BT FORKLIFT REFLEX RR B/E, RR B/E CC SERVICE MANUAL 232808-040 – PDF DOWNLOAD

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BT FORKLIFT REFLEX RR B/E, RR B/E CC SERVICE MANUAL 232808-040 – PDF DOWNLOAD

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BT FORKLIFT REFLEX RR B/E, RR B/E CC SERVICE MANUAL 232808-040 – PDF DOWNLOAD

Language : English
Pages : 506
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS

BT FORKLIFT REFLEX RR B/E, RR B/E CC SERVICE MANUAL 232808-040 – PDF DOWNLOAD

1- - Contents...............................................................................................  3
2- General product information - M2......................................................................... 17
	2.1 Presentation of the reach trucks.................................................................... 17
		2.1.1 Application areas for the reach trucks........................................................ 17
		2.1.2 Prohibited applications for the reach trucks.................................................. 17
	2.2 Truck data.......................................................................................... 18
	2.3 Truck dimensions.................................................................................... 19
	2.4 Identification plate, truck......................................................................... 21
		2.4.1 Capacity plate................................................................................ 21
		2.4.2 Modification plate............................................................................ 22
		2.4.3 Identification plate, mast.................................................................... 22
		2.4.4 Information plate, only Japan................................................................. 22
	2.5 Main components RR B/E 1-8.......................................................................... 23
	2.6 Main components RR B/E 2-8 CC....................................................................... 25
	2.7 Warning and information plates and symbols RR B/E 1-8............................................... 27
	2.8 Warning and information plates and symbols RR B/E 2-8 CC............................................ 29
3- Technical data - M4...................................................................................... 31
	3.1 General tightening torque........................................................................... 35
		3.1.1 Galvanised, non-oiled bolts................................................................... 35
		3.1.2 Untreated, oiled bolts........................................................................ 35
4- Introduction, maintenance - P1........................................................................... 37
	4.1 Safety regulations during maintenance work.......................................................... 37
	4.2 Cleaning and washing................................................................................ 38
		4.2.1 Cleaning the exterior......................................................................... 38
		4.2.2 Cleaning the motor compartment................................................................ 39
		4.2.3 Electrical components......................................................................... 39
	4.3 Safe lifting........................................................................................ 39
	4.4 Opening motor compartment........................................................................... 40
		4.4.1 RR B 1-8...................................................................................... 40
	4.5 Cab tilting......................................................................................... 41
		4.5.1 RR E 1-8...................................................................................... 41
		4.5.2 RR E 2-8 CC................................................................................... 43
5- Preventive maintenance - P2.............................................................................. 45
	5.1 Maintenance Schedule................................................................................ 45
		5.1.1 RR B/E 1-8.................................................................................... 45
		5.1.2 RR B/E 2-8 CC................................................................................. 55
6- Oil and grease specification - P3........................................................................ 65
7- Tools - P4............................................................................................... 67
	7.1 Super Seal connector................................................................................ 67
		7.1.1 AMP connector................................................................................. 68
		7.1.2 AMP microtimer................................................................................ 69
		7.1.3 Diverse tools................................................................................. 70
8- Cab heating/ventilation - 0630........................................................................... 77
	8.1 General............................................................................................. 77
	8.2 Air conditioning unit............................................................................... 77
		8.2.1 Ventilation................................................................................... 77
		8.2.2 Main heater................................................................................... 77
		8.2.3 Auxiliary heater.............................................................................. 77
		8.2.4 Temperature................................................................................... 77
		8.2.5 Air direction................................................................................. 78
		8.2.6 Fuses......................................................................................... 78
		8.2.7 Air filter.................................................................................... 78
		8.2.8 Emergency exit (12)........................................................................... 79
		8.2.9 Lighting...................................................................................... 79
9- Driver protection - 0840................................................................................. 81
	9.1 General............................................................................................. 81
	9.2 Tilt Stops.......................................................................................... 82
		9.2.1 Inspection and Adjustment..................................................................... 82
		9.2.2 Removing the tilt stops....................................................................... 83
10- Electric pump motor -1710............................................................................... 85
	10.1 General............................................................................................ 85
	10.2 Dismantling the pump motor......................................................................... 85
	10.3 Dismantling and assembling the pump motor.......................................................... 86
		10.3.1 Dismantling.................................................................................. 86
		10.3.2 Assembling................................................................................... 86
	10.4 Bearing replacement................................................................................ 87
		10.4.1 Dismantling.................................................................................. 87
		10.4.2 Assembling................................................................................... 88
	10.5 Installation instructions for external temperature sensor.......................................... 89
11- Electric steering motor - 1730.......................................................................... 93
	11.1 General............................................................................................ 93
	11.2 Replacing the steering motor....................................................................... 93
		11.2.1 Dismantling.................................................................................. 93
		11.2.2 Assembling................................................................................... 93
	11.3 Dismantling and assembling the carbon brushes...................................................... 94
12- Electric drive motor - 1760............................................................................. 95
	12.1 General............................................................................................ 95
	12.2 Dismantling the drive motor........................................................................ 95
	12.3 Dismantling and assembling the drive motor......................................................... 96
		12.3.1 Dismantling the drive motor.................................................................. 96
			Removing the gear wheel......................................................................... 96
			Removing the brakes............................................................................. 96
		12.3.2 Assembling the drive motor................................................................... 97
			Assembling the brakes........................................................................... 97
			Assembling the gear wheel....................................................................... 97
	12.4 Bearing replacement................................................................................ 98
		12.4.1 Dismantling.................................................................................. 98
		12.4.2 N-side....................................................................................... 98
