.4 Start-up .......................................................................... 4-82
4.9.5 Shutdown ....................................................................... 4-83
4.9.6 Driving ........................................................................... 4-83
Introduction .................................................................... 4-83
Acceleration and speed reduction ................................. 4-83
Reversing ...................................................................... 4-84
Brake ............................................................................. 4-84
Travel speed .................................................................. 4-85
1– 2 Repair Manual RRE140/160/180/200/250 © BT
Contents
7510399-040 2009-12-22 6070557- 815, 816
4.9.7 OTP ............................................................................... 4-86

Travel speed reduction - steering angle ........................ 4-86
Travel speed reduction - extension of reach carriage ... 4-86
Travel speed reduction - mast splitting .......................... 4-86
Prevention of lifting/lowering of the forks ....................... 4-86
Reduced extension speed ............................................. 4-86
4.9.8 Steering ......................................................................... 4-87
Steering position check ................................................. 4-87
Steering speed .............................................................. 4-87
Steering reference ......................................................... 4-88
Travel speed limitation ................................................... 4-88
Compass card ............................................................... 4-88
4.9.9 Hydraulic system ........................................................... 4-89
Definitions ...................................................................... 4-89
Controls ......................................................................... 4-89
Lift .................................................................................. 4-89
Reach movement .......................................................... 4-90
Lift height limitation ........................................................ 4-90
Maximum height limitation ............................................. 4-90
Auxiliary/Extra functions (option) ................................... 4-91
4.10 Height preselector, description of function ................................... 4-92
4.10.1 Using the height preselector .......................................... 4-92
4.10.2 Symbols ......................................................................... 4-92
4.10.3 Buzzer ........................................................................... 4-92
4.10.4 Height preselector levels ............................................... 4-93
4.10.5 Level selection ............................................................... 4-93
4.10.6 Height programming ...................................................... 4-94
4.10.7 Height preselector and TruckCom ................................. 4-95
4.10.8 Lift/lowering movement .................................................. 4-95
4.10.9 Parameter settings, braking at height preselection ....... 4-96
4.11 Hydraulic system 6000................................................................. 4-97
4.11.1 General .......................................................................... 4-97
4.11.2 Tank ............................................................................... 4-97
4.11.3 Filter ............................................................................... 4-97
Return filter .................................................................... 4-97
Dehumidification filter .................................................... 4-97
4.11.4 Hydraulic pump .............................................................. 4-98
4.11.5 Valve block .................................................................... 4-98
Main valve block ............................................................ 4-98
Second valve block ........................................................ 4-99
4.11.6 Cylinders ...................................................................... 4-100
Main lift cylinders ......................................................... 4-100
Free lift cylinder ........................................................... 4-100
Cylinders for the reach movement, cabin tilt, sideshift and fork
tilt ................................................................................. 4-100
4.11.7 Lift and lowering function ............................................. 4-101
Lifting and lowering of free lift ...................................... 4-101
Transition from free lift to main lift ............................... 4-101
Lifting and lowering of main lift .................................... 4-101
Reach movement, in and out ....................................... 4-101
Simultaneous operation of mast lift and reach movement . 4-
102
4.11.8 Extra functions ............................................................. 4-102

Contents
815, 816 6070557- 2009-12-22 7510399-040
4.11.9 Cabin tilt (RRE Ergo) ................................................... 4-102

Hydraulic priority system ............................................. 4-102
Cabin tilt (RRE Ergo) during servicing ......................... 4-103
Cabin tilt in the event of hydraulic or electrical power loss 4-
103
4.12 Mast 7000 .................................................................................. 4-104
4.12.1 Mast and reach carriage .............................................. 4-104
4.13 Lifting devices ............................................................................ 4-105
4.13.1 Fork extensions ........................................................... 4-105
4.13.2 Telescopic forks ........................................................... 4-105
4.14 Accessories – 9000.................................................................... 4-107
4.14.1 Radio equipment ......................................................... 4-107
4.14.2 Extra work lights .......................................................... 4-107
4.14.3 Extra warning light/alarm ............................................. 4-108
4.14.4 Direction indicators ...................................................... 4-108
4.14.5 Travel alarm ................................................................. 4-109
4.14.6 Positioning/TV equipment ............................................ 4-110
4.14.7 Extra electrical equipment ........................................... 4-112
4.14.8 Extra equipment, miscellaneous .................................. 4-113
Fork spacers ................................................................ 4-113
Load support ................................................................ 4-114
E-bar ............................................................................ 4-115
Fire extinguisher .......................................................... 4-116
5 - Parameters .......................................................................................... 5-1

5.1 General .......................................................................................... 5-1
5.2 Displaying/changing parameters.................................................... 5-1
5.3 Operator parameters...................................................................... 5-2
5.3.1 Overview .......................................................................... 5-2
5.3.2 Coupling to logged-in operator ........................................ 5-3
5.3.3 Description ....................................................................... 5-4
Parameter 1 (Steering) .................................................... 5-4
Parameter 2 and 3 - Maximum travel speed ................... 5-6
Parameters 4 and 5 - Acceleration/Retardation .............. 5-6
Parameter 6 - Cab tilt ...................................................... 5-6
5.4 General service parameters........................................................... 5-7
5.4.1 Overview .......................................................................... 5-7
5.4.2 Description ....................................................................... 5-7
Parameter 101/104 - Service/Log-out ............................. 5-7
Parameter 105/106/114/115/117 (Travel alarms 1 and 2) 5-8
Parameter 107/108 - Battery ......................................... 5-10
Parameter 109/110/111/112 - Collision sensor ............. 5-13
Parameter 113 (shunt value) ......................................... 5-14
Parameter 116 (Door for cold storage cab) ................... 5-15
5.4.3 Service parameters, travel functions ............................. 5-16
5.4.4 Overview ........................................................................ 5-16
5.4.5 Description ..................................................................... 5-17
Parameter 201 - Retardation when reversing ................ 5-17
Parameter 202/203/204 - Adjusting erroneous, maximum
travel speeds ................................................................. 5-17
Parameter 205/206/207 - Adjusting erroneous, maximum
travel speeds ................................................................. 5-18
Parameter 208 - Creep speed in travel direction control 5-19
Parameter 209/210 - Reduced maximum travel speed above
a certain lift height ......................................................... 5-19

