BT Forklift REFLEX RR B/E, RR B/E CC Service manual PDF

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BT Forklift REFLEX RR B/E, RR B/E CC Service manual -PDF DOWNLOAD

FILE DETAILS:

BT Forklift REFLEX RR B/E, RR B/E CC Service manual -PDF DOWNLOAD

Language : English,German,French,Swedish
Pages :482
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Forklift REFLEX RR B/E RR B/E CC Service manual -PDF DOWNLOAD

1- Contents 3
2- Technical data – M4 15
21 General tightening torque 19
211 Galvanised, non-oiled bolts 19
212 Untreated, oiled bolts 19
3- Introduction, maintenance – P1 21
31 Safety regulations during maintenance work 21
32 Cleaning and washing 22
321 Cleaning the exterior 22
322 Cleaning the motor compartment 23
323 Electrical components 23
33 Safe lifting 23
34 Opening motor compartment 24
341 RR B 1-8 24
35 Cab tilting 25
351 RR E 1-8 25
352 RR E 2-8 CC 27
4- Preventive maintenance – P2 29
41 Maintenance Schedule 29
411 RR B/E 1-8 29
412 RR B/E 2-8 CC 39
5- Oil and grease specification – P3 49
6- Tools – P4 51
61 Super Seal connector 51
611 AMP connector 52
612 AMP microtimer 53
613 Diverse tools 54
7- Cab heating/ventilation – 0630 61
71 General 61
72 Air conditioning unit 61
721 Ventilation 61
722 Main heater 61
723 Auxiliary heater 61
724 Temperature 61
725 Air direction 62
726 Fuses 62
727 Air filter 62
728 Emergency exit (12) 63
729 Lighting 63
8- Driver protection – 0840 65
81 General 65
82 Tilt Stops 66
821 Inspection and Adjustment 66
822 Removing the tilt stops 67
9- Electric pump motor -1710 69
91 General 69
92 Dismantling the pump motor 69
93 Dismantling and assembling the pump motor 70
931 Dismantling 70
932 Assembling 70
94 Bearing replacement 71
941 Dismantling 71
942 Assembling 72
95 Installation instructions for external temperature sensor 73
10- Electric steering motor – 1730 77
101 General 77
102 Replacing the steering motor 77
1021 Dismantling 77
1022 Assembling 77
103 Dismantling and assembling the carbon brushes 78
11- Electric drive motor – 1760 79
111 General 79
112 Dismantling the drive motor 79
113 Dismantling and assembling the drive motor 80
1131 Dismantling the drive motor 80
Removing the gear wheel 80
Removing the brakes 80
1132 Assembling the drive motor 81
Assembling the brakes 81
Assembling the gear wheel 81
114 Bearing replacement 82
1141 Dismantling 82
1142 N-side 82
D-side 82
1143 Assembling 83
N-side 83
D-side 83
115 Installation instructions for external temperature sensor 84
12- Mechanical drive gear unit – 2550 87
121 General 87
122 Components/data for the drive assembly/transmission 87
1221 Component placement 88
1222 Technical data 90
1223 Dismantling the transmission 90
123 Replacing the drive motor/drive transmission 91
1231 Dismantling the drive motor 91
1232 Dismantling the gear wheel 91
1233 Dismantling the drive transmission 91
1234 Assembling the transmission 92
1235 Installing the drive motor 93
1236 Assembling the gear wheel 93
124 Checking/replacing the oil 94
1241 Checking/refilling the oil 94
1242 Changing the Oil 94
125 Repairs 95
1251 Replacing the drive shaft sealing ring 95
Dismantling 95
Assembling 96
1252 Leakage from the upper cover 97
1253 Leakage from the lower cover 97
1254 Replacing wheel bolts 98
13- Travel brake system – 31001 99
Without support arm brakes 99
131 General 99
132 Operating description 99
1321 Releasing the accelerator100
1322 Travel direction selector100
1323 Pressing down the brake pedal101
1324 Parking brake102
1325 Emergency brake102
133 Electromechanical disc brake, drive motor103
134 Disassembly104
135 Inspection104
136 Assembly105
137 Maintenance106
1371 Adjusting the play106
1372 Wear107
1373 Checking the braking force107
14- Travel brake system – 31002109
With support arm brake109
141 General109
142 Operating description109
1421 Releasing the accelerator110
1422 Travel direction selector110