			D-side.......................................................................................... 98
		12.4.3 Assembling................................................................................... 99
			N-side.......................................................................................... 99
			D-side.......................................................................................... 99
	12.5 Installation instructions for external temperature sensor..........................................100
13- Mechanical drive gear unit - 2550.......................................................................103
	13.1 General............................................................................................103
	13.2 Components/data for the drive assembly/transmission................................................103
		13.2.1 Component placement..........................................................................104
		13.2.2 Technical data...............................................................................106
		13.2.3 Dismantling the transmission.................................................................106
	13.3 Replacing the drive motor/drive transmission.......................................................107
		13.3.1 Dismantling the drive motor..................................................................107
		13.3.2 Dismantling the gear wheel...................................................................107
		13.3.3 Dismantling the drive transmission...........................................................107
		13.3.4 Assembling the transmission..................................................................108
		13.3.5 Installing the drive motor...................................................................109
		13.3.6 Assembling the gear wheel....................................................................109
	13.4 Checking/replacing the oil.........................................................................110
		13.4.1 Checking/refilling the oil...................................................................110
		13.4.2 Changing the Oil.............................................................................110
	13.5 Repairs............................................................................................111
		13.5.1 Replacing the drive shaft sealing ring.......................................................111
			Dismantling.....................................................................................111
			Assembling......................................................................................112
		13.5.2 Leakage from the upper cover.................................................................113
		13.5.3 Leakage from the lower cover.................................................................113
		13.5.4 Replacing wheel bolts........................................................................114
14- Travel brake system - 3100.1............................................................................115
	Without support arm brakes..............................................................................115
	14.1 General............................................................................................115
	14.2 Operating description..............................................................................115
		14.2.1 Releasing the accelerator....................................................................116
		14.2.2 Travel direction selector....................................................................116
		14.2.3 Pressing down the brake pedal................................................................117
		14.2.4 Parking brake................................................................................118
		14.2.5 Emergency brake..............................................................................118
	14.3 Electromechanical disc brake, drive motor..........................................................119
		14.3.1 Assembling...................................................................................119
		14.3.2 Dismantling..................................................................................120
		14.3.3 Inspection...................................................................................120
		14.3.4 Assembling...................................................................................120
	14.4 Maintenance........................................................................................121
		14.4.1 Adjusting the play...........................................................................121
		14.4.2 Wear.........................................................................................121
		14.4.3 Check the braking force......................................................................122
15- Travel brake system - 3100.2............................................................................123
	With support arm brake..................................................................................123
	15.1 General............................................................................................123
	15.2 Operating description..............................................................................123
		15.2.1 Releasing the accelerator....................................................................124
		15.2.2 Travel direction selector....................................................................124
		15.2.3 Pressing down the brake pedal................................................................124
		15.2.4 Parking brake................................................................................124
		15.2.5 Emergency braking............................................................................125
	15.3 Electromechanical disc brake, drive motor..........................................................126
		15.3.1 Assembling...................................................................................126
		15.3.2 Dismantling..................................................................................127
		15.3.3 Inspection...................................................................................127
		15.3.4 Assembling...................................................................................127
	15.4 Maintenance........................................................................................128
		15.4.1 Adjusting the play...........................................................................128
		15.4.2 Wear.........................................................................................128
		15.4.3 Check the braking force......................................................................129
	15.5 Multiple disc brake, support arm...................................................................130
		15.5.1 Assembling...................................................................................130
		15.5.2 Dismantling..................................................................................131
		15.5.3 Inspection...................................................................................132
		15.5.4 Assembling...................................................................................132
	15.6 Maintenance........................................................................................132
		15.6.1 Adjusting the play...........................................................................133
16- Drive wheel - 3530......................................................................................135
	16.1 General............................................................................................135
	16.2 Dismantling the drive wheel........................................................................135
	16.3 Assembling the drive wheel.........................................................................135
17- Fork/support arm wheel - 3550.1.........................................................................137
	17.1 General............................................................................................137
	17.2 Dismantling the wheel..............................................................................138
	17.3 Assembling the wheel...............................................................................139
	17.4 Dismantling/assembling the wheel bearings..........................................................141
		17.4.1 265 mm wheel and 300 mm wheel without brakes.................................................141
			Dismantling the bearing.........................................................................141
			Assembling bearings.............................................................................141
		17.4.2 300 mm wheel with brake and 350 mm wheel.....................................................142
			Dismantling the bearing.........................................................................142
			Assembling bearings.............................................................................142
18- Fork/support arm wheel - 3550.2.........................................................................143
	Valid for T-code 403-404................................................................................143
	18.1 General............................................................................................143
	18.2 Dismantling the wheel..............................................................................143
	18.3 Assembling the drive wheel.........................................................................144
	18.4 Dismantling the wheel bearings.....................................................................144
	18.5 Assembling the wheel bearings......................................................................144