Contents
7510399-040 2009-12-22 6070557- 815, 816
Parameter 211/212 - Reduced maximum travel speed with a

certain reach length ....................................................... 5-20
Parameter 213 - Permanently reduced maximum travel speed
5-20
Parameter 214 - Adjusting the maximum travel speed in main
lift range ......................................................................... 5-20
5.5 Service parameters, hydraulics.................................................... 5-21
5.5.1 Overview ........................................................................ 5-21
5.5.2 Description ..................................................................... 5-24
Parameter 301/302/303/304 - Extra valve function ....... 5-24
Parameter 305/306/307/308 - Max. oil pressure through valve
Q8 .................................................................................. 5-26
Parameter 313/314/315/316 - Closing time ................... 5-27
Q8 .................................................................................. 5-27
Q9 .................................................................................. 5-28
Parameter 325/326/327/328 - Opening/closing time valve Q8
5-28
Parameter 329/330/331/332 - Opening/closing time valve Q9
5-29
Parameter 341/342 - Reducing the lifting/lowering speed . 5-
29
Parameter 343 - Reduction of reach speed ................... 5-30
Parameter 344 - Reduction of fork lowering speed before floor
level ............................................................................... 5-30
Parameter 347/348 - Prevents the lifting/lowering of forks 5-
31
Parameter 349 - Fork weight ......................................... 5-31
Parameter 350 - Multi-function ...................................... 5-32
Parameter 360 - Deactivation of hydraulic functions ..... 5-33
Parameter 361/362/363/364/365 /366 - Function related,
maximum lifting/lowering speeds ................................... 5-34
Parameter 367/368 - Fork limit for deactivating the extension
of the fork carriage and for sideshift .............................. 5-35
Parameter 369 up to and including 379 - Height pre-selection
5-36
Parameter 380 up to and including 386 - Lift height limitations
5-38
Parameters 387 up to and including 393 - Configuring the lift
height limitations ............................................................ 5-39
Parameters 395, 396/397 Function-related, maximum lift
heights ........................................................................... 5-40
Parameters 398/399 -Operator profile-dependent, maximum
lift heights ...................................................................... 5-41
5.6 Service parameters, CID.............................................................. 5-42
5.6.1 Overview ........................................................................ 5-42
5.6.2 Description ..................................................................... 5-43
Parameter 503 - Login method ...................................... 5-43
Parameter 504/505/506/507 - Smart Access ................ 5-44
Parameters 508/509/512/513/514 - CID configuration .. 5-48
Parameter 510/511 - Height pre-selector ...................... 5-50

Contents
815, 816 6070557- 2009-12-22 7510399-040
5.7 General factory parameters ......................................................... 5-51

5.7.1 Overview ........................................................................ 5-51
5.7.2 Description ..................................................................... 5-52
Parameter 1001 (Truck type) ......................................... 5-52
Parameter 1002 - (Drive motor) ..................................... 5-52
Parameter 1003 - Pedal type ......................................... 5-52
Parameter 1004 - Steering servo .................................. 5-53
Parameter 1005 - Pump motor ...................................... 5-53
Parameter 1006 - Hydraulic pump ................................. 5-53
Parameter 1007 - Activation of hydraulic levers ............ 5-54
Parameter 1008 - Mast type .......................................... 5-54
Parameter 1009 - Height indication ............................... 5-55
Parameter 1010 - Weight indicating .............................. 5-55
5.8 Factory parameters, activation of options .................................... 5-56
5.9 Factory parameters, calibration ................................................... 5-58
6 – Installation ......................................................................................... 6-1

6.1 Transporting the truck .................................................................... 6-1
Method 1 .......................................................................... 6-1
Method 2 .......................................................................... 6-1
6.2 Initial operation............................................................................... 6-2
6.2.1 Tool .................................................................................. 6-2
6.2.2 Battery ............................................................................. 6-2
Placing the battery ........................................................... 6-2
Battery parameters .......................................................... 6-3
6.2.3 Mast, fitting ...................................................................... 6-3
6.2.4 Parameters on initial operation ........................................ 6-3
Load indicator .................................................................. 6-3
Ergo cabin ....................................................................... 6-4
Cold store cabin ............................................................... 6-4
6.2.5 Parameters for optional equipment ................................. 6-5
Height measurement (option) .......................................... 6-5
Travel speed limitation, height-dependent ....................... 6-5
Travel speed limitation, reach movement dependent ...... 6-5
Travel speed limitation, parameter-dependent ................ 6-6
Collision sensor (BT) ....................................................... 6-6
6.2.6 Test driving ...................................................................... 6-6
7 – Maintenance ....................................................................................... 7-1

7.1 Introduction, maintenance.............................................................. 7-1
7.2 Safety regulations during maintenance work ................................. 7-2
7.3 Periodic maintenance .................................................................... 7-4
7.3.1 Every 500 B-hours/180 days ........................................... 7-4
7.3.2 Every 1,000 B-hours/360 days ........................................ 7-6
7.3.3 Every 2,000 B-hours/720 days ...................................... 7-11
7.3.4 Every 3,000 B-hours/1,080 days ................................... 7-11
7.3.5 Every 5,000 B-hours/1,800 days ................................... 7-13
7.3.6 Annual status inspection ................................................ 7-13
7.4 Maintenance instructions ............................................................. 7-14
7.4.1 Cleaning and washing ................................................... 7-14
High-pressure washers .................................................. 7-14
Degreasing agents ........................................................ 7-14
Cleaning the exterior ..................................................... 7-14
Cleaning the chain ......................................................... 7-15
Cleaning the motor compartment .................................. 7-15

Contents
7510399-040 2009-12-22 6070557- 815, 816
Electrical components ................................................... 7-15
8 – Troubleshooting ................................................................................ 8-1

8.1 Abbreviations used in this section .................................................. 8-1
8.2 Truck help functions ....................................................................... 8-1
8.2.1 Error log menu ................................................................. 8-1
Description ....................................................................... 8-1
Driver ............................................................................... 8-1
8.2.2 Error information menu .................................................... 8-2
Description ....................................................................... 8-2
Driver ............................................................................... 8-2
8.2.3 Diagnostic screens .......................................................... 8-2
Driver ............................................................................... 8-2
State 1 – Voltage from the control console levers ........... 8-3
State 2 – Digital signals from the truck control to CID .... 8-4
State 3 – Voltage from control/sensor to MCU ............... 8-5
State 4 – Digital input signals to MCU ............................ 8-6
State 5 – Digital output signals from MCU ...................... 8-8
State 6 – PWM output signals from MCU ....................... 8-9
State 7 – FCU (not used) ................................................. 8-9
State 8 – FCU (not used) ................................................. 8-9
State 9 – GFU (not used) ................................................ 8-9
State 10 – GFU (not used) .............................................. 8-9
State 11 – Temperature signals ................................... 8-10
State 12 – Voltage levels .............................................. 8-10
State 13 – Travel information ....................................... 8-11
State 14 – Steering information .................................... 8-12
State 15 – Lift/lowering information ............................... 8-13
Stage 16 – Reach movement information .................... 8-14
Stage 17 – Hydraulic information ................................. 8-15
8.3 Initial troubleshooting ................................................................... 8-17
8.4 Troubleshooting using catch symbol............................................ 8-18
8.5 Troubleshooting using error code ................................................ 8-25
8.5.1 CID, warnings and errors ............................................... 8-27
8.5.2 MCU and other warnings and errors ............................. 8-31
8.5.3 Drive system error ......................................................... 8-41
8.5.4 Hydraulic system error ................................................... 8-53
8.5.5 Steering system, warnings and errors ........................... 8-88
8.5.6 GFU, warnings and errors ............................................. 8-95
8.6 Troubleshooting without indications ............................................. 8-96
8.6.1 Mechanical brake (3000) ............................................... 8-96
8.6.2 Steering (4000) .............................................................. 8-96
8.6.3 Telescopic forks ............................................................. 8-97
8.6.4 Log-in normal but one or more functions cannot be used. 8-
98
9 – Frame/Chassis 0000 .......................................................................... 9-1

