BT FORKLIFT REFLEX RR B,E RR B,E CC SERVICE MANUAL 218920-040 – PDF DOWNLOAD

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BT FORKLIFT REFLEX RR B,E RR B,E CC SERVICE MANUAL 218920-040 – PDF DOWNLOAD

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BT FORKLIFT REFLEX RR B,E RR B,E CC SERVICE MANUAL 218920-040 – PDF DOWNLOAD

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

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TABLE OF CONTENTS:

BT FORKLIFT REFLEX RR B,E RR B,E CC SERVICE MANUAL 218920-040 – PDF DOWNLOAD

1- Table of contents........................................................................................  3
2- General product information - M2......................................................................... 27
	2.1 Presentation of the reach trucks.................................................................... 27
		2.1.1 Application areas for the reach trucks........................................................ 27
		2.1.2 Prohibited applications for the reach trucks.................................................. 27
	2.2 Truck data.......................................................................................... 28
	2.3 Truck dimensions.................................................................................... 29
	2.4 Identification plate, truck......................................................................... 31
		2.4.1 Capacity plate................................................................................ 31
		2.4.2 Modification plate............................................................................ 32
		2.4.3 Identification plate, mast.................................................................... 32
	2.5 Main components RR B/E 1-8.......................................................................... 33
	2.6 Main components RR B/E 2-8 CC....................................................................... 35
	2.7 Warning and information plates and symbols RR B/E 1-8............................................... 37
	2.8 Warning and information plates and symbols RR B/E 2-8 CC............................................ 39
3- Technical data - M4...................................................................................... 41
	3.1 General tightening torque........................................................................... 45
		3.1.1 Galvanised, non-oiled bolts................................................................... 45
		3.1.2 Untreated, oiled bolts........................................................................ 45
4- Introduction, maintenance - P1........................................................................... 47
	4.1 Safety regulations during maintenance work.......................................................... 47
	4.2 Cleaning and washing................................................................................ 48
		4.2.1 Cleaning the exterior......................................................................... 49
		4.2.2 Cleaning the motor compartment................................................................ 49
		4.2.3 Electrical components......................................................................... 49
	4.3 Safe lifting........................................................................................ 49
	4.4 Opening motor compartment........................................................................... 50
		4.4.1 RR B 1-8...................................................................................... 50
	4.5 Cab tilting......................................................................................... 51
		4.5.1 RR E 1-8...................................................................................... 51
		4.5.2 RR E 2-8 CC................................................................................... 52
5- Preventive maintenance - P2.............................................................................. 55
	5.1 Maintenance Schedule................................................................................ 55
		5.1.1 RR B/E 1-8.................................................................................... 55
		5.1.2 RR B/E 2-8 CC................................................................................. 65
6- Oil and grease specification - P3........................................................................ 75
7- Tools - P4............................................................................................... 77
	7.1 Super Seal connector................................................................................ 77
		7.1.1 AMP connector................................................................................. 78
		7.1.2 AMP microtimer................................................................................ 79
		7.1.3 Diverse tools................................................................................. 80
8- Cab heating/ventilation - 0630........................................................................... 87
	8.1 General............................................................................................. 87
	8.2 Air conditioning unit............................................................................... 87
		8.2.1 Ventilation................................................................................... 87
		8.2.2 Main heater................................................................................... 87
		8.2.3 Auxiliary heater.............................................................................. 87
		8.2.4 Temperature................................................................................... 87
		8.2.5 Air direction................................................................................. 88
		8.2.6 Fuses......................................................................................... 88
		8.2.7 Air filter.................................................................................... 88
		8.2.8 Emergency exit (12)........................................................................... 89
		8.2.9 Lighting...................................................................................... 89
9- Driver protection - 0840................................................................................. 91
	9.1 General............................................................................................. 91
	9.2 Tilt Stops.......................................................................................... 92
		9.2.1 Inspection and Adjustment..................................................................... 92
		9.2.2 Removing the tilt stops....................................................................... 93
10- Electric pump motor -1710............................................................................... 95
	10.1 General............................................................................................ 95
	10.2 Dismantling the pump motor......................................................................... 95
	10.3 Dismantling and assembling the pump motor.......................................................... 96
		10.3.1 Dismantling.................................................................................. 96
		10.3.2 Assembling................................................................................... 96
	10.4 Bearing replacement................................................................................ 97
		10.4.1 Dismantling.................................................................................. 97
		10.4.2 Assembling................................................................................... 98
	10.5 Installation instructions for external temperature sensor.......................................... 99
11- Electric steering motor - 1730..........................................................................103
	11.1 General............................................................................................103
	11.2 Replacing the steering motor.......................................................................103
		11.2.1 Dismantling..................................................................................103