19- Mechanical steering system - 4100.......................................................................145
	19.1 General............................................................................................145
	19.2 Replacing the steering generator...................................................................145
		19.2.1 Dismantling..................................................................................145
		19.2.2 Assembling...................................................................................145
20- Steering angle sensor - 4350............................................................................147
	20.1 General............................................................................................147
	20.2 Procedure..........................................................................................147
		20.1.1 Adjustment of the steering angle sensor......................................................148
22- Battery - 5110..........................................................................................149
	22.1 Battery dimensions.................................................................................149
	22.2 Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries.............150
		22.2.1 General......................................................................................150
		22.2.2 Battery recommendation.......................................................................150
		22.2.3 Battery installation.........................................................................150
		22.2.4 Recommended parameter setting for ventilation regulated batteries............................151
		22.2.5 Instructions for verifying the parameter setting.............................................151
21- Electrical system - 5000................................................................................153
	21.1 Electrical Panel...................................................................................153
	21.2 List of symbols and wiring diagrams................................................................154
		21.2.1 List of symbols..............................................................................154
		21.2.2 Wiring diagram (1/16)........................................................................157
	21.3 Component list.....................................................................................173
		21.3.1 Figure 1.....................................................................................179
		21.3.2 Figure 2.....................................................................................179
		21.3.3 Figure 3.....................................................................................180
		21.3.4 Figure 4.....................................................................................180
		21.3.5 Figure 5.....................................................................................181
		21.3.6 Figure 6.....................................................................................182
		21.3.7 Figure 7.....................................................................................182
		21.3.8 Figure 8.....................................................................................183
		21.3.9 Figure 9.....................................................................................184
		21.3.10 Figure 10...................................................................................185
		21.3.11 Figure 11...................................................................................186
		21.3.12 Figure 12...................................................................................186
	21.4 Functional description.............................................................................187
		21.4.1 Truck not started up.........................................................................187
		21.4.2 Truck started up.............................................................................188
		21.4.3 Selection of travel direction................................................................189
			On the operating console........................................................................189
			On the left-hand handle.........................................................................189
			On the accelerator..............................................................................189
		21.4.4 Driving......................................................................................190
		21.4.5 Steering.....................................................................................191
		21.4.6 Steering wheel indicator.....................................................................191
		21.4.7 Braking......................................................................................192
			Auto-brakes.....................................................................................192
			Motor brakes (electric).........................................................................192
			Foot brake......................................................................................192
			Parking brake...................................................................................192
		21.4.8 Fork lift....................................................................................193
		21.4.9 Maximum height...............................................................................193
		21.4.10 Maximum height..............................................................................194
		21.4.11 Fork lowering...............................................................................194
		21.4.12 Mast out/in.................................................................................195
		21.4.13 Fork tilt up/down...........................................................................195
		21.4.14 Hydraulic function 4........................................................................195
		21.4.15 Hydraulic function 5........................................................................196
		21.4.16 Cab tilt....................................................................................196
		21.4.17 Height indication...........................................................................197
		21.4.18 Height pre-set..............................................................................197
		21.4.19 Weighing....................................................................................197
		21.4.20 Driver identification.......................................................................198
			Without pin code................................................................................198
			With pin code...................................................................................198
23- Transistor panel - 5460.................................................................................199
	23.1 Frequency converter................................................................................199
		23.1.1 General description..........................................................................199
		23.1.2 Terminal connections and pole bolts..........................................................200
		23.1.3 Technical data...............................................................................201
		23.1.4 Programming..................................................................................201
24- Electronic card - 5710..................................................................................203
	24.1 General description................................................................................203
	24.2 Terminal connections and voltages on A5............................................................204
		24.2.1 10X..........................................................................................204
		24.2.2 20X..........................................................................................205
		24.2.3 30X..........................................................................................205
		24.2.4 40X..........................................................................................206
		24.2.5 50X..........................................................................................206
		24.2.6 60X..........................................................................................207
		24.2.7 70X..........................................................................................207
		24.2.8 80X..........................................................................................208
		24.2.9 90X..........................................................................................208
	24.3 Adjusting the lowering speed.......................................................................209
	24.4 Display and programming............................................................................210
		24.4.1 Keyboard.....................................................................................210
			Clock...........................................................................................211
			Driver parameters 1-7...........................................................................211
	24.5 Parameter settings for all parameters..............................................................212
		Clock...............................................................................................213
		Parameters..........................................................................................213
		24.5.1 Parameter 1..................................................................................217
		24.5.2 Parameter 2..................................................................................217
		24.5.3 Parameter 3..................................................................................217