9.1 General .......................................................................................... 9-1
9.2 Motor hood (0340).......................................................................... 9-1
9.2.1 Opening the motor compartment ..................................... 9-1
RRE 140-RRE 250 .......................................................... 9-1
To open the motor compartment: .................................... 9-1
To close the motor compartment: .................................... 9-1
Replacing the motor hood ............................................... 9-2
Adjustment of motor hood ............................................... 9-2

Contents
815, 816 6070557- 2009-12-22 7510399-040
9.3 Battery compartment components (0390)...................................... 9-4

9.3.1 Adjusting the battery bed ................................................. 9-4
9.4 Operator's cab (0500) .................................................................... 9-5
9.4.1 Cab tilting RRE 140 – 250 Ergo ...................................... 9-5
9.3.1 Cab windows (0530) ........................................................ 9-6
Fitting a window ............................................................... 9-6
9.3.2 Cab door (0550) .............................................................. 9-8
Disassembly of the door lock ........................................... 9-8
Tools required .................................................................. 9-9
Method ............................................................................. 9-9
Disassembly of the lock device ..................................... 9-10
9.4 Operator compartment (0600) ..................................................... 9-12
9.4.1 Operator's seat (0620) ................................................... 9-12
Disassembling the entire seat ....................................... 9-12
Replacing the seat switch .............................................. 9-13
Replacing the back rest ................................................. 9-14
Replacing the chair seat ................................................ 9-15
Replacing the seat heater switch ................................... 9-15
9.4.2 Cab heating/ventilation (0630) ....................................... 9-16
Replacing the air filter on the cold store cabin: .............. 9-16
Removing the fan and heater ........................................ 9-17
Replacing the potentiometers ........................................ 9-21
9.4.3 Internal fittings (0680) .................................................... 9-23
9.4.4 Disassembling/assembling the floor plate, B version 0680 9-
24
9.5 Safety equipment (0800).............................................................. 9-26
9.5.1 Checking the overhead guard (0810) ............................ 9-26
9.5.2 Adjusting the tilt stops (0840) ........................................ 9-27
10 – Motors 1000 ................................................................................... 10-1

10.1 Motor sensors .............................................................................. 10-1
10.1.1 Temperature sensor ...................................................... 10-1
Retrofitting an external temperature sensor .................. 10-2
10.1.2 Replacing the motor speed sensor ................................ 10-2
10.2 Pump motor (1710) ...................................................................... 10-3
10.2.1 General .......................................................................... 10-3
The pump motor dismantled .......................................... 10-3
10.2.2 Replacing the bearing on the pump motor .................... 10-4
Dismantling the pump motor .......................................... 10-4
Reassembling the pump motor ...................................... 10-6
10.3 Steering motor and steering unit (1730)....................................... 10-7
10.3.1 General .......................................................................... 10-7
10.3.2 Layout of the flange holes ............................................. 10-7
10.3.3 Removing the steering motor from the truck ................. 10-8
10.3.4 Fitting the steering motor in the truck ............................ 10-8
10.4 Fan motor/fan (1740) ................................................................... 10-9
10.4.1 General .......................................................................... 10-9
10.4.2 Replacing the frequency converter cooling fan ............. 10-9
Standard truck ............................................................... 10-9
Ergo truck ...................................................................... 10-9
10.4.3 Replacing the motor compartment cooling fan ............ 10-11
10.5 Drive motor (1760) ..................................................................... 10-12
10.5.1 General ........................................................................ 10-12
The drive motor dismantled ........................................ 10-12
10.5.2 Removing the drive motor from the truck .................... 10-13

Contents
7510399-040 2009-12-22 6070557- 815, 816
10.5.3 Dismantling the drive motor ......................................... 10-15

10.5.4 Cleaning ...................................................................... 10-16
10.5.5 Assembling the drive motor ......................................... 10-17
10.5.6 Fitting the drive motor in the truck ............................... 10-19
11 – Drive gear 2000 .............................................................................. 11-1

11.1 General ........................................................................................ 11-1
11.2 Repairs/servicing ......................................................................... 11-1
11.3 Actions ......................................................................................... 11-2
11.3.1 Checking the oil level ..................................................... 11-2
11.3.2 Changing the oil ............................................................. 11-2
11.3.3 Leakage from the bottom cover ..................................... 11-4
11.3.4 Replacing the drive gear ................................................ 11-5
Special tools .................................................................. 11-5
Exposing the drive gear ................................................. 11-5
Removing the drive motor from the truck ...................... 11-5
Removing the steering motor from the truck ................. 11-5
Removing the drive gear from the truck ........................ 11-6
Replacing the drive gear in the truck ............................. 11-8
Fitting the steering motor in the truck ............................ 11-9
Fitting the drive motor in the truck ................................. 11-9
Completion work ............................................................ 11-9
12 – Brake and wheel 3000 ................................................................... 12-1