		11.2.2 Assembling...................................................................................103
	11.3 Dismantling and assembling the carbon brushes......................................................104
12- Electric drive motor - 1760.............................................................................105
	12.1 General............................................................................................105
	12.2 Dismantling the drive motor........................................................................105
	12.3 Dismantling and assembling the drive motor.........................................................106
		12.3.1 Dismantling the drive motor..................................................................106
			Removing the gear wheel.........................................................................106
			Removing the brakes.............................................................................106
		12.3.2 Assembling the drive motor...................................................................107
			Assembling the brakes...........................................................................107
			Assembling the gear wheel.......................................................................107
	12.4 Bearing replacement................................................................................108
		12.4.1 Dismantling..................................................................................108
		12.4.2 N-side.......................................................................................108
			D-side..........................................................................................108
		12.4.3 Assembling...................................................................................109
			N-side..........................................................................................109
			D-side..........................................................................................109
	12.5 Installation instructions for external temperature sensor..........................................110
13- Mechanical drive gear unit - 2550.......................................................................113
	13.1 General............................................................................................113
	13.2 Components/data for the drive assembly/transmission................................................113
		13.2.1 Component placement..........................................................................114
		13.2.2 Technical data...............................................................................116
		13.2.3 Dismantling the transmission.................................................................116
	13.3 Replacing the drive motor/drive transmission.......................................................117
		13.3.1 Dismantling the drive motor..................................................................117
		13.3.2 Dismantling the gear wheel...................................................................117
		13.3.3 Dismantling the drive transmission...........................................................118
		13.3.4 Assembling the transmission..................................................................118
		13.3.5 Installing the drive motor...................................................................119
		13.3.6 Assembling the gear wheel....................................................................119
	13.4 Checking/replacing the oil.........................................................................120
		13.4.1 Checking/refilling the oil...................................................................120
		13.4.2 Changing the Oil.............................................................................120
	13.5 Repairs............................................................................................121
		13.5.1 Replacing the drive shaft sealing ring.......................................................121
			Dismantling.....................................................................................121
			Assembling......................................................................................122
		13.5.2 Leakage from the upper cover.................................................................123
		13.5.3 Leakage from the lower cover.................................................................123
		13.5.4 Replacing wheel bolts........................................................................124
14- Travel brake system - 3100.1............................................................................125
	Without support arm brakes..............................................................................125
	14.1 General............................................................................................125
	14.2 Operating description..............................................................................125
		14.2.1 Releasing the accelerator....................................................................126
		14.2.2 Travel direction selector....................................................................126
		14.2.3 Pressing down the brake pedal................................................................127
		14.2.4 Parking brake................................................................................128
		14.2.5 Emergency brake..............................................................................128
	14.3 Electromechanical disc brake, drive motor..........................................................129
		14.3.1 Assembling...................................................................................129
		14.3.2 Dismantling..................................................................................130
		14.3.3 Inspection...................................................................................130
		14.3.4 Assembling...................................................................................130
	14.4 Maintenance........................................................................................131
		14.4.1 Adjusting the play...........................................................................131
		14.4.2 Wear.........................................................................................131
		14.4.3 Check the braking force......................................................................132
15- Travel brake system - 3100.2............................................................................133
	With support arm brake..................................................................................133
	15.1 General............................................................................................133
	15.2 Operating description..............................................................................133
		15.2.1 Releasing the accelerator....................................................................134
		15.2.2 Travel direction selector....................................................................134
		15.2.3 Pressing down the brake pedal................................................................135
		15.2.4 Parking brake................................................................................136
		15.2.5 Emergency braking............................................................................136
	15.3 Electromechanical disc brake, drive motor..........................................................137
		15.3.1 Assembling...................................................................................137
		15.3.2 Dismantling..................................................................................138
		15.3.3 Inspection...................................................................................138
		15.3.4 Assembling...................................................................................138
	15.4 Maintenance........................................................................................139
		15.4.1 Adjusting the play...........................................................................139
		15.4.2 Wear.........................................................................................139
		15.4.3 Check the braking force......................................................................140