		24.5.4 Parameter 4..................................................................................217
		24.5.5 Parameter 5..................................................................................217
		24.5.6 Parameters 6 and 7...........................................................................217
		24.5.7 Parameter 11.................................................................................217
		24.5.8 Parameter 12.................................................................................217
		24.5.9 Parameters 13 to 14..........................................................................217
		24.5.10 Parameters 15 and 16........................................................................218
		24.5.11 Parameters 17 and 18........................................................................218
		24.5.12 Parameter 19................................................................................218
		24.5.13 Parameter 20................................................................................219
		24.5.14 Parameter 21................................................................................219
		24.5.15 Parameter 22................................................................................220
		24.5.16 Parameter 23................................................................................220
		24.5.17 Parameter 24................................................................................220
		24.5.18 Parameter 25................................................................................220
		24.5.19 Parameter 26................................................................................220
		24.5.20 Parameter 27................................................................................220
		24.5.21 Parameter 28................................................................................220
		24.5.22 Parameter 29................................................................................220
		24.5.23 Parameter 30................................................................................221
		24.5.24 Parameter 37................................................................................221
		24.5.25 Parameter 38................................................................................221
		24.5.26 Parameter 39................................................................................222
		24.5.27 Parameters 40 to 42.........................................................................222
		24.5.28 Other parameters............................................................................222
	24.6 Operating Time.....................................................................................223
		24.6.1 Installing a new card in the truck...........................................................223
	24.7 Warning Codes......................................................................................224
	24.8 Error codes........................................................................................225
		24.8.1 Error mode...................................................................................225
		24.8.2 Safety logic.................................................................................226
	24.9 Warning codes without registration.................................................................227
	24.10 Warning codes with registration...................................................................248
	24.11 Error codes.......................................................................................267
		24.11.1 Error codes with registration...............................................................268
25- Keyboard................................................................................................297
	25.1 General............................................................................................297
	25.2 Display............................................................................................297
		25.2.1 Description of the keyboard symbols..........................................................298
	25.3 Function...........................................................................................299
		25.3.1 Function 0...................................................................................299
		25.3.2 Function 1...................................................................................299
		25.3.3 Function 2...................................................................................299
		25.3.4 Function 3...................................................................................300
	25.4 Programming........................................................................................300
		25.4.1 LED status...................................................................................300
		25.4.2 Driver codes.................................................................................301
26- Hydraulics - 6000.......................................................................................303
	26.1 General............................................................................................303
	26.2 Symbols............................................................................................303
		26.2.1 Hydraulics diagram 1 (4).....................................................................305
		26.2.2 Hydraulics diagram 2 (4).....................................................................306
		26.2.3 Hydraulics diagram 3 (4).....................................................................307
		26.2.4 Hydraulics diagram 4 (4).....................................................................308
	26.3 List of symbols....................................................................................309
		26.3.1 Component placement 1 (3)....................................................................311
		26.3.2 Component placement 2 (3)....................................................................312
		26.3.3 Component placement 3 (3)....................................................................313
	26.4 Adjusting fork lowering............................................................................314
	26.5 Adjusting the maximum lifting capacity.............................................................315
27- Hydraulic pump - 6140...................................................................................317
	27.1 General............................................................................................317
	27.2 Replacing the hydraulic pump.......................................................................317
		27.2.1 Dismantling..................................................................................317
		27.2.2 Assembling...................................................................................318
28- Hydraulic connections - 6230............................................................................319
	28.1 General............................................................................................319
	28.2 Tightening torque for hydraulic connections........................................................319
		28.2.1 Conical connection with O-ring...............................................................319
		28.2.2 Tredo seal...................................................................................320
		28.2.3 Pipe coupling................................................................................320
		28.2.4 Connection screwed into aluminium............................................................320
		28.2.5 Connection screwed into steel................................................................321
			Pressure class L................................................................................321
29- Mast mounted hose reel - 6370...........................................................................323
	29.1 General............................................................................................323
	29.2 Assembling.........................................................................................323
	29.3 Check after assembly...............................................................................324
30- Main lift cylinder - 6610...............................................................................325
	30.1 General............................................................................................325
	30.2 Tools..............................................................................................325
	30.3 Dismantling the lift cylinders from the mast.......................................................326
	30.4 Dismantling the cylinder...........................................................................326
		30.4.1 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder....327
		30.4.2 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder........327
		30.4.3 Dismantling and assembling the hose rupture valve............................................328
	30.5 Assembling the cylinder............................................................................328
		30.5.1 Assembling the cylinder in the mast..........................................................328
31- Free lift cylinder - 6620...............................................................................329
	31.1 General............................................................................................329
	31.2 Tools..............................................................................................329
	31.3 Dismantling........................................................................................330
		31.3.1 Dismantling the cylinder.....................................................................331