12.1 Travel brake system (3100) ......................................................... 12-1
12.1.1 Removing the support arm's multiple disc brake ........... 12-1
12.1.2 Dismantling the multiple disc brake ............................... 12-1
Inspection ...................................................................... 12-2
Adjusting play ................................................................ 12-2
Assembling the multiple disc brake ............................... 12-3
12.1.3 Installing the multiple disc brake in the truck ................. 12-3
12.1.4 Checking the wheel brake's brake force ........................ 12-4
12.2 Parking brake (3300).................................................................... 12-5
12.2.1 General .......................................................................... 12-5
12.2.2 Emergency release of the parking brake ....................... 12-6
12.2.3 Checking the brake force ............................................... 12-6
12.2.4 Removing the parking brake from the truck ................... 12-7
Dismantling and checking for wear ................................ 12-8
Adjusting the air gap .................................................... 12-10
12.2.5 Installing the parking brake in the truck ....................... 12-12
12.3 Drive wheel (3530) ..................................................................... 12-13
12.3.1 General ........................................................................ 12-13
12.3.2 Removing the drive wheel from the truck .................... 12-13
12.3.3 Installing the drive wheel on the truck ......................... 12-13
12.4 Wheel bolt (3530)....................................................................... 12-14
General ........................................................................ 12-14
12.4.1 Replacing wheel bolts .................................................. 12-14
12.5 Support arm wheel (3550).......................................................... 12-15
12.5.1 Removing the support arm wheel from the truck ......... 12-15
12.5.2 Replacing a wheel bearing - braked wheel (A) ............ 12-16
12.5.3 Replacing a wheel bearing - unbraked wheel (B) ........ 12-17
12.5.4 Fitting the support arm wheel to the truck ................... 12-18
12.5.5 Wheel wear and tear ................................................... 12-19

Contents
815, 816 6070557- 2009-12-22 7510399-040
13 – Steering system 4000 .................................................................... 13-1

13.1 Electric steering wheel (4310)...................................................... 13-1
13.1.1 General .......................................................................... 13-1
13.1.2 Replacing the pulse transducer on the steering wheel module
13-1
13.1.3 Removing the operating console from the truck ............ 13-2
13.1.4 Replacing the wiring harness in the operating console . 13-3
13.1.5 Fitting the operating console in the truck ....................... 13-5
13.2 Steering reference sensor (4350) ................................................ 13-6
General .......................................................................... 13-6
13.2.1 Replacing the reference transducer [B17] ..................... 13-6
13.3 Steering bearings (4380) ............................................................. 13-7
13.3.1 Removing a steering bearing from the drive gear ......... 13-7
13.3.2 Fitting a steering bearing on the drive gear ................... 13-7
14 – Electrical system 5000 .................................................................. 14-1

14.1 Battery (5110) .............................................................................. 14-1
14.1.1 Battery recommendation ............................................... 14-1
Exide gel batteries (Sonnenschein, for example) .......... 14-1
Hawker Evolution gel batteries ...................................... 14-1
14.1.2 Battery installation ......................................................... 14-2
Replacement/installation of battery. .............................. 14-2
Procedure without battery changing table ..................... 14-3
Procedure with battery changing table .......................... 14-3
14.2 LID (5200) .................................................................................... 14-4
14.2.1 Replacement of LID ....................................................... 14-4
14.2.2 Replacement of LID cold store cab ............................... 14-5
14.3 Replacing pedals ......................................................................... 14-6
14.3.1 Replacing/repairing safety pedal ................................... 14-7
14.4 Control console (5510)................................................................. 14-8
14.4.1 General .......................................................................... 14-8
14.4.2 Replacement/installation of a control ............................. 14-8
14.4.3 Replacing the multi-function control .............................. 14-9
Replacing the multi-function control's buttons. .............. 14-9
14.4.4 Remove the control console from the truck ................. 14-10
14.4.5 Replacing the access card's circuit board ................... 14-11
14.4.6 Dismantling the control console ................................... 14-12
Installing an extra push button ..................................... 14-14
Replacing the travel direction selector with signal button 14-
14
Replacing the display .................................................. 14-15
14.4.7 Assembling the control console ................................... 14-15
14.4.8 Placing the control console in the truck ....................... 14-16
14.5 Magnetic sensor (5850) ............................................................. 14-18
General ........................................................................ 14-18
14.5.1 Replacing the magnetic sensor [B47] .......................... 14-18
14.5.2 Reference magnet ....................................................... 14-19
14.6 Parameter settings..................................................................... 14-20
14.6.1 Configuration menu ..................................................... 14-20
Calendar/hour counter menu ....................................... 14-20
Parameter menu (PAR) .............................................. 14-20
Setting driver parameters ............................................ 14-21
14.7 PIN menu ................................................................................... 14-22
14.7.1 Menu for activating a PIN block ................................... 14-23
14.7.2 Menu for programming a PIN (P) ................................ 14-23
1 – 10 Repair Manual RRE140/160/180/200/250 © BT

Contents
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14.8 Calibrations ................................................................................ 14-24

14.8.1 Calibrating the hydraulic function control ..................... 14-24
14.8.2 Height measurement/reach movement length calibration 14-
25
Calibrating height measurement (option; must have height en-
coders fitted) ................................................................ 14-26
Calibrating reach movement length ............................. 14-27
Calibration of the zero position for the fork tilt ............. 14-28
14.8.3 Valve calibration .......................................................... 14-29
Lift valve calibration ..................................................... 14-29
Mast transition lift ......................................................... 14-30
Lowering valve calibration with height indication ......... 14-31
Lowering calibration without height indication ............. 14-33
Reach movement valve calibration .............................. 14-35
Calibration of the Ergo cabin ....................................... 14-38
14.8.4 Weight calibration ........................................................ 14-39
Calibrating the weight indication .................................. 14-39
14.9 Changing cabling ....................................................................... 14-41
14.10 Main computer unit MCU (A5).................................................... 14-42
14.10.1 Installing a new card in the truck. ................................ 14-43
14.10.2 Voltage feed ................................................................ 14-43
14.10.3 Battery minus ............................................................... 14-43
14.10.4 Internal status monitoring ............................................ 14-43
14.10.5 Resetting the battery indicator ..................................... 14-43
15 - Hydraulic system 6000 ................................................................... 15-1

15.1 Hydraulic hygiene ........................................................................ 15-1
15.1.1 Cleaning ........................................................................ 15-1
15.1.2 Packaging ...................................................................... 15-1
15.1.3 Handling ........................................................................ 15-1
15.1.4 Storage .......................................................................... 15-2
15.1.5 Procedure ...................................................................... 15-2
15.2 Hydraulic unit (6100) .................................................................... 15-3
15.2.1 Emptying the hydraulic tank .......................................... 15-4
15.2.2 Hydraulic system, bleeding ............................................ 15-5
15.2.3 Remove the pump motor from the truck ........................ 15-6
15.2.4 Replacing the hydraulic pump ....................................... 15-7
15.2.5 Fitting the pump motor in the truck ................................ 15-8
15.3 Main valve (6210)......................................................................... 15-9
15.3.1 Emergency lowering of forks ......................................... 15-9
15.3.2 Replacing the main valve block ................................... 15-10
15.3.3 Replacing the Q4 valve ............................................... 15-12
Calibration of valve ...................................................... 15-13
15.3.4 Adjusting the maximum opening pressure .................. 15-14
15.4 Hydraulic couplings (6230)......................................................... 15-16
15.4.1 Hydraulic couplings, tightening torques ....................... 15-16
Tapered coupling with O-ring ...................................... 15-16
Tredo seal .................................................................... 15-17
Pipe coupling ............................................................... 15-17
15.4.2 Quick coupling ............................................................. 15-19
..................................................................................... 15-20
15.5 Hydraulic system, mast (6300)................................................... 15-21
15.5.1 Mast-mounted hose reel (6370) .................................. 15-21
General ........................................................................ 15-21
© BT Repair Manual RRE140/160/180/200/250 1 – 11