1423 Pressing down the brake pedal110
1424 Parking brake110
1425 Emergency braking111
143 Electromechanical disc brake, drive motor112
144 Removal113
145 Inspection113
146 Assembly114
147 Maintenance115
1471 Adjusting the play115
1472 Wear116
1473 Checking the braking force116
148 Multiple disc brake, support arm118
1481 Assembling118
1482 Dismantling119
1483 Inspection120
1484 Assembling120
149 Maintenance120
1491 Adjusting the play121
15- Drive wheel – 3530123
151 General123
152 Dismantling the drive wheel123
153 Assembling the drive wheel123
16- Fork/support arm wheel – 35501125
161 General125
162 Dismantling the wheel126
163 Assembling the wheel127
164 Dismantling/assembling the wheel bearings129
1641 265 mm wheel and 300 mm wheel without brakes129
Dismantling the bearing129
Assembling bearings129
1642 300 mm wheel with brake and 350 mm wheel130
Dismantling the bearing130
Assembling bearings130
17- Fork/support arm wheel – 35502131
Valid for T-code 403-404131
171 General131
172 Dismantling the wheel131
173 Assembling the drive wheel132
174 Dismantling the wheel bearings132
175 Assembling the wheel bearings132
18- Mechanical steering system – 4100133
181 General133
182 Replacing the steering generator133
1821 Dismantling133
1822 Assembling133
19- Steering angle sensor – 4350135
191 General135
192 Procedure135
1911 Adjustment of the steering angle sensor136
20- Electrical system – 5000137
201 Electrical Panel137
202 List of symbols and wiring diagrams138
2021 List of symbols138
2022 Wiring diagram141
203 Component list157
2031 Figure 1163
2032 Figure 2163
2033 Figure 3164
2034 Figure 4164
2035 Figure 5165
2036 Figure 6166
2037 Figure 7166
2038 Figure 8167
2039 Figure 9168
20310 Figure 10169
20311 Figure 11170
20312 Figure 12170
204 Functional description171
2041 Truck not started up171
2042 Truck started up172
2043 Selection of travel direction173
On the operating console173
On the left-hand handle173
On the accelerator173
2044 Driving174
2045 Steering175
2046 Steering wheel indicator175
2047 Braking176
Auto-brakes176
Motor brakes (electric)176
Foot brake176
Parking brake176
2048 Fork lift177
2049 Maximum height177
20410 Maximum height178
20411 Fork lowering178
20412 Mast out/in179
20413 Fork tilt up/down179
20414 Hydraulic function 4179
20415 Hydraulic function 5180
20416 Cab tilt180
20417 Height indication181
20418 Height pre-set181
20419 Weighing181
20420 Driver identification182
Without pin code182
With pin code182
21- Battery – 5110183
211 Battery dimensions183
212 Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries184
2121 General184
2122 Battery recommendation184
2123 Battery installation184
2124 Recommended parameter setting for ventilation regulated batteries185
2125 Instructions for verifying the parameter setting185
22- Transistor panel – 5460187
221 Frequency converter187
2211 General description187
2212 Terminal connections and pole bolts188
2213 Technical data189
2214 Programming189
23- Electronic card – 5710191
231 General description191
232 Terminal connections and voltages on A5192
2321 10X192
2322 20X193
2323 30X193
2324 40X194
2325 50X194
2326 60X195
2327 70X195
2328 80X196
2329 90X196
233 Adjusting the lowering speed197
234 Display and programming198
2341 Keyboard198
Clock199
Driver parameters 1-7199
235 Parameter settings for all parameters200
Clock201
Parameters201
2351 Parameter 1205
2352 Parameter 2205
2353 Parameter 3205
2354 Parameter 4205
2355 Parameter 5205
2356 Parameters 6 and 7205
2357 Parameter 11205
2358 Parameter 12205
2359 Parameters 13 to 14205
23510 Parameters 15 and 16206
23511 Parameters 17 and 18206
23512 Parameter 19206
23513 Parameter 20207
23514 Parameter 21207
23515 Parameter 22208
23516 Parameter 23208
23517 Parameter 24208
23518 Parameter 25208
23519 Parameter 26208
23520 Parameter 27208
23521 Parameter 28208
23522 Parameter 29208
23523 Parameter 30209