	31.4 Dismantle the rod seal and support ring............................................................331
		31.4.1 Assembling the rod seal and support ring.....................................................331
	31.5 Dismantling the piston.............................................................................332
		31.5.1 Fitting the piston in the free lift cylinder.................................................332
	31.6 Dismantling and assembling the hose rupture valve..................................................332
	31.7 Assembling the cylinder............................................................................333
	31.8 Assembly...........................................................................................333
32- Reach cylinder - 6650...................................................................................335
	32.1 General............................................................................................335
	32.2 Assembling and dismantling the reach cylinder......................................................335
	32.3 Dismantling........................................................................................335
		32.3.1 Dismantling the cylinder.....................................................................336
		32.3.2 Dismantle the rod seal and the support ring..................................................336
		32.3.3 Assembling the rod seal and the support ring.................................................336
		32.3.4 Dismantling the ram..........................................................................337
		32.3.5 Assembling the ram...........................................................................337
		32.3.6 Assembling the cylinder......................................................................337
	32.4 Assembling.........................................................................................337
33- Tilt cylinder - 6660.1..................................................................................339
	33.1 General............................................................................................339
	33.2 Mast with valve on the fork carriage...............................................................339
		33.2.1 Dismantling the fork carriage................................................................339
		33.2.2 Dismantling the cylinder.....................................................................340
		33.2.3 Dismantling the rod seal.....................................................................340
		33.2.4 Dismantling the ram..........................................................................341
		33.2.5 Assembling the ram...........................................................................341
		33.2.6 Assembling the rod seal......................................................................341
		33.2.7 Assembling the cylinder......................................................................341
		33.2.8 Assembling the fork carriage.................................................................342
	33.3 Mast without valve on the fork carriage............................................................343
		33.3.1 Dismantling the fork carriage................................................................343
		33.3.2 Dismantling the cylinder.....................................................................344
		33.3.3 Dismantling the rod seal.....................................................................344
		33.3.4 Dismantling the ram..........................................................................344
		33.3.5 Assembling the ram...........................................................................344
		33.3.6 Assembling the rod seal......................................................................345
		33.3.7 Assembling the cylinder......................................................................345
		33.3.8 Assembling the fork carriage.................................................................345
34- Tilt cylinder - 6660.2..................................................................................347
	34.1 General............................................................................................347
	34.2 Dismantling the cylinder from the truck............................................................347
	34.3 Dismantling and assembling the cylinder............................................................348
		34.3.1 Dismantling the cylinder.....................................................................348
		34.3.2 Dismantle the seals and the support ring.....................................................348
		34.3.3 Assembling the rod seal and the support ring.................................................349
		34.3.4 Dismantling the ram..........................................................................349
		34.3.5 Assembling the ram...........................................................................349
		34.3.6 Assembling the cylinder......................................................................349
	34.4 Refitting the cylinder in the truck................................................................350
35- Main mast -7100.........................................................................................351
	35.1 General............................................................................................351
	35.2 List of tools......................................................................................351
	35.3 Transporting the truck.............................................................................352
	35.4 Assembling the mast................................................................................353
	35.5 Dismantling the mast...............................................................................358
	35.6 Adjusting the play.................................................................................359
		35.6.1 Adjusting the mast play......................................................................362
			Lateral play....................................................................................362
		35.6.2 Radial play..................................................................................363
	35.7 Assembly...........................................................................................363
36- Main lift chain system - 7120...........................................................................365
	36.1 General............................................................................................365
	36.2 Checking the chain setting.........................................................................365
	36.3 Chain inspection...................................................................................365
		36.3.1 Noise........................................................................................365
		36.3.2 Surface rust.................................................................................365
		36.3.3 Rusty links..................................................................................365
		36.3.4 Stiff links..................................................................................366
		36.3.5 Bolt rotation................................................................................366
		36.3.6 Loose bolts..................................................................................366
		36.3.7 Outline wear.................................................................................367
		36.3.8 Stretching...................................................................................368
		36.3.9 Damage.......................................................................................369
		36.3.10 Damaged discs...............................................................................369
		36.3.11 Damaged bolts...............................................................................369
		36.3.12 Dirty chain.................................................................................369
	36.4 Cleaning...........................................................................................369
	36.5 Lubrication........................................................................................370
37- Lifting devices - 7400..................................................................................371
	37.1 General............................................................................................371
		37.1.1 Inspection intervals.........................................................................371
		37.1.2 Inspection...................................................................................371
		37.1.3 Surface cracks...............................................................................371
		37.1.4 Difference in height between the fork tips...................................................371
		37.1.5 Position locks...............................................................................371
		37.1.6 Legible markings.............................................................................371
		37.1.7 Fork blade and shaft.........................................................................372
		37.1.8 Assembly aid on fork.........................................................................372
		37.1.9 Repairs and testing..........................................................................372
			Repairs.........................................................................................372
			Testing the yield point.........................................................................372
			Fork............................................................................................373
			Fixed extended fork.............................................................................373