Contents
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15.5.2 Fitting the hose reel ..................................................... 15-21

Spring preloading (turns) ............................................. 15-21
15.5.3 Checks after fitting ....................................................... 15-22
15.6 Main lift cylinder 6610 ................................................................ 15-23
General ........................................................................ 15-23
15.6.1 Overview ...................................................................... 15-24
Cylinder nomenclature ................................................. 15-24
Nomenclature for cylinder head ................................... 15-25
Nomenclature for piston .............................................. 15-25
15.6.2 Remove the lift cylinder from the mast ........................ 15-26
15.6.3 Replacing the hose rupture valve ................................ 15-27
15.6.4 Dismantling the cylinder .............................................. 15-28
15.6.5 Dismantling the piston. ................................................ 15-30
Method ......................................................................... 15-30
15.6.6 Dismantling the cylinder head ..................................... 15-30
15.6.7 Fitting the cylinder head seals. .................................... 15-32
15.6.8 Fitting the piston seals. ................................................ 15-34
15.6.9 Assembling the cylinder ............................................... 15-36
15.6.10 Assembling the cylinder in the mast ............................ 15-38
15.7 Free lift cylinder (6620) .............................................................. 15-40
General ........................................................................ 15-40
15.7.1 Removing the free lift cylinder from the truck .............. 15-41
15.7.2 Replacing the hose rupture valve, free lift cylinder ...... 15-42
15.7.3 Fitting the free lift cylinder in the truck ......................... 15-42
15.8 Reach cylinder (6650) ................................................................ 15-43
15.8.1 General ........................................................................ 15-43
15.8.2 Remove the reach cylinder from the truck ................... 15-43
15.8.3 Fitting the reach cylinder in the truck ........................... 15-44
15.9 Fork tilt cylinder (6660)............................................................... 15-45
15.9.1 General ........................................................................ 15-45
15.9.2 Remove the tilt cylinder from the truck ........................ 15-46
Mast with valve on the fork carriage: ........................... 15-46
Mast without valve on the fork carriage: ...................... 15-48
15.9.3 Fit the tilt cylinder in the truck ...................................... 15-50
Mast without valve on the fork carriage. ...................... 15-52
15.10 Cab tilt cylinder (6660) ............................................................... 15-54
15.10.1 General ........................................................................ 15-54
15.10.2 Overview ...................................................................... 15-54
15.10.4 Dismantling the piston rod ........................................... 15-58
15.11 Sideshift cylinder (6670) ............................................................ 15-68
15.11.1 General ........................................................................ 15-68
15.11.2 Overview ...................................................................... 15-69
15.11.3 Dismantling the cylinder from the truck ....................... 15-71

Contents
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15.11.10 Refitting the cylinder in the truck ................................ 15-83
16 – Mast/Lift system 7000 ................................................................... 16-1

16.1 Main mast 1.6-2.5 t (7100) ........................................................... 16-1
16.1.1 Replacing the complete mast ........................................ 16-1
16.1.2 Removing the mast from the truck ................................. 16-2
16.1.3 Adjusting mast play ....................................................... 16-5
General .......................................................................... 16-5
Preparations .................................................................. 16-5
Adjusting lateral play ..................................................... 16-8
Adjusting radial play ...................................................... 16-9
Adjusting the damping elements ................................... 16-9
Adjusting the damper plate .......................................... 16-10
Refitting the mast ......................................................... 16-10
16.1.4 Replacing the mast's damper plates .......................... 16-11
16.1.5 Fitting the mast on the truck ........................................ 16-12
16.2 Main lift chain system (7120)...................................................... 16-16
16.2.1 General ........................................................................ 16-16
16.2.2 Inspecting the chain ..................................................... 16-16
Noise ........................................................................... 16-16
Surface rust ................................................................. 16-16
Rusty links ................................................................... 16-16
Stiff links ...................................................................... 16-17
Bolt rotation ................................................................. 16-17
Loose bolts .................................................................. 16-17
Link plate wear ............................................................ 16-18
Elongation .................................................................... 16-19
Damage ....................................................................... 16-19
Damaged plates .......................................................... 16-20
Damaged bolts ............................................................ 16-20
Dirty chain .................................................................... 16-20
16.2.3 Lubricating the chain ................................................... 16-20
16.2.4 Main lift chain system, adjusting the fork-to-floor distance ....
16-21
16.3 Reach carriage (7190) ............................................................... 16-22
16.3.1 Adjusting radial play in the reach carriage ................... 16-22
16.3.2 Adjusting axial play in the reach carriage .................... 16-24
16.4 Lifting devices (7400) ................................................................. 16-25
16.4.1 Forks ............................................................................ 16-25
General ........................................................................ 16-25
Inspection .................................................................... 16-25
Inspection intervals ...................................................... 16-25
Surface cracks ............................................................. 16-25
Difference in height between the fork tips ................... 16-26
Position locks ............................................................... 16-26
Legibility of markings ................................................... 16-26
Fork blades and back .................................................. 16-26
Mounting elements on the fork .................................... 16-26

Contents
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16.4.2 Forks, repairs and testing ............................................ 16-27

Repair .......................................................................... 16-27
Testing the yield point .................................................. 16-27
Fork ............................................................................. 16-27
16.5 Fork carriage.............................................................................. 16-28
16.5.1 Checking the fork carriage's wear strip ........................ 16-28
16.5.2 Lubricating the fork carriage ........................................ 16-29
16.6 Fork spread unit ......................................................................... 16-30
16.6.1 Servicing the fork spread unit ...................................... 16-30
Replacing bearings ...................................................... 16-31
Replacing the rollers .................................................... 16-31
16.7 Fork extensions with adjustable fork length ............................... 16-32
16.8 Manual telescopic forks ............................................................. 16-34
16.8.1 Fitting ........................................................................... 16-34
16.8.2 Maintenance ................................................................ 16-35
16.9 Hydraulic telescopic forks .......................................................... 16-36
16.9.1 Telescopic forks with separate flow dividers ............... 16-37
Assembly instructions .................................................. 16-38
Initial operation of telescopic forks with separate flow dividers
16-38
16.9.2 Telescopic forks with integrated flow dividers ............. 16-39
Assembly instructions .................................................. 16-40
Initial operation of telescopic forks with integrated flow divid-
ers ................................................................................ 16-40
16.9.3 Maintenance of telescopic forks .................................. 16-41
16.9.4 Dismantling telescopic forks ........................................ 16-42
16.9.5 Assembling telescopic forks ........................................ 16-43
17 – Peripherals - 8000 .......................................................................... 17-1