23524 Parameter 31209
23525 Parameter 37209
23526 Parameter 38209
23527 Parameter 39210
23528 Parameters 40 to 42210
23529 Other parameters210
236 Operating Time211
2361 Installing a new card in the truck211
237 Warning Codes212
238 Error codes213
2381 Error mode213
2382 Safety logic214
239 Warning codes without registration215
2310 Warning codes with registration236
2311 Error codes255
23111 Error codes with registration256
24- Keyboard285
241 General285
242 Display285
2421 Description of the keyboard symbols286
243 Function287
2431 Function 0287
2432 Function 1287
2433 Function 2287
2434 Function 3288
244 Programming288
2441 LED status288
2442 Driver codes289
25- Hydraulics – 6000291
251 General291
252 Symbols291
2521 Hydraulics diagram 1 (4)293
2522 Hydraulics diagram 2 (4)294
2523 Hydraulics diagram 3 (4)295
2524 Hydraulics diagram 4 (4)296
253 List of symbols297
2531 Component placement 1 (3)299
2532 Component placement 2 (3)300
2533 Component placement 3 (3)301
254 Adjusting fork lowering302
255 Adjusting the maximum lifting capacity303
26- Hydraulic pump – 6140305
261 General305
262 Replacing the hydraulic pump305
2621 Dismantling305
2622 Assembling306
27- Hydraulic connections – 6230307
271 General307
272 Tightening torque for hydraulic connections307
2721 Conical connection with O-ring307
2722 Tredo seal308
2723 Pipe coupling308
2724 Connection screwed into aluminium308
2725 Connection screwed into steel309
Pressure class L309
28- Mast mounted hose reel – 6370311
281 General311
282 Assembling311
283 Check after assembly312
29- Main lift cylinder – 6610313
291 General313
292 Tools313
293 Dismantling the lift cylinders from the mast314
294 Dismantling the cylinder314
2941 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder315
2942 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder315
2943 Dismantling and assembling the hose rupture valve316
295 Assembling the cylinder316
2951 Assembling the cylinder in the mast316
30- Free lift cylinder – 6620317
301 General317
302 Tools317
303 Dismantling318
3031 Dismantling the cylinder319
304 Dismantle the rod seal and support ring319
3041 Assembling the rod seal and support ring319
305 Dismantling the piston320
3051 Fitting the piston in the free lift cylinder320
306 Dismantling and assembling the hose rupture valve320
307 Assembling the cylinder321
308 Assembly321
31- Reach cylinder – 6650323
311 General323
312 Assembling and dismantling the reach cylinder323
313 Dismantling323
3131 Dismantling the cylinder324
3132 Dismantle the rod seal and the support ring324
3133 Assembling the rod seal and the support ring324
3134 Dismantling the ram325
3135 Assembling the ram325
3136 Assembling the cylinder325
314 Assembling325
32- Tilt cylinder – 66601327
321 General327
322 Mast with valve on the fork carriage327
3221 Dismantling the fork carriage327
3222 Dismantling the cylinder328
3223 Dismantling the rod seal328
3224 Dismantling the ram329
3225 Assembling the ram329
3226 Assembling the rod seal329
3227 Assembling the cylinder329
3228 Assembling the fork carriage330
323 Mast without valve on the fork carriage331
3231 Dismantling the fork carriage331
3232 Dismantling the cylinder332
3233 Dismantling the rod seal332
3234 Dismantling the ram332
3235 Assembling the ram332
3236 Assembling the rod seal333
3237 Assembling the cylinder333
3238 Assembling the fork carriage333
33- Tilt cylinder – 66602335
331 General335
332 Dismantling the cylinder from the truck335
333 Dismantling and assembling the cylinder336
3331 Dismantling the cylinder336
3332 Dismantle the seals and the support ring336
3333 Assembling the rod seal and the support ring337
3334 Dismantling the ram337
3335 Assembling the ram337
3336 Assembling the cylinder337
334 Refitting the cylinder in the truck338
34- Main mast -7100339
341 General339
342 List of tools339
343 Transporting the truck340
344 Assembling the mast341