	37.2 Extended forks with adjustable fork length.........................................................374
	37.3 Manual telescopic forks............................................................................376
		37.3.1 Assembly.....................................................................................376
		37.3.2 Maintenance..................................................................................377
	37.4 Hydraulic telescopic forks.........................................................................378
		37.4.1 Assembly instructions........................................................................378
			Telescopic forks with separate flow dividers....................................................379
			Commissioning of telescopic forks with separate flow dividers...................................380
			Telescopic forks with integrated flow dividers..................................................381
			Commissioning of telescopic forks with integrated flow dividers.................................383
	37.5 Maintenance........................................................................................383
		37.5.1 Maintenance..................................................................................383
	37.6 Troubleshooting, telescopic forks with separate flow dividers......................................384
		37.6.1 Troubleshooting for telescopic forks with integrated flow dividers...........................386
		37.6.2 Instructions for replacing hydraulic parts...................................................388
			Disassembly.....................................................................................388
			Assembly........................................................................................388
	37.7 Fork carriage......................................................................................390
		37.7.1 Checking the fork carriage’s wearing strip...................................................390
		37.7.2 Lubrication..................................................................................391
	37.8 Fork spread unit...................................................................................392
		37.8.1 Servicing of fork spread unit................................................................392
38- Battery charger - 8340..................................................................................393
	38.1 General............................................................................................393
	38.2 Installation.......................................................................................394
	38.3 Functional description.............................................................................394
		38.3.1 Display functions............................................................................394
		38.3.2 Charging process.............................................................................394
		38.3.3 Shutdown conditions..........................................................................395
		38.3.4 Delayed power on and charging................................................................395
		38.3.5 Extra charging...............................................................................395
		38.3.6 Equalised charging...........................................................................396
		38.3.7 Current and voltage characteristics..........................................................396
		38.3.8 Safety shutdowns.............................................................................396
		38.3.9 Display and keyboard.........................................................................397
			Reading of analogue measurement values..........................................................397
			Error indication and error messages.............................................................398
			Reading statistics from the previous charge.....................................................399
			Reading of long term statistics.................................................................400
			Storing parameters..............................................................................400
			Reading parameters..............................................................................401
			Battery specific parameters.....................................................................401
			Charger specific parameters.....................................................................402
			Mains voltage codes.............................................................................402
			Other functions.................................................................................402
			Changing parameters.............................................................................403
		38.3.10 Acid circulation............................................................................403
			General.........................................................................................403
			BTM with acid circulation.......................................................................403
			Pump type APE, VPM..............................................................................404
			Pump type API...................................................................................404
	38.4 Service and maintenance............................................................................404
		38.4.1 Basic programming, code 30...................................................................404
		38.4.2 Resetting the statistics, code 31............................................................404
		38.4.3 Calibrating the measurement value............................................................405
			Calibrating the current’s zero value and temperatures, code 21..................................405
			Calibrating the battery voltage’s measurement value, code 20....................................405
			Calibrating the charging current, code 25.......................................................406
			Calibrating the mains voltage display, code 26..................................................406
		38.4.4 Calibrating and programming API..............................................................406
			Calibrating zero pressure.......................................................................406
			Calibrating the pressure........................................................................406
			Programming the alarm limits....................................................................406
			Programming the API function....................................................................407
		38.4.5 Adjusting the charging characteristics.......................................................407
		38.4.6 Trouble shooting.............................................................................408
			Error message, analysis and action..............................................................408
			Errors without indication.......................................................................409
		38.4.7 Trouble shooting acid circulation............................................................409
		38.4.8 Service measures.............................................................................409
			Switching to the timer charger..................................................................410
			Replacing the display card......................................................................410
			Replacing the computer board....................................................................411
			Replacing the mother board......................................................................411
			Replacing the diodes............................................................................411
		38.4.9 Preventive maintenance.......................................................................411
39- Control/computer equipment - 8700.......................................................................413
	39.1 General............................................................................................413
	39.2 Connection.........................................................................................413
	39.3 Layout.............................................................................................414
		39.3.1 Main window..................................................................................414
		39.3.2 Nodes........................................................................................414
		39.3.3 Icons........................................................................................415
		39.3.4 Tool buttons and menu list...................................................................416
		39.3.5 Information window...........................................................................416
		39.3.6 Status row...................................................................................416
	39.4 Function for connection............................................................................417
	39.5 Function for disconnecting.........................................................................417
	39.6 Function for program downloading...................................................................417
		39.6.1 Normal loading...............................................................................418
		39.6.2 Loading in old versions of the electronic card...............................................418
		39.6.3 Emergency loading............................................................................418
	39.7 Function for truck report..........................................................................419
	39.8 Function for parameters............................................................................420
	39.9 Function for diagnostics...........................................................................422
