BT Electric Forklift REFLEX RR B,E RR B,E CC Service Manual – PDF DOWNLOAD

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BT Electric Forklift REFLEX RR B,E RR B,E CC Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT Electric Forklift REFLEX RR B,E RR B,E CC Service Manual – PDF DOWNLOAD

Language : English
Pages :514
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Electric Forklift REFLEX RR B,E RR B,E CC Service Manual – PDF DOWNLOAD

1- Table of contents 3
2- General product information – M2 27
21 Presentation of the reach trucks 27
211 Application areas for the reach trucks 27
212 Prohibited applications for the reach trucks 27
22 Truck data 28
23 Truck dimensions 29
24 Identification plate, truck 31
241 Capacity plate 31
242 Modification plate 32
243 Identification plate, mast 32
25 Main components RR B/E 1-8 33
26 Main components RR B/E 2-8 CC 35
27 Warning and information plates and symbols RR B/E 1-8 37
28 Warning and information plates and symbols RR B/E 2-8 CC 39
3- Technical data – M4 41
31 General tightening torque 45
311 Galvanised, non-oiled bolts 45
312 Untreated, oiled bolts 45
4- Introduction, maintenance – P1 47
41 Safety regulations during maintenance work 47
42 Cleaning and washing 48
421 Cleaning the exterior 49
422 Cleaning the motor compartment 49
423 Electrical components 49
43 Safe lifting 49
44 Opening motor compartment 50
441 RR B 1-8 50
45 Cab tilting 51
451 RR E 1-8 51
452 RR E 2-8 CC 52
5- Preventive maintenance – P2 55
51 Maintenance Schedule 55
511 RR B/E 1-8 55
512 RR B/E 2-8 CC 65
6- Oil and grease specification – P3 75
7- Tools – P4 77
71 Super Seal connector 77
711 AMP connector 78
712 AMP microtimer 79
713 Diverse tools 80
8- Cab heating/ventilation – 0630 87
81 General 87
82 Air conditioning unit 87
821 Ventilation 87
822 Main heater 87
823 Auxiliary heater 87
824 Temperature 87
825 Air direction 88
826 Fuses 88
827 Air filter 88
828 Emergency exit (12) 89
829 Lighting 89
9- Driver protection – 0840 91
91 General 91
92 Tilt Stops 92
921 Inspection and Adjustment 92
922 Removing the tilt stops 93
10- Electric pump motor -1710 95
101 General 95
102 Dismantling the pump motor 95
103 Dismantling and assembling the pump motor 96
1031 Dismantling 96
1032 Assembling 96
104 Bearing replacement 97
1041 Dismantling 97
1042 Assembling 98
105 Installation instructions for external temperature sensor 99
11- Electric steering motor – 1730103
111 General103
112 Replacing the steering motor103
1121 Dismantling103
1122 Assembling103
113 Dismantling and assembling the carbon brushes104
12- Electric drive motor – 1760105
121 General105
122 Dismantling the drive motor105
123 Dismantling and assembling the drive motor106
1231 Dismantling the drive motor106
Removing the gear wheel106
Removing the brakes106
1232 Assembling the drive motor107
Assembling the brakes107
Assembling the gear wheel107
124 Bearing replacement108
1241 Dismantling108
1242 N-side108
D-side108
1243 Assembling109
N-side109
D-side109
125 Installation instructions for external temperature sensor110
13- Mechanical drive gear unit – 2550113
131 General113
132 Components/data for the drive assembly/transmission113
1321 Component placement114
1322 Technical data116
1323 Dismantling the transmission116
133 Replacing the drive motor/drive transmission117
1331 Dismantling the drive motor117
1332 Dismantling the gear wheel117
1333 Dismantling the drive transmission118
1334 Assembling the transmission118
1335 Installing the drive motor119
1336 Assembling the gear wheel119
134 Checking/replacing the oil120
1341 Checking/refilling the oil120
1342 Changing the Oil120
135 Repairs121
1351 Replacing the drive shaft sealing ring121
Dismantling121
Assembling122
1352 Leakage from the upper cover123
1353 Leakage from the lower cover123
1354 Replacing wheel bolts124
14- Travel brake system – 31001125
Without support arm brakes125
141 General125
142 Operating description125
1421 Releasing the accelerator126
1422 Travel direction selector126
1423 Pressing down the brake pedal127
1424 Parking brake128
1425 Emergency brake128
143 Electromechanical disc brake, drive motor129
1431 Assembling129
1432 Dismantling130
1433 Inspection130
1434 Assembling130
144 Maintenance131