	15.5 Multiple disc brake, support arm...................................................................141
		15.5.1 Assembling...................................................................................141
		15.5.2 Dismantling..................................................................................142
		15.5.3 Inspection...................................................................................143
		15.5.4 Assembling...................................................................................143
	15.6 Maintenance........................................................................................143
		15.6.1 Adjusting the play...........................................................................144
16- Drive wheel - 3530......................................................................................145
	16.1 General............................................................................................145
	16.2 Dismantling the drive wheel........................................................................145
	16.3 Assembling the drive wheel.........................................................................145
17- Fork/support arm wheel - 3550.1.........................................................................147
	17.1 General............................................................................................147
	17.2 Dismantling the wheel..............................................................................148
	17.3 Assembling the wheel...............................................................................149
	17.4 Dismantling/assembling the wheel bearings..........................................................151
		17.4.1 265 mm wheel and 300 mm wheel without brakes.................................................151
			Dismantling the bearing.........................................................................151
			Assembling bearings.............................................................................151
		17.4.2 300 mm wheel with brake and 350 mm wheel.....................................................152
			Dismantling the bearing.........................................................................152
			Assembling bearings.............................................................................152
18- Fork/support arm wheel - 3550.2.........................................................................153
	18.1 General............................................................................................153
	18.2 Dismantling the wheel..............................................................................153
	18.3 Assembling the drive wheel.........................................................................154
	18.4 Dismantling the wheel bearing......................................................................154
	18.5 Assembling the wheel bearing.......................................................................154
19- Mechanical steering system - 4100.......................................................................155
	19.1 General............................................................................................155
	19.2 Replacing the steering generator...................................................................155
		19.2.1 Dismantling..................................................................................155
		19.2.2 Assembling...................................................................................155
20- Steering angle sensor - 4350............................................................................157
	20.1 General............................................................................................157
	20.2 Procedure..........................................................................................157
		20.1.1 Adjustment of the steering angle sensor......................................................158
21- Electrical system - 5000................................................................................159
	21.1 General............................................................................................159
		21.1.1 Electrical panel.............................................................................159
	21.2 Symbol list and wiring diagrams....................................................................160
		21.2.1 List of symbols..............................................................................160
		21.2.2 Wiring diagram (1/16)........................................................................163
		21.2.3 Wiring diagram (2/16)........................................................................164
		21.2.4 Wiring diagram (3/16)........................................................................165
		21.2.5 Wiring diagram (4/16)........................................................................166
		21.2.6 Wiring diagram (5/16)........................................................................167
		21.2.7 Wiring diagram (6/16)........................................................................168
		21.2.8 Wiring diagram (7/16)........................................................................169
		21.2.9 Wiring diagram (8/16)........................................................................170
		21.2.10 Wiring diagram (9/16).......................................................................171
		21.2.11 Wiring diagram (10/16)......................................................................172
		21.2.12 Wiring diagram (11/16)......................................................................173
		21.2.13 Wiring diagram (12/16)......................................................................174
		21.2.14 Wiring diagram (13/16)......................................................................175
		21.2.15 Wiring diagram (14/16)......................................................................176
		21.2.16 Wiring diagram (15/16)......................................................................177
		21.2.17 Wiring diagram (16/16)......................................................................178
	21.3 Component list.....................................................................................179
		21.3.1 Figure 1.....................................................................................185
		21.3.2 Figure 2.....................................................................................185
		21.3.3 Figure 3.....................................................................................186
		21.3.4 Figure 4.....................................................................................186
		21.3.5 Figure 5.....................................................................................187
		21.3.6 Figure 6.....................................................................................188
		21.3.7 Figure 7.....................................................................................188
		21.3.8 Figure 8.....................................................................................189
		21.3.9 Figure 9.....................................................................................190
		21.3.10 Figure 10...................................................................................191
		21.3.11 Figure 11...................................................................................192
		21.3.12 Figure 12...................................................................................192
	21.4 Functional description.............................................................................193
		21.4.1 Truck not started up.........................................................................193
		21.4.2 Truck started up.............................................................................194
		21.4.3 Choice of travel direction...................................................................195
			On the control console..........................................................................195
			On the left-hand handle.........................................................................195
			On the accelerator..............................................................................195