		39.9.1 Signal colours...............................................................................422
		39.9.2 Tab for “Analogue”...........................................................................423
		39.9.3 Tab for “Temperature”........................................................................424
		39.9.4 Tab for “Digital”............................................................................425
	39.10 Other menu functions..............................................................................426
		39.10.1 Save to file................................................................................426
		39.10.2 Loading from a file.........................................................................426
		39.10.3 Resetting the CAN adapter...................................................................426
		39.10.4 Deleting the fault code log.................................................................426
		39.10.5 Resetting the hour meter....................................................................426
		39.10.6 Reading the fault code log..................................................................426
		39.10.7 Adjusting the date/time.....................................................................426
		39.10.8 Adjusting the hour meter on older cards.....................................................427
		39.10.9 Help........................................................................................427
			About TruckCom..................................................................................427
		39.10.10 Conclude...................................................................................427
	39.11 Specifications....................................................................................427
	39.12 Installation......................................................................................428
		39.12.1 Installation on a PC with Windows XP/ 2000/NT...............................................428
		39.12.2 IInstallation on a PC with Windows 95/ 98...................................................428
		39.12.3 In the event of any problems with communication with CAN....................................429
		39.12.4 Uninstallation..............................................................................429
40- Extra warning light/alarm - 9370........................................................................431
	40.1 General............................................................................................431
	40.2 Wiring diagram.....................................................................................433
41- Positioning equipment - 9390............................................................................435
	41.1 General............................................................................................435
	41.2 Height indication..................................................................................436
	41.3 Function...........................................................................................437
	41.4 Display............................................................................................438
	41.5 Height pre-set.....................................................................................439
	41.6 Function...........................................................................................440
	41.7 Display............................................................................................441
		41.7.1 Description of the display symbols...........................................................442
	41.8 Assembly of height pre-set.........................................................................443
	41.9 Programming........................................................................................443
		41.9.1 Programming a level..........................................................................443
			Collect level...................................................................................443
			Leave level.....................................................................................444
		41.9.2 Deleting programmed levels...................................................................444
	41.10 Automatic driving.................................................................................445
		41.10.1 Collect load................................................................................445
		41.10.2 Depositing a load...........................................................................446
		41.10.3 Inspection..................................................................................446
	41.11 Parameters........................................................................................447
		41.11.1 Parameter 1.................................................................................447
		41.11.2 Parameter 2.................................................................................447
		41.11.3 Parameter 3.................................................................................448
		41.11.4 Parameter 4.................................................................................448
		41.11.5 Parameter 5.................................................................................448
		41.11.6 Parameter 7.................................................................................449
		41.11.7 Parameter 8.................................................................................449
		41.11.8 Parameter 9.................................................................................449
	41.12 Programming parameters............................................................................450
	41.13 Error codes.......................................................................................452
42- TV equipment - 9390.....................................................................................453
	42.1 General............................................................................................453
	42.2 Camera mounted on fork.............................................................................453
		42.2.1 Colour camera A51............................................................................454
		42.2.2 Colour monitor A50...........................................................................454
		42.2.3 Voltage converter A10........................................................................456
43- Truck log system, code lock - 9420......................................................................457
	43.1 General............................................................................................457
	43.2 SD 16..............................................................................................457
		43.2.1 Login with code (5-digit)....................................................................457
		43.2.2 Logout.......................................................................................457
	43.3 Components.........................................................................................458
		If the truck does not start:........................................................................460
	43.4 I/O Module.........................................................................................460
44- Extra equipment - 9500..................................................................................461
	44.1 Dry powder extinguisher............................................................................461
		In the event of fire, the powder extinguisher should be employed as follows:........................461
		44.1.1 Regular checks of the powder extinguisher - truck driver.....................................462
		44.1.2 Inspection of powder extinguisher in service inspection of the truck.........................462
45- Instructions for destruction............................................................................463
	45.1 General............................................................................................463
	45.2 Procedure..........................................................................................463
	45.3 Abbreviations......................................................................................464
	45.4 Sorting............................................................................................464
	45.5 Frame/chassis (0300)...............................................................................465
		45.5.1 Dismantling..................................................................................465
			Material handling...............................................................................465
	45.6 Operator's seat, cushion (0620)....................................................................466
		45.6.1 Dismantling..................................................................................466
			Material handling...............................................................................466
	45.7 Cab heating/ventilation (0630).....................................................................467
		45.7.1 Dismantling..................................................................................467
			Material handling...............................................................................467
	45.8 Driver controls (0640).............................................................................468
		45.8.1 Dismantling..................................................................................468
			Material handling...............................................................................468
	45.9 Interior fittings RR-B (0680)......................................................................469
		45.9.1 Dismantling..................................................................................469