1441 Adjusting the play131
1442 Wear131
1443 Check the braking force132
15- Travel brake system – 31002133
With support arm brake133
151 General133
152 Operating description133
1521 Releasing the accelerator134
1522 Travel direction selector134
1523 Pressing down the brake pedal135
1524 Parking brake136
1525 Emergency braking136
153 Electromechanical disc brake, drive motor137
1531 Assembling137
1532 Dismantling138
1533 Inspection138
1534 Assembling138
154 Maintenance139
1541 Adjusting the play139
1542 Wear139
1543 Check the braking force140
155 Multiple disc brake, support arm141
1551 Assembling141
1552 Dismantling142
1553 Inspection143
1554 Assembling143
156 Maintenance143
1561 Adjusting the play144
16- Drive wheel – 3530145
161 General145
162 Dismantling the drive wheel145
163 Assembling the drive wheel145
17- Fork/support arm wheel – 35501147
171 General147
172 Dismantling the wheel148
173 Assembling the wheel149
174 Dismantling/assembling the wheel bearings151
1741 265 mm wheel and 300 mm wheel without brakes151
Dismantling the bearing151
Assembling bearings151
1742 300 mm wheel with brake and 350 mm wheel152
Dismantling the bearing152
Assembling bearings152
18- Fork/support arm wheel – 35502153
181 General153
182 Dismantling the wheel153
183 Assembling the drive wheel154
184 Dismantling the wheel bearing154
185 Assembling the wheel bearing154
19- Mechanical steering system – 4100155
191 General155
192 Replacing the steering generator155
1921 Dismantling155
1922 Assembling155
20- Steering angle sensor – 4350157
201 General157
202 Procedure157
2011 Adjustment of the steering angle sensor158
21- Electrical system – 5000159
211 General159
2111 Electrical panel159
212 Symbol list and wiring diagrams160
2121 List of symbols160
2122 Wiring diagram (1/16)163
2123 Wiring diagram (2/16)164
2124 Wiring diagram (3/16)165
2125 Wiring diagram (4/16)166
2126 Wiring diagram (5/16)167
2127 Wiring diagram (6/16)168
2128 Wiring diagram (7/16)169
2129 Wiring diagram (8/16)170
21210 Wiring diagram (9/16)171
21211 Wiring diagram (10/16)172
21212 Wiring diagram (11/16)173
21213 Wiring diagram (12/16)174
21214 Wiring diagram (13/16)175
21215 Wiring diagram (14/16)176
21216 Wiring diagram (15/16)177
21217 Wiring diagram (16/16)178
213 Component list179
2131 Figure 1185
2132 Figure 2185
2133 Figure 3186
2134 Figure 4186
2135 Figure 5187
2136 Figure 6188
2137 Figure 7188
2138 Figure 8189
2139 Figure 9190
21310 Figure 10191
21311 Figure 11192
21312 Figure 12192
214 Functional description193
2141 Truck not started up193
2142 Truck started up194
2143 Choice of travel direction195
On the control console195
On the left-hand handle195
On the accelerator195
2144 Driving196
2145 Steering197
2146 Steering wheel indicator197
2147 Braking198
Auto-brakes198
Motor brakes (electric)198
Foot brake198
Parking brake198
2148 Fork lift199
2149 Maximum height199
21410 Maximum height200
21411 Fork lowering200
21412 Mast out/in201
21413 Fork tilt up/down201
21414 Hydraulic function 4201
21415 Hydraulic function 5202
21416 Cab tilt202
21417 Height indication203
21418 Height pre-set203
21419 Weighing203
21420 Driver identification204
Without pin code204
With pin code204
22- Battery – 5110205
221 Battery dimensions205
222 Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries206
2221 General206
2222 Battery recommendation206
2223 Battery installation206
2224 Recommended parameter setting for ventilation regulated batteries207
2225 Instructions for verifying the parameter setting207
23- Transistor panel – 5460209
231 Frequency converter209
2311 Terminal connections and pole bolts210
2312 Technical Data211
2313 Installation of new frequency converter on truck211
2314 Programming211
24- Electronic card – 5710213
241 General description213
242 Terminal connections and voltages on A5214
2421 10X214
2422 20X215
2423 30X215
2424 40X216
2425 50X216
2426 60X217
2427 70X217
2428 80X218
2429 90X218
243 Adjusting the lowering speed219
244 Displaying and programming220
2441 Keypad220
Clock221
Driver parameters 1-7221
245 Parameter setting of all parameters222
Clock222
Parameters223
2451 Parameter 1227
2452 Parameter 2227
2453 Parameter 3227
2454 Parameter 4227
2455 Parameter 5227
2456 Parameters 6 and 7227