		21.4.4 Driving......................................................................................196
		21.4.5 Steering.....................................................................................197
		21.4.6 Steering wheel indicator.....................................................................197
		21.4.7 Braking......................................................................................198
			Auto-brakes.....................................................................................198
			Motor brakes (electric).........................................................................198
			Foot brake......................................................................................198
			Parking brake...................................................................................198
		21.4.8 Fork lift....................................................................................199
		21.4.9 Maximum height...............................................................................199
		21.4.10 Maximum height..............................................................................200
		21.4.11 Fork lowering...............................................................................200
		21.4.12 Mast out/in.................................................................................201
		21.4.13 Fork tilt up/down...........................................................................201
		21.4.14 Hydraulic function 4........................................................................201
		21.4.15 Hydraulic function 5........................................................................202
		21.4.16 Cab tilt....................................................................................202
		21.4.17 Height indication...........................................................................203
		21.4.18 Height pre-set..............................................................................203
		21.4.19 Weighing....................................................................................203
		21.4.20 Driver identification.......................................................................204
			Without pin code................................................................................204
			With pin code...................................................................................204
22- Battery - 5110..........................................................................................205
	22.1 Battery dimensions.................................................................................205
	22.2 Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries.............206
		22.2.1 General......................................................................................206
		22.2.2 Battery recommendation.......................................................................206
		22.2.3 Battery installation.........................................................................206
		22.2.4 Recommended parameter setting for ventilation regulated batteries............................207
		22.2.5 Instructions for verifying the parameter setting.............................................207
23- Transistor panel - 5460.................................................................................209
	23.1 Frequency converter................................................................................209
		23.1.1 Terminal connections and pole bolts..........................................................210
		23.1.2 Technical Data...............................................................................211
		23.1.3 Installation of new frequency converter on truck.............................................211
		23.1.4 Programming..................................................................................211
24- Electronic card - 5710..................................................................................213
	24.1 General description................................................................................213
	24.2 Terminal connections and voltages on A5............................................................214
		24.2.1 10X..........................................................................................214
		24.2.2 20X..........................................................................................215
		24.2.3 30X..........................................................................................215
		24.2.4 40X..........................................................................................216
		24.2.5 50X..........................................................................................216
		24.2.6 60X..........................................................................................217
		24.2.7 70X..........................................................................................217
		24.2.8 80X..........................................................................................218
		24.2.9 90X..........................................................................................218
	24.3 Adjusting the lowering speed.......................................................................219
	24.4 Displaying and programming.........................................................................220
		24.4.1 Keypad.......................................................................................220
			Clock...........................................................................................221
			Driver parameters 1-7...........................................................................221
	24.5 Parameter setting of all parameters................................................................222
		Clock...............................................................................................222
		Parameters..........................................................................................223
		24.5.1 Parameter 1..................................................................................227
		24.5.2 Parameter 2..................................................................................227
		24.5.3 Parameter 3..................................................................................227
		24.5.4 Parameter 4..................................................................................227
		24.5.5 Parameter 5..................................................................................227
		24.5.6 Parameters 6 and 7...........................................................................227
		24.5.7 Parameter 11.................................................................................227
		24.5.8 Parameter 12.................................................................................227
		24.5.9 Parameters 13 and 14.........................................................................227
		24.5.10 Parameters 15 and 16........................................................................228
		24.5.11 Parameters 17 and 18........................................................................228
		24.5.12 Parameter 19................................................................................229
		24.5.13 Parameter 20................................................................................229
		24.5.14 Parameter 21................................................................................229
		24.5.15 Parameter 22................................................................................231
		24.5.16 Parameter 23................................................................................231
		24.5.17 Parameter 24................................................................................231
		24.5.18 Parameter 25................................................................................231
		24.5.19 Parameter 26................................................................................231
		24.5.20 Parameter 27................................................................................231
		24.5.21 Parameter 28................................................................................232
		24.5.22 Parameter 29................................................................................232