			Material handling...............................................................................470
	45.10 Interior fittings RR-E (0680).....................................................................471
		45.10.1 Dismantling.................................................................................471
			Material handling...............................................................................472
	45.11 Interior fittings RR-B-CC (0680)..................................................................473
		45.11.1 Dismantling.................................................................................473
			Material handling...............................................................................474
	45.12 Interior fittings RR-E-CC (0680)..................................................................475
		45.12.1 Dismantling.................................................................................475
			Material handling...............................................................................476
	45.13 Rollover guard/head guard (0810)..................................................................477
		45.13.1 Dismantling.................................................................................477
			Material handling...............................................................................477
	45.14 Finger protectors (0820)..........................................................................477
		45.14.1 Dismantling.................................................................................477
			Material handling...............................................................................477
	45.15 Finger/foot protectors (0820).....................................................................478
		45.15.1 Dismantling.................................................................................478
			Material handling...............................................................................478
	45.16 Finger/foot protectors (0820).....................................................................479
		45.16.1 Dismantling.................................................................................479
			Material handling...............................................................................479
	45.17 Electric motors (1700)............................................................................480
		45.17.1 Dismantling.................................................................................480
			Material handling...............................................................................480
	45.18 Electric fan motor (1740).........................................................................481
		45.18.1 Dismantling.................................................................................481
			Material handling...............................................................................481
	45.19 Drive unit, final gear (2500).....................................................................482
		45.19.1 Dismantling.................................................................................482
			Material handling...............................................................................482
	45.20 Wheels (3500).....................................................................................483
		45.20.1 Dismantling.................................................................................483
			Material handling...............................................................................483
	45.21 Electric steering system (4300)...................................................................484
		45.21.1 Dismantling.................................................................................485
			Material handling...............................................................................485
	45.22 General electric equipment (5100).................................................................486
		45.22.1 Dismantling.................................................................................486
			Material handling...............................................................................486
	45.23 Manöversystem, körfunktion (5300).................................................................487
		45.23.1 Dismantling.................................................................................487
			Material handling...............................................................................487
	45.24 Power system, drive function (5400)...............................................................488
		45.24.1 Dismantling.................................................................................488
			Material handling...............................................................................488
	45.25 Control system, operation function (5500).........................................................489
		45.25.1 Dismantling.................................................................................489
			Material handling...............................................................................489
	45.26 Steering/protective electronics (5700)............................................................490
		45.26.1 Dismantling.................................................................................490
			Material handling...............................................................................490
	45.27 Hydraulic unit (6100).............................................................................491
		45.27.1 Dismantling.................................................................................492
			Material handling...............................................................................492
	45.28 Hydraulic system, fitted on the chassis (6200)....................................................493
		45.28.1 Dismantling.................................................................................494
			Material handling...............................................................................494
	45.29 Hydraulic system, fitted on the mast (6300).......................................................495
		45.29.1 Dismantling.................................................................................495
			Material handling...............................................................................495
	45.30 Hydraulcylindrar (6600)...........................................................................496
		45.30.1 Dismantling.................................................................................497
			Material handling...............................................................................497
	45.31 Main mast (7100)..................................................................................498
		45.31.1 Dismantling.................................................................................498
			Material handling...............................................................................498
	45.32 Lift fork (7410)..................................................................................499
		45.32.1 Dismantling.................................................................................499
			Material handling...............................................................................499
	45.33 Optional electric equipment (9300)................................................................499
		45.33.1 Dismantling.................................................................................499
			Material handling...............................................................................499
	45.34 Radio/CD player (9330)............................................................................500
		45.34.1 Dismantling.................................................................................500
			Material handling...............................................................................500
	45.35 Extra work light (9360)...........................................................................501
		45.35.1 Dismantling.................................................................................501
			Material handling...............................................................................501
	45.36 Optional electric equipment (9400)................................................................502
		45.36.1 Dismantling.................................................................................502
			Material handling...............................................................................502
	45.37 Optional electric equipment (9400)................................................................503
		45.37.1 Dismantling.................................................................................503
			Material handling...............................................................................503

DESCRIPTION:

BT FORKLIFT REFLEX RR B/E, RR B/E CC SERVICE MANUAL 232808-040 – PDF DOWNLOAD

General product information 
Presentation of the reach trucks
The reach truck program is intended for handling pallets indoors or alternatively other types of loads using other load carriers. The trucks are operated seated in a protected and ergonomic operator position. The reach trucks are available in different size classes and have as standard a lifting capacity of up to 2500 kg and a lifting height of up to 11,5 m.
The trucks are equipped with a 48 V electrical system. The travel and lifting speeds are transistor controlled to provide smooth operations. In addition, the travel function and the different hydraulic functions have additional controls which further enhance these features. Different speeds, steering and cab tilt (optional) can be set using parameters to give the best possible individual setting for the functions

S.S 05/01/2025