2457 Parameter 11227
2458 Parameter 12227
2459 Parameters 13 and 14227
24510 Parameters 15 and 16228
24511 Parameters 17 and 18228
24512 Parameter 19229
24513 Parameter 20229
24514 Parameter 21229
24515 Parameter 22231
24516 Parameter 23231
24517 Parameter 24231
24518 Parameter 25231
24519 Parameter 26231
24520 Parameter 27231
24521 Parameter 28232
24522 Parameter 29232
24523 Parameter 30232
24524 Parameter 37232
24525 Parameter 38233
24526 Parameter 39234
24527 Parameters 40 to 42234
24528 Miscellaneous parameters234
246 Operating hours235
2461 Installing a new electronic card in the truck235
247 Warning codes236
248 Error Codes237
2481 Error mode237
2482 Safety logic238
249 Warning Codes without registration238
2410 Warning codes with registration259
2411 Error Codes278
24111 Error codes with registration279
25- Keypad311
251 General311
252 Display311
2521 Description of the keypad symboles312
253 Function313
2531 Function 0313
2532 Function 1313
2533 Function 2313
2534 Function 3314
254 Programming314
2541 LED status314
2542 Driver PIN-codes315
26- Hydraulics – 6000317
261 General317
262 Symbols317
2621 Hydraulics diagram 1 (4)319
2622 Hydraulics diagram 2 (4)320
2623 Hydraulics diagram 3 (4)321
2624 Hydraulics diagram 4 (4)322
263 List of symbols323
2631 Component placement 1 (3)325
2632 Component placement 2 (3)326
2633 Component placement 3 (3)327
264 Adjusting fork lowering328
265 Adjusting the maximum lifting capacity329
27- Hydraulic pump – 6140331
271 General331
272 Replacing the hydraulic pump331
2721 Dismantling331
2722 Assembling332
28- Hydraulic connections – 6230333
281 General333
282 Tightening torque for hydraulic connections333
2821 Conical connection with O-ring333
2822 Tredo seal334
2823 Pipe coupling334
2824 Connection screwed into aluminium334
2825 Connection screwed into steel335
Pressure class L335
29- Mast mounted hose reel – 6370337
291 General337
292 Assembling337
293 Check after assembly338
30- Main lift cylinder – 6610339
301 General339
302 Tools339
303 Dismantling the lift cylinders from the mast340
304 Dismantling the cylinder340
3041 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder341
3042 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder341
3043 Dismantling and assembling the hose rupture valve342
305 Assembling the cylinder342
3051 Assembling the cylinder in the mast342
31- Free lift cylinder – 6620343
311 General343
312 Tools343
313 Dismantling344
3131 Dismantling the cylinder345
314 Dismantle the rod seal and support ring345
3141 Assembling the rod seal and support ring345
315 Dismantling the piston346
3151 Fitting the piston in the free lift cylinder346
316 Dismantling and assembling the hose rupture valve346
317 Assembling the cylinder347
318 Assembly347
32- Reach cylinder – 6650349
321 General349
322 Assembling and dismantling the reach cylinder349
323 Dismantling349
3231 Dismantling the cylinder350
3232 Dismantle the rod seal and the support ring350
3233 Assembling the rod seal and the support ring350
3234 Dismantling the ram351
3235 Assembling the ram351
3236 Assembling the cylinder351
324 Assembling351
33- Tilt cylinder – 66601353
331 General353
332 Mast with valve on the fork carriage354
3321 Dismantling the fork carriage354
3322 Dismantling the cylinder355
3323 Dismantling the rod seal355
3324 Dismantling the ram355
3325 Assembling the ram355
3326 Assembling the rod seal356
3327 Assembling the cylinder356
3328 Assembling the fork carriage356
333 Mast without valve on the fork carriage357
3331 Dismantling the fork carriage357
3332 Dismantling the cylinder358
3333 Dismantling the rod seal358
3334 Dismantling the ram358
3335 Assembling the ram358
3336 Assembling the rod seal359
3337 Assembling the cylinder359
3338 Assembling the fork carriage359
34- Tilt cylinder – 66602361
341 General361
342 Dismantling the cylinder from the truck361
343 Dismantling and assembling the cylinder362
3431 Dismantling the cylinder362
3432 Dismantle the seals and the support ring362
3433 Assembling the rod seal and the support ring363
3434 Dismantling the ram363
3435 Assembling the ram363
3436 Assembling the cylinder363
344 Refitting the cylinder in the truck364
35- Main mast -7100365
351 General365