345 Dismantling the mast346
346 Adjusting the play347
3461 Adjusting the mast play350
Lateral play350
3462 Radial play351
347 Assembly351
348 Problem with the mast rollers352
349 Adjusting the distance between the forks and floor353
35- Main lift chain system – 7120355
351 General355
352 Checking the chain setting355
353 Chain inspection355
3531 Noise355
3532 Surface rust355
3533 Rusty links355
3534 Stiff links356
3535 Bolt rotation356
3536 Loose bolts356
3537 Outline wear357
3538 Stretching358
3539 Damage359
35310 Damaged discs359
35311 Damaged bolts359
35312 Dirty chain359
354 Cleaning359
355 Lubrication360
36- Lifting devices – 7400361
361 General361
3611 Inspection intervals361
3612 Inspection361
3613 Surface cracks361
3614 Difference in height between the fork tips361
3615 Position locks361
3616 Legible markings361
3617 Fork blade and shaft362
3618 Assembly aid on fork362
3619 Repairs and testing362
Repairs362
Testing the yield point362
Fork363
Fixed extended fork363
362 Extended forks with adjustable fork length364
363 Manual telescopic forks366
3631 Assembly366
3632 Maintenance367
364 Hydraulic telescopic forks368
3641 Assembly instructions368
Telescopic forks with separate flow dividers369
Commissioning of telescopic forks with separate flow dividers370
Telescopic forks with integrated flow dividers371
Commissioning of telescopic forks with integrated flow dividers373
365 Maintenance373
3651 Maintenance373
366 Troubleshooting, telescopic forks with separate flow dividers374
3661 Troubleshooting for telescopic forks with integrated flow dividers376
3662 Instructions for replacing hydraulic parts378
Disassembly378
Assembly378
367 Fork carriage380
3671 Checking the fork carriage’s wearing strip380
3672 Lubrication381
368 Fork spread unit382
3681 Servicing of fork spread unit382
Replacing bearings384
37- Battery charger – 8340385
371 General385
372 Installation386
373 Functional description386
3731 Display functions386
3732 Charging process386
3733 Shutdown conditions387
3734 Delayed power on and charging387
3735 Extra charging387
3736 Equalised charging388
3737 Current and voltage characteristics388
3738 Safety shutdowns388
3739 Display and keyboard389
Reading of analogue measurement values389
Error indication and error messages390
Reading statistics from the previous charge391
Reading of long term statistics392
Storing parameters392
Reading parameters393
Battery specific parameters393
Charger specific parameters394
Mains voltage codes394
Other functions394
Changing parameters395
37310 Acid circulation395
General395
BTM with acid circulation395
Pump type APE, VPM396
Pump type API396
374 Service and maintenance396
3741 Basic programming, code 30396
3742 Resetting the statistics, code 31396
3743 Calibrating the measurement value397
Calibrating the current’s zero value and temperatures, code 21397
Calibrating the battery voltage’s measurement value, code 20397
Calibrating the charging current, code 25398
Calibrating the mains voltage display, code 26398
3744 Calibrating and programming API398
Calibrating zero pressure398
Calibrating the pressure398
Programming the alarm limits398
Programming the API function399
3745 Adjusting the charging characteristics399
3746 Trouble shooting400
Error message, analysis and action400
Errors without indication401
3747 Trouble shooting acid circulation401
3748 Service measures401
Switching to the timer charger402
Replacing the display card402
Replacing the computer board403
Replacing the mother board403
Replacing the diodes403
3749 Preventive maintenance403
38- Extra Lighting – 9360405
39- Extra warning light/alarm – 9370407
391 General407
392 Wiring diagram409
40- Positioning equipment – 9390411
401 General411
402 Height indication412
403 Function413
404 Display414
405 Height pre-set415
406 Function416
407 Display417
4071 Description of the display symbols418