		24.5.23 Parameter 30................................................................................232
		24.5.24 Parameter 37................................................................................232
		24.5.25 Parameter 38................................................................................233
		24.5.26 Parameter 39................................................................................234
		24.5.27 Parameters 40 to 42.........................................................................234
		24.5.28 Miscellaneous parameters....................................................................234
	24.6 Operating hours....................................................................................235
		24.6.1 Installing a new electronic card in the truck................................................235
	24.7 Warning codes......................................................................................236
	24.8 Error Codes........................................................................................237
		24.8.1 Error mode...................................................................................237
		24.8.2 Safety logic.................................................................................238
	24.9 Warning Codes without registration.................................................................238
	24.10 Warning codes with registration...................................................................259
	24.11 Error Codes.......................................................................................278
		24.11.1 Error codes with registration...............................................................279
25- Keypad..................................................................................................311
	25.1 General............................................................................................311
	25.2 Display............................................................................................311
		25.2.1 Description of the keypad symboles...........................................................312
	25.3 Function...........................................................................................313
		25.3.1 Function 0...................................................................................313
		25.3.2 Function 1...................................................................................313
		25.3.3 Function 2...................................................................................313
		25.3.4 Function 3...................................................................................314
	25.4 Programming........................................................................................314
		25.4.1 LED status...................................................................................314
		25.4.2 Driver PIN-codes.............................................................................315
26- Hydraulics - 6000.......................................................................................317
	26.1 General............................................................................................317
	26.2 Symbols............................................................................................317
		26.2.1 Hydraulics diagram 1 (4).....................................................................319
		26.2.2 Hydraulics diagram 2 (4).....................................................................320
		26.2.3 Hydraulics diagram 3 (4).....................................................................321
		26.2.4 Hydraulics diagram 4 (4).....................................................................322
	26.3 List of symbols....................................................................................323
		26.3.1 Component placement 1 (3)....................................................................325
		26.3.2 Component placement 2 (3)....................................................................326
		26.3.3 Component placement 3 (3)....................................................................327
	26.4 Adjusting fork lowering............................................................................328
	26.5 Adjusting the maximum lifting capacity.............................................................329
27- Hydraulic pump - 6140...................................................................................331
	27.1 General............................................................................................331
	27.2 Replacing the hydraulic pump.......................................................................331
		27.2.1 Dismantling..................................................................................331
		27.2.2 Assembling...................................................................................332
28- Hydraulic connections - 6230............................................................................333
	28.1 General............................................................................................333
	28.2 Tightening torque for hydraulic connections........................................................333
		28.2.1 Conical connection with O-ring...............................................................333
		28.2.2 Tredo seal...................................................................................334
		28.2.3 Pipe coupling................................................................................334
		28.2.4 Connection screwed into aluminium............................................................334
		28.2.5 Connection screwed into steel................................................................335
			Pressure class L................................................................................335
29- Mast mounted hose reel - 6370...........................................................................337
	29.1 General............................................................................................337
	29.2 Assembling.........................................................................................337
	29.3 Check after assembly...............................................................................338
30- Main lift cylinder - 6610...............................................................................339
	30.1 General............................................................................................339
	30.2 Tools..............................................................................................339
	30.3 Dismantling the lift cylinders from the mast.......................................................340
	30.4 Dismantling the cylinder...........................................................................340
		30.4.1 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder....341
		30.4.2 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder........341
		30.4.3 Dismantling and assembling the hose rupture valve............................................342
	30.5 Assembling the cylinder............................................................................342
		30.5.1 Assembling the cylinder in the mast..........................................................342
31- Free lift cylinder - 6620...............................................................................343
	31.1 General............................................................................................343
	31.2 Tools..............................................................................................343
	31.3 Dismantling........................................................................................344
		31.3.1 Dismantling the cylinder.....................................................................345
	31.4 Dismantle the rod seal and support ring............................................................345
		31.4.1 Assembling the rod seal and support ring.....................................................345
	31.5 Dismantling the piston.............................................................................346
		31.5.1 Fitting the piston in the free lift cylinder.................................................346