352 List of tools365
353 Transporting the truck366
354 Assembling the mast367
355 Dismantling the mast372
356 Adjusting the play373
3561 Adjusting the mast play376
Lateral play376
3562 Radial play377
357 Assembly377
36- Main lift chain system – 7120379
361 General379
362 Checking the chain setting379
363 Chain inspection379
3631 Noise379
3632 Surface rust379
3633 Rusty links379
3634 Stiff links380
3635 Bolt rotation380
3636 Loose bolts380
3637 Outline wear381
3638 Stretching381
3639 Damage382
36310 Damaged discs382
36311 Damaged bolts383
36312 Dirty chain383
364 Cleaning383
365 Lubrication383
37- Lifting devices – 7400385
371 General385
3711 Inspection intervals385
3712 Inspection385
3713 Surface cracks385
3714 Difference in height of fork tips385
3715 Positioning lock385
3716 Legibility of marking386
3717 Fork arm blade and shank386
3718 Fork arm mountings386
3719 Repair and testing386
Repair386
Yield test386
Fork387
Extended fork387
372 Checking the fork carriage’s wearing strips388
373 Fork spread unit390
3731 Servicing of fork spread unit390
374 Telescopic forks391
3741 Telescopic forks391
3742 Putting the telescopic forks into operation:392
375 Maintenance392
How to remove the outer fork392
How to mount the outer fork392
3751 Maintenance396
376 Troubleshooting397
3761 Instructions for replacing hydraulic parts399
377 Extended forks401
38- Battery charger – 8340403
381 General403
382 Installation404
383 Functional description404
3831 Display functions404
3832 Charging process404
3833 Shutdown conditions405
3834 Delayed power on and charging405
3835 Extra charging405
3836 Equalised charging406
3837 Current and voltage characteristics406
3838 Safety shutdowns406
3839 Display and keyboard407
Reading of analogue measurement values407
Error indication and error messages408
Reading statistics from the previous charge409
Reading of long term statistics410
Storing parameters410
Reading parameters411
Battery specific parameters411
Charger specific parameters412
Mains voltage codes412
Other functions412
Changing parameters413
38310 Acid circulation413
General413
BTM with acid circulation413
Pump type APE, VPM414
Pump type API414
384 Service and maintenance414
3841 Basic programming, code 30414
3842 Resetting the statistics, code 31414
3843 Calibrating the measurement value415
Calibrating the current’s zero value and temperatures, code 21415
Calibrating the battery voltage’s measurement value, code 20415
Calibrating the charging current, code 25416
Calibrating the mains voltage display, code 26416
3844 Calibrating and programming API416
Calibrating zero pressure416
Calibrating the pressure416
Programming the alarm limits416
Programming the API function417
3845 Adjusting the charging characteristics417
3846 Trouble shooting418
Error message, analysis and action418
Errors without indication419
3847 Trouble shooting acid circulation419
3848 Service measures419
Switching to the timer charger420
Replacing the display card420
Replacing the computer board421
Replacing the mother board421
Replacing the diodes421
3849 Preventive maintenance421
39- Control/computer equipment – 8700423
391 General423
392 Connection423
393 Layout424
3931 Main window424
3932 Nodes424
3933 Icons425
3934 Tool buttons and menu list426
3935 Information window426
3936 Status row426
394 Function for connection427
395 Function for disconnecting427
396 Function for program downloading427
3961 Normal loading428
3962 Loading in old versions of the electronic card428
3963 Emergency loading428
397 Function for truck report429
398 Function for parameters430
399 Function for diagnostics432
3991 Signal colours432
3992 Tab for “Analogue”433
3993 Tab for “Temperature”434
3994 Tab for “Digital”435
3910 Other menu functions436
39101 Save to file436
39102 Loading from a file436
39103 Resetting the CAN adapter436
39104 Deleting the fault code log436
39105 Resetting the hour meter436
39106 Reading the fault code log436
39107 Adjusting the date/time436
39108 Adjusting the hour meter on older cards437
39109 Help437
About TruckCom437
391010 Conclude437
3911 Specifications437
3912 Installation438
39121 Installation on a PC with Windows XP/ 2000/NT438
39122 IInstallation on a PC with Windows 95/ 98438