17.1 Introduction .................................................................................. 17-1
18 – Extra equipment - 9000 ................................................................. 18-1

18.1 Introduction .................................................................................. 18-1
19 – Appendix “Destruction instructions” .......................................... 19-1

19.1 General ........................................................................................ 19-1
19.2 Marking of plastics ....................................................................... 19-1
19.2.1 General marking of products and packaging material ... 19-1
19.2.2 Marking according to our standard ................................ 19-2
Abbreviations ................................................................. 19-2
Marking examples ......................................................... 19-2
19.3 Pressure vessels.......................................................................... 19-3
19.3.1 Gas dampers ................................................................. 19-3
19.4 Sorting categories ........................................................................ 19-4
20 - Circuit diagram ............................................................................... 20-1

20.1 Components ................................................................................ 20-1
20.2 Component location ..................................................................... 20-9
Figure 1 (Fork carriage) ................................................. 20-9
Figure 2 (Chassis cabling) ........................................... 20-10
Figure 3 (Chassis cabling) ........................................... 20-11
Figure 4 (Support leg brake) ........................................ 20-12
Figure 5 (Pedals) ......................................................... 20-12
Figure 6 (Motor cabling) .............................................. 20-13

Contents
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Figure 7 (Pushout carriage cabling) ............................ 20-14

Figure 8 (Level/position meter) .................................... 20-15
Figure 9 (seat) ............................................................. 20-16
Figure 10 (DC/DC) ....................................................... 20-17
Figure 11 (Cabling driver position) .............................. 20-18
Figure 12 (Extra hydraulic function(s)) ........................ 20-19
Figure 13 (Travel alarm) .............................................. 20-20
Figure 14 (Cabling roof) ............................................... 20-21
Figure 15 (Roof) .......................................................... 20-22
Figure 16 (Sound system) ........................................... 20-23
Figure 17 (Forks camera) ............................................ 20-24
Figure 18 (Battery cabling) .......................................... 20-25
Figure 19 (Fuse box) ................................................... 20-26
Figure 20 (LID) ............................................................ 20-27
Figure 21 (Frame cabling) ........................................... 20-28
Figure 22 (Fork carriage cabling) ................................ 20-29
Figure 23 (Pushout carriage cabling options) .............. 20-30
Figure 24 (Working light cabling) ................................. 20-31
Figure 24 (Extra outlet DC) .......................................... 20-32
Figure 25 (T.W.I.S.) ..................................................... 20-32
Figure 26 (Shock Switch / Impact Manager) ............... 20-33
Figure 27 (Heated windows CC) ................................. 20-34
Figure 28 (Cabling driver position CC) ........................ 20-35
Figure 29 (Heater CC) ................................................. 20-36
Figure 30 (Cabling cab heater CC) .............................. 20-37
Figure 31 (Safety switch for door CC) ......................... 20-38
Figure 32 (Cabling cab tilt) .......................................... 20-38
Figure 33 (Control panel) ............................................. 20-39
Figure 34 (Control panel) ............................................. 20-40
Figure 35 (Steering arm) ............................................. 20-41
Figure 36 (MCU) .......................................................... 20-42
Figure 37 (Control motor) ............................................ 20-43
Figure 38 (Main valve block) ....................................... 20-44
20.3 Cable connections and pole bolts .............................................. 20-45
20.3.1 ACT/ACH transistor regulators .................................... 20-45
20.3.2 Connections to CID ..................................................... 20-47
20.3.3 Connections on the MCU ............................................ 20-48
20.4 Fuse box A9 ............................................................................... 20-51
20.5 Overview .................................................................................... 20-52
20.6 Wiring diagram........................................................................... 20-56
20.7 Detailed diagram cold-store cab ................................................ 20-79
21 – Hydraulics schematics .................................................................. 21-1

21.1 Main valve unit ............................................................................. 21-1
21.1.1 RRE Std. ....................................................................... 21-1
21.1.2 RRE Ergo ..................................................................... 21-2
21.2 Hydraulics schematics ................................................................. 21-3
21.2.1 Schematics designations ............................................... 21-3
21.2.2 List of symbols ............................................................... 21-4
21.2.3 Wiring diagrams RRE/RRE Ergo ................................... 21-5

Contents
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22 – Tools ............................................................................................... 22-1

22.1 AMP contacts............................................................................... 22-1
22.2 MQS contacts .............................................................................. 22-2
22.3 CPC contacts ............................................................................... 22-4
22.4 Other tools ................................................................................... 22-5
23 – Appendix “Service data and grease specifications” .................. 23-1

23.1 General tightening torques........................................................... 23-1
23.1.1 Galvanised non-oiled bolts ............................................ 23-1
23.1.2 Untreated oiled bolts ...................................................... 23-2
23.2 Oil and grease specification ......................................................... 23-3
24 – Technical data ............................................................................... 24-1

General introduction
How to use the manual
7510399-040 2009-12-22 6070557- 815, 816
2 – General introduction
2.1 How to use the manual

The service manual is divided into chapters containing the following
information:
• Safety regulations – This chapter includes general safety regula-
tions regaring working with the truck.
• Function – This chapter provides a basic description of the main
functions of the truck.
• Parameters – This chapter contains a basic description of the steer-
ing system's parameters.
• Installation – This chapter describes the work that needs to be done
before the truck is used for the first time.
• Maintenance – the chapter contains a general periodic maintenance
schedule and a detailed description of the maintenance to be carried
out.
• Troubleshooting – This chapter describes the error codes that ap-
pear in the display when the truck completely or partly stops work-
ing. The chapter also describes the reason why the errors occur and
suggested remedies.
• Actions chapter – This chapter describes the various parts of the
truck, what the parts look like and the service actions that need to be
carried out. The various chapters are organised according to BT's C-
code system.
• Appendixes – The appendixes contain:
- instructions for disposal
- information about electrical components and wiring diagrams
- hydraulics diagrams
- list of required tools
- information about general tightening torques
- oil and grease specifications
- technical data.