	31.6 Dismantling and assembling the hose rupture valve..................................................346
	31.7 Assembling the cylinder............................................................................347
	31.8 Assembly...........................................................................................347
32- Reach cylinder - 6650...................................................................................349
	32.1 General............................................................................................349
	32.2 Assembling and dismantling the reach cylinder......................................................349
	32.3 Dismantling........................................................................................349
		32.3.1 Dismantling the cylinder.....................................................................350
		32.3.2 Dismantle the rod seal and the support ring..................................................350
		32.3.3 Assembling the rod seal and the support ring.................................................350
		32.3.4 Dismantling the ram..........................................................................351
		32.3.5 Assembling the ram...........................................................................351
		32.3.6 Assembling the cylinder......................................................................351
	32.4 Assembling.........................................................................................351
33- Tilt cylinder - 6660.1..................................................................................353
	33.1 General............................................................................................353
	33.2 Mast with valve on the fork carriage...............................................................354
		33.2.1 Dismantling the fork carriage................................................................354
		33.2.2 Dismantling the cylinder.....................................................................355
		33.2.3 Dismantling the rod seal.....................................................................355
		33.2.4 Dismantling the ram..........................................................................355
		33.2.5 Assembling the ram...........................................................................355
		33.2.6 Assembling the rod seal......................................................................356
		33.2.7 Assembling the cylinder......................................................................356
		33.2.8 Assembling the fork carriage.................................................................356
	33.3 Mast without valve on the fork carriage............................................................357
		33.3.1 Dismantling the fork carriage................................................................357
		33.3.2 Dismantling the cylinder.....................................................................358
		33.3.3 Dismantling the rod seal.....................................................................358
		33.3.4 Dismantling the ram..........................................................................358
		33.3.5 Assembling the ram...........................................................................358
		33.3.6 Assembling the rod seal......................................................................359
		33.3.7 Assembling the cylinder......................................................................359
		33.3.8 Assembling the fork carriage.................................................................359
34- Tilt cylinder - 6660.2..................................................................................361
	34.1 General............................................................................................361
	34.2 Dismantling the cylinder from the truck............................................................361
	34.3 Dismantling and assembling the cylinder............................................................362
		34.3.1 Dismantling the cylinder.....................................................................362
		34.3.2 Dismantle the seals and the support ring.....................................................362
		34.3.3 Assembling the rod seal and the support ring.................................................363
		34.3.4 Dismantling the ram..........................................................................363
		34.3.5 Assembling the ram...........................................................................363
		34.3.6 Assembling the cylinder......................................................................363
	34.4 Refitting the cylinder in the truck................................................................364
35- Main mast -7100.........................................................................................365
	35.1 General............................................................................................365
	35.2 List of tools......................................................................................365
	35.3 Transporting the truck.............................................................................366
	35.4 Assembling the mast................................................................................367
	35.5 Dismantling the mast...............................................................................372
	35.6 Adjusting the play.................................................................................373
		35.6.1 Adjusting the mast play......................................................................376
			Lateral play....................................................................................376
		35.6.2 Radial play..................................................................................377
	35.7 Assembly...........................................................................................377
36- Main lift chain system - 7120...........................................................................379
	36.1 General............................................................................................379
	36.2 Checking the chain setting.........................................................................379
	36.3 Chain inspection...................................................................................379
		36.3.1 Noise........................................................................................379
		36.3.2 Surface rust.................................................................................379
		36.3.3 Rusty links..................................................................................379
		36.3.4 Stiff links..................................................................................380
		36.3.5 Bolt rotation................................................................................380
		36.3.6 Loose bolts..................................................................................380
		36.3.7 Outline wear.................................................................................381
		36.3.8 Stretching...................................................................................381
		36.3.9 Damage.......................................................................................382
		36.3.10 Damaged discs...............................................................................382
		36.3.11 Damaged bolts...............................................................................383
		36.3.12 Dirty chain.................................................................................383
	36.4 Cleaning...........................................................................................383
	36.5 Lubrication........................................................................................383
37- Lifting devices - 7400..................................................................................385
	37.1 General............................................................................................385
		37.1.1 Inspection intervals.........................................................................385
		37.1.2 Inspection...................................................................................385