408 Assembly of height pre-set419
409 Programming419
4091 Programming a level419
Collect level419
Leave level420
4092 Deleting programmed levels420
4010 Automatic driving421
40101 Collect load421
40102 Depositing a load422
40103 Inspection422
4011 Parameters423
40111 Parameter 1423
40112 Parameter 2423
40113 Parameter 3424
40114 Parameter 4424
40115 Parameter 5424
40116 Parameter 7425
40117 Parameter 8425
40118 Parameter 9425
4012 Programming parameters426
4013 Error codes428
41- TV equipment – 9390429
411 General429
412 Camera mounted on fork429
4121 Colour camera A51430
4122 Colour monitor A50430
4123 Voltage converter A10432
42- Truck log system, code lock – 9420433
421 General433
422 SD 16433
4221 Login with code (5-digit)433
4222 Logout433
423 Components434
If the truck does not start:436
424 I/O Module436
43- Extra equipment – 9500437
431 Dry powder extinguisher437
In the event of fire, the powder extinguisher should be employed as follows:437
4311 Regular checks of the powder extinguisher – truck driver438
4312 Inspection of powder extinguisher in service inspection of the truck438
44- Instructions for destruction439
441 General439
442 Procedure439
443 Abbreviations440
444 Sorting440
445 Frame/chassis (0300)441
4451 Dismantling441
Material handling441
446 Operator’s seat, cushion (0620)442
4461 Dismantling442
Material handling442
447 Cab heating/ventilation (0630)443
4471 Dismantling443
Material handling443
448 Driver controls (0640)444
4481 Dismantling444
Material handling444
449 Interior fittings RR-B (0680)445
4491 Dismantling445
Material handling446
4410 Interior fittings RR-E (0680)447
44101 Dismantling447
Material handling448
4411 Interior fittings RR-B-CC (0680)449
44111 Dismantling449
Material handling450
4412 Interior fittings RR-E-CC (0680)451
44121 Dismantling451
Material handling452
4413 Rollover guard/head guard (0810)453
44131 Dismantling453
Material handling453
4414 Finger protectors (0820)453
44141 Dismantling453
Material handling453
4415 Finger/foot protectors (0820)454
44151 Dismantling454
Material handling454
4416 Finger/foot protectors (0820)455
44161 Dismantling455
Material handling455
4417 Electric motors (1700)456
44171 Dismantling456
Material handling456
4418 Electric fan motor (1740)457
44181 Dismantling457
Material handling457
4419 Drive unit, final gear (2500)458
44191 Dismantling458
Material handling458
4420 Wheels (3500)459
44201 Dismantling459
Material handling459
4421 Electric steering system (4300)460
44211 Dismantling461
Material handling461
4422 General electric equipment (5100)462
44221 Dismantling462
Material handling462
4423 Manöversystem, körfunktion (5300)463
44231 Dismantling463
Material handling463
4424 Power system, drive function (5400)464
44241 Dismantling464
Material handling464
4425 Control system, operation function (5500)465
44251 Dismantling465
Material handling465
4426 Steering/protective electronics (5700)466
44261 Dismantling466
Material handling466
4427 Hydraulic unit (6100)467
44271 Dismantling468
Material handling468
4428 Hydraulic system, fitted on the chassis (6200)469
44281 Dismantling470
Material handling470
4429 Hydraulic system, fitted on the mast (6300)471
44291 Dismantling471
Material handling471
4430 Hydraulcylindrar (6600)472
44301 Dismantling473
Material handling473
4431 Main mast (7100)474
44311 Dismantling474
Material handling474
4432 Lift fork (7410)475
44321 Dismantling475
Material handling475
4433 Optional electric equipment (9300)475
44331 Dismantling475
Material handling475
4434 Radio/CD player (9330)476
44341 Dismantling476
Material handling476
4435 Extra work light (9360)477
44351 Dismantling477
Material handling477
4436 Optional electric equipment (9400)478
44361 Dismantling478
Material handling478
4437 Optional electric equipment (9400)479
44371 Dismantling479
Material handling479

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