General introduction
Warning symbols
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2.2 Warning symbols

The following warning symbols are used in the repair manual:
DANGER!
DANGER! means there is a risk of accident potentially leading to
death or serious injury and material loss or damage. Always accom-
panied by the warning symbol.
WARNING!
WARNING! means that there is a risk of damage to components that
are sensitive to electro static discharge.
Follow the ESD-protection regulations.
Note!
NOTE! means there is a risk of material loss or damage if the instruc-
tions are not followed. Also used to draw attention to a non-standard
torque.
2.3 Pictogram
Pictograms are used, where possible, to describe certain elements.
Pictograms are maily used at moments requiring the loosening or tight-
ening of screws:
×n
s mm
A pictogram contains information about the type of screw head and an
arrow shows whether the screw should be loosened or tightened.
Text beneath the pictogram provides additional information about 's':
key size, 'n': the number of screws as well as the recommended torque
where necessary.
Another type of Pictogram is "Cut cable ties":
Additional information under the Pictogram can, for example, indicate

the number of cable ties to be cut.

General safety rules
Safety while working
7510399-040 2009-12-22 6070557- 815, 816
3 – General safety rules

Only personnel trained in servicing and repairing this type of truck are
authorised to carry out service and repair activities.
3.1 Safety while working

To ensure that you work safely and to prevent accidents while working
on a truck, remember the following:
• keep the area where servicing activities are performed clean. Oil or
water will make the floor slippery.
• use the correct working position. Service activities often involve
kneeling or bending forward. Try sitting on a toolbox, for example, to
relieve the strain on your knees and back.
• loose articles and jewellery may become trapped in the moving parts
of the truck. So never wear loose articles or jewellery while working
on the truck.
• use the correct tools for the work you are carrying out.
• keep all tools well maintained.
• store and transport old oil according to applicable local regulations.
• do not flush solvents, etc. down the drain unless they are intended to
be disposed of in this way.
Follow the local disposal regulations.
• 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.

Electrical system
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3.2 Electrical system

When working on the electrical system of the truck, remember the fol-
lowing:
• a short circuit may occur if metal objects come into contact with live
connections. This can result in burns. So remove watches, rings and
other metal jewellery before starting work.
• always use insulated tools while working on the electrical system.
• always switch off the truck's power supply before opening the hoods
to the drive assembly and the electrical system.
• disconnect the battery when using electric welding equipment. The
welding current may damage the battery.
• always remove the battery plug when carrying out maintenance on
the truck, unless the instructions in this service manual state other-
wise.
• blow electric motors clean using compressed air.
• clean electrical panels, electronic cards, connectors, contactors, so-
lenoid valves, etc. with a moist cloth and a cleaning agent that will
not damage the part.
IMPORTANT
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the electronic cards.

Safe lifting
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3.3 Safe lifting
All lifting must be carried out on a flat, nonslip and stable surface.
Asphalt floors must be avoided if possible.
• To prevent the truck moving while it is being lifted, it must not be lift-
ed with anyone on the platform or with the tiller arm in the lowered
position.
• If the drive wheel, which is braked, is being lifted the other wheel
must be chocked to stop the truck moving.
• Select the lifting point so that the lift is as light as possible, for exam-
ple one corner at a time. If the truck has marked lifting points on the
lower part of the chassis, these should be used for a well-balanced
lift.
• 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.

Safe lifting
815, 816 6070557- 2009-12-22 7510399-040
• Use the lever supplied with the jack. If the lever is too short, it will re-
quire more effort than is necessary. If the lever is too long there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing – a poorly chocked truck may fall.
• Never work under a truck that is not blocked with supports or secured
by a lifting device.
• Place supports:
- as close to the raised part of the chassis as possible to reduce the
falling height if the truck tips over
- 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.

Function descriptions
Chassis 0000
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4 – Function descriptions
4.1 Chassis 0000
4.1.1 Operator’s cabin (0500)

Versions for cold-store cabs
Both the standard and the tilting cabs are available to cold-store
specifications with or without a heated cab. They are all designed for
use in temperatures down to -35 °C.
Features
• All switches and electrical components are designed for use in cold-
stores.
• The air supply to the hydraulic system is filtered to prevent
accumulation of air.
• The hydraulic system uses a special oil that withstands cold
temperatures.
• All exposed axles are manufactured in stainless steel.
• Exposed parts have been rust-protected with Tectyl ®

Chassis 0000
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Emergency exit from the cab
If the truck has stopped against an obstacle that blocks the door and
cannot be moved, the cab can be evacuated through the roof.
• Release the locks in the roof and raise the hatch.
• Stand on the seat and armrest to get out onto the roof.
DANGER!
Risk of injury.
Risk of injury if the steering console is used as a step.
Never step up onto the steering console to climb onto the roof in the
event of an emergency.
• Call for assistance to get down from the roof.
DANGER!
Risk of slipping.
The roof might be slippery.
Never stand on the roof.

Chassis 0000
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4.1.2 Cab windows (0530)

Electrically heated windows
If the truck enters and exits cold.stores frequently, there may be
problems with condensation on the cab windows. To prevent this, the
truck can be ordered with electric window heating.
• Press button (a) to switch on this feature. A symbol in the button
remains lit for as long as window heating is active. After a preset
time, this feature is switched off, and it will be necessary to push
the button once again to reactivate the feature.
Note!
This function only operates if knob (b) for the climate control system
has been activated.
a b

Chassis 0000
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4.1.3 Driver's seat (0620)

The driver's seat is available in two different designs:
• For trucks in Standard design
• For trucks in Ergo design
An armrest (d) is an available option and the chair can also be fitted
with a safety belt to increase the driver's safety.
d In the seat there is a switch [B49] which must be activated; the driver
must sit in the seat in order for the truck to be driven.
Adjustment:
• Press button (a) to set the incline of the back rest.
• Lift the clamp (b) and release the lock to adjust the forward/back-
ward position of the seat.
• Set the seat's spring pressure using the knob (c). Sit on the seat and
turn so that the green arrow points upwards in order to set the spring
pressure to current weight.
a
Button for seat heater
• Switch on the heat by pressing (I) on the button located on the left-
c hand side below the seat. Heater operation is controlled by a
b thermostat.
• Switch off the heater by pressing (0) on the button.

Chassis 0000
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4.1.4 Cab heating/ventilation (0630)

Climate control knobs
For maximum operator comfort, it is possible to adjust the ventilation
and temperature as desired in the cab.
b
0
c a
Ventilation
• Turn knob (a) clockwise to start the fan. Release the knob at the
desired fan speed.
• To switch off the fan, turn the knob to 0.
Temperature
• Turn knob (b) clockwise to switch on the heater. Release the knob
at the desired temperature setting.
• To switch off the heater, turn the knob to 0.
Note!
Knob (a) operates as the main switch for the climate control system.
To enable operation of knob (b), knob (a) must first be switched on.
The cab has a number of air outlets (c) from which air and heat are
released into the cab. Make sure these outlets are not covered, as this
can cause malfunction of the climate control system.