39123 In the event of any problems with communication with CAN439
39124 Uninstallation439
40- Extra warning lights/alarm – 9370441
401 General441
41- Positioning equipment – 9390443
411 General443
412 Height indication444
413 Function445
414 Display445
415 Height pre-set447
416 Function448
417 Display449
4171 Description of the display symbols450
418 Assembly of height pre-set451
419 Programming451
4191 Programming a level451
Collect level451
Leave level452
4192 Deleting programmed levels452
4110 Automatic driving453
41101 Collect load453
41102 Depositing a load454
41103 Inspection454
4111 Parameters455
41111 Parameter 1455
41112 Parameter 2455
41113 Parameter 3456
41114 Parameter 4456
41115 Parameter 5456
41116 Parameter 7457
41117 Parameter 8457
41118 Parameter 9457
4112 Programming parameters458
4113 Error codes460
42- TV equipment – 9390461
421 General461
422 Camera mounted on fork461
4221 Colour camera A51462
4222 Colour monitor A50462
4223 Voltage converter A10464
43- Truck log system, code lock – 9420465
431 General465
432 SD 16465
4321 Login with code (5-digit)465
4322 Logout465
433 Components466
If the truck does not start:468
434 I/O Module468
44- Extra equipment – 9500469
441 Dry powder extinguisher469
In the event of fire, the powder extinguisher should be employed as follows:469
4411 Regular checks of the powder extinguisher – truck driver470
4412 Inspection of powder extinguisher in service inspection of the truck470
45- Instructions for destruction471
451 General471
452 Procedure471
453 Abbreviations472
454 Sorting472
455 Frame/chassis (0300)473
4551 Dismantling473
Material handling473
456 Operator’s seat, cushion (0620)474
4561 Dismantling474
Material handling474
457 Cab heating/ventilation (0630)475
4571 Dismantling475
Material handling475
458 Driver controls (0640)476
4581 Dismantling476
Material handling476
459 Interior fittings RR-B (0680)477
4591 Dismantling477
Material handling478
4510 Interior fittings RR-E (0680)479
45101 Dismantling479
Material handling480
4511 Interior fittings RR-B-CC (0680)481
45111 Dismantling481
Material handling482
4512 Interior fittings RR-E-CC (0680)483
45121 Dismantling483
Material handling484
4513 Rollover guard/head guard (0810)485
45131 Dismantling485
Material handling485
4514 Finger protectors (0820)485
45141 Dismantling485
Material handling485
4515 Finger/foot protectors (0820)486
45151 Dismantling486
Material handling486
4516 Finger/foot protectors (0820)487
45161 Dismantling487
Material handling487
4517 Electric motors (1700)488
45171 Dismantling488
Material handling488
4518 Electric fan motor (1740)489
45181 Dismantling489
Material handling489
4519 Drive unit, final gear (2500)490
45191 Dismantling490
Material handling490
4520 Wheels (3500)491
45201 Dismantling491
Material handling491
4521 Electric steering system (4300)492
45211 Dismantling493
Material handling493
4522 General electric equipment (5100)494
45221 Dismantling494
Material handling494
4523 Manöversystem, körfunktion (5300)495
45231 Dismantling495
Material handling495
4524 Power system, drive function (5400)496
45241 Dismantling496
Material handling496
4525 Control system, operation function (5500)497
45251 Dismantling497
Material handling497
4526 Steering/protective electronics (5700)498
45261 Dismantling498
Material handling498
4527 Hydraulic unit (6100)499
45271 Dismantling500
Material handling500
4528 Hydraulic system, fitted on the chassis (6200)501
45281 Dismantling502
Material handling502
4529 Hydraulic system, fitted on the mast (6300)503
45291 Dismantling503
Material handling503
4530 Hydraulcylindrar (6600)504
45301 Dismantling505
Material handling505
4531 Main mast (7100)506
45311 Dismantling506
Material handling506
4532 Lift fork (7410)507
45321 Dismantling507
Material handling507
4533 Optional electric equipment (9300)507
45331 Dismantling507
Material handling507
4534 Radio/CD player (9330)508
45341 Dismantling508
Material handling508
4535 Extra work light (9360)509
45351 Dismantling509
Material handling509
4536 Optional electric equipment (9400)510
45361 Dismantling510
Material handling510
4537 Optional electric equipment (9400)511
45371 Dismantling511
Material handling512

IMAGES PREVIEW OF THE MANUAL:

S.M 5/24