Chassis 0000
815, 816 6070557- 2009-12-22 7510399-040
4.1.5 Driver protection (0840)

Tilt stops
To increase truck capacity, tilt stops are fitted to some trucks. Tilt stops
are also available as an option.
It is permissible however to temporarily remove tilt stops when trans-
porting the truck, e.g. between different warehouses; but then it is not
permitted to use the truck for transporting loads.
DANGER!
Reduced stability.
Trucks without tilt stops can tip over if used to transport loads.
Ensure that tilt stops are refitted at the correct floor distance if they
have been temporarily removed.
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.
.
a
a
b b
c c d
d

Chassis 0000
7510399-040 2009-12-22 6070557- 815, 816
Width between
Model Lift height NOTE
support arms
RRE140 900 All lift heights Tilt stops are optional
RRE140 1100 and 1300 All lift heights No tilt stops available
RRE160 900 and 1050 Lh ≤ 7500 The tilt stops can be removed
RRE160 900 and 1050 Lh ≤ 8000 The tilt stops cannot be removed
RRE180 900 All lift heights The tilt stops cannot be removed

Chassis 0000
815, 816 6070557- 2009-12-22 7510399-040
Overhead guard
The cabin is protected from falling objects by a casing with bars (c) bolt-
ed into the roof of the cabin shell.
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.

Motors 1000
7510399-040 2009-12-22 6070557- 815, 816
4.2 Motors 1000
4.2.1 General
The truck motors are the drive motor, the pump motor for the hydrau-
lics, and the steering motor for rotating the drive unit (steering).
The drive and pump motor are three-phase AC motors. The steering
motor is a brushless DC stepper motor. The voltage for all motors is 48
Volts.
4.2.2 Electric pump motor (1710)

General
The pump motor is a three-phase AC motor. In the motor, there is a
thermoelement that measures the motor temperature, as well as a cog
with a sensor for measuring rotational speed and direction.
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

Motors 1000
815, 816 6070557- 2009-12-22 7510399-040
4.2.3 Electric steering motor (1730)

General
The steering motor is located on the drive unit housing. It receives sig-
nals from the pulse generator located in the steering column. The steer-
ing motor is equipped with a gear wheel working directly on the gear rim
of the drive gear.
The steering motor is available in two sizes, one which is used in
RRE140 – RRE160 and one that is used in RRE180 – RRE250.
Design
The steering servo's electronics (a) are directly mounted on the steer-
ing motor.
The motor (b) is a brushless synchronous motor with permanently mag-
netised rotor.
The steering motor is integrated with a two-stage planetary gear (c) that
has a gear wheel on its output shaft in direct contact with the gear rim
on the drive gear.
RRE180 – RRE250 RRE140 – RRE160

Motors 1000
7510399-040 2009-12-22 6070557- 815, 816
4.2.4 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.

Motors 1000
815, 816 6070557- 2009-12-22 7510399-040
4.2.5 Electric drive motor (1760)

General
The drive motor is a three-phase AC motor. In the motor, there is a ther-
moelement that measures the motor temperature, as well as a cog with
a sensor for measuring rotational speed and direction.
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

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PICTURE HERE

Order number: 7510399-040

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

© BT Repair Manual RRE140/160/180/200/250

3 – General safety rules .......................................................................... 3-1

4 – Function descriptions ....................................................................... 4-1

© BT Repair Manual RRE140/160/180/200/250 1– 1

4.9.7 OTP ............................................................................... 4-86

© BT Repair Manual RRE140/160/180/200/250 1– 3

4.11.9 Cabin tilt (RRE Ergo) ................................................... 4-102

5 - Parameters .......................................................................................... 5-1

1– 4 Repair Manual RRE140/160/180/200/250 © BT

Parameter 211/212 - Reduced maximum travel speed with a

© BT Repair Manual RRE140/160/180/200/250 1– 5

5.7 General factory parameters ......................................................... 5-51

6 – Installation ......................................................................................... 6-1

7 – Maintenance ....................................................................................... 7-1

1– 6 Repair Manual RRE140/160/180/200/250 © BT

Electrical components ................................................... 7-15

8 – Troubleshooting ................................................................................ 8-1

9 – Frame/Chassis 0000 .......................................................................... 9-1

© BT Repair Manual RRE140/160/180/200/250 1– 7

9.3 Battery compartment components (0390)...................................... 9-4

10 – Motors 1000 ................................................................................... 10-1

1– 8 Repair Manual RRE140/160/180/200/250 © BT

10.5.3 Dismantling the drive motor ......................................... 10-15

11 – Drive gear 2000 .............................................................................. 11-1

12 – Brake and wheel 3000 ................................................................... 12-1

© BT Repair Manual RRE140/160/180/200/250 1– 9

13 – Steering system 4000 .................................................................... 13-1

14 – Electrical system 5000 .................................................................. 14-1

1 – 10 Repair Manual RRE140/160/180/200/250 © BT

14.8 Calibrations ................................................................................ 14-24

15 - Hydraulic system 6000 ................................................................... 15-1

© BT Repair Manual RRE140/160/180/200/250 1 – 11

15.5.2 Fitting the hose reel ..................................................... 15-21

1 – 12 Repair Manual RRE140/160/180/200/250 © BT

15.11.5 Dismantling the piston rod ........................................... 15-74

16 – Mast/Lift system 7000 ................................................................... 16-1

© BT Repair Manual RRE140/160/180/200/250 1 – 13

16.4.2 Forks, repairs and testing ............................................ 16-27

17 – Peripherals - 8000 .......................................................................... 17-1

18 – Extra equipment - 9000 ................................................................. 18-1

19 – Appendix “Destruction instructions” .......................................... 19-1

20 - Circuit diagram ............................................................................... 20-1

1 – 14 Repair Manual RRE140/160/180/200/250 © BT

Figure 7 (Pushout carriage cabling) ............................ 20-14

21 – Hydraulics schematics .................................................................. 21-1

© BT Repair Manual RRE140/160/180/200/250 1 – 15

22 – Tools ............................................................................................... 22-1

23 – Appendix “Service data and grease specifications” .................. 23-1

24 – Technical data ............................................................................... 24-1

1 – 16 Repair Manual RRE140/160/180/200/250 © BT

2.1 How to use the manual

© BT Repair Manual RRE140/160/180/200/250 2– 1

2.2 Warning symbols

Additional information under the Pictogram can, for example, indicate