		37.1.3 Surface cracks...............................................................................385
		37.1.4 Difference in height of fork tips............................................................385
		37.1.5 Positioning lock.............................................................................385
		37.1.6 Legibility of marking........................................................................386
		37.1.7 Fork arm blade and shank.....................................................................386
		37.1.8 Fork arm mountings...........................................................................386
		37.1.9 Repair and testing...........................................................................386
			Repair..........................................................................................386
			Yield test......................................................................................386
			Fork............................................................................................387
			Extended fork...................................................................................387
	37.2 Checking the fork carriage’s wearing strips........................................................388
	37.3 Fork spread unit...................................................................................390
		37.3.1 Servicing of fork spread unit................................................................390
	37.4 Telescopic forks...................................................................................391
		37.4.1 Telescopic forks.............................................................................391
		37.4.2 Putting the telescopic forks into operation:.................................................392
	37.5 Maintenance........................................................................................392
		How to remove the outer fork........................................................................392
		How to mount the outer fork.........................................................................392
		37.5.1 Maintenance..................................................................................396
	37.6 Troubleshooting....................................................................................397
		37.6.1 Instructions for replacing hydraulic parts...................................................399
	37.7 Extended forks.....................................................................................401
38- Battery charger - 8340..................................................................................403
	38.1 General............................................................................................403
	38.2 Installation.......................................................................................404
	38.3 Functional description.............................................................................404
		38.3.1 Display functions............................................................................404
		38.3.2 Charging process.............................................................................404
		38.3.3 Shutdown conditions..........................................................................405
		38.3.4 Delayed power on and charging................................................................405
		38.3.5 Extra charging...............................................................................405
		38.3.6 Equalised charging...........................................................................406
		38.3.7 Current and voltage characteristics..........................................................406
		38.3.8 Safety shutdowns.............................................................................406
		38.3.9 Display and keyboard.........................................................................407
			Reading of analogue measurement values..........................................................407
			Error indication and error messages.............................................................408
			Reading statistics from the previous charge.....................................................409
			Reading of long term statistics.................................................................410
			Storing parameters..............................................................................410
			Reading parameters..............................................................................411
			Battery specific parameters.....................................................................411
			Charger specific parameters.....................................................................412
			Mains voltage codes.............................................................................412
			Other functions.................................................................................412
			Changing parameters.............................................................................413
		38.3.10 Acid circulation............................................................................413
			General.........................................................................................413
			BTM with acid circulation.......................................................................413
			Pump type APE, VPM..............................................................................414
			Pump type API...................................................................................414
	38.4 Service and maintenance............................................................................414
		38.4.1 Basic programming, code 30...................................................................414
		38.4.2 Resetting the statistics, code 31............................................................414
		38.4.3 Calibrating the measurement value............................................................415
			Calibrating the current’s zero value and temperatures, code 21..................................415
			Calibrating the battery voltage’s measurement value, code 20....................................415
			Calibrating the charging current, code 25.......................................................416
			Calibrating the mains voltage display, code 26..................................................416
		38.4.4 Calibrating and programming API..............................................................416
			Calibrating zero pressure.......................................................................416
			Calibrating the pressure........................................................................416
			Programming the alarm limits....................................................................416
			Programming the API function....................................................................417
		38.4.5 Adjusting the charging characteristics.......................................................417
		38.4.6 Trouble shooting.............................................................................418
			Error message, analysis and action..............................................................418
			Errors without indication.......................................................................419
		38.4.7 Trouble shooting acid circulation............................................................419
		38.4.8 Service measures.............................................................................419
			Switching to the timer charger..................................................................420
			Replacing the display card......................................................................420
			Replacing the computer board....................................................................421
			Replacing the mother board......................................................................421
			Replacing the diodes............................................................................421
		38.4.9 Preventive maintenance.......................................................................421
39- Control/computer equipment - 8700.......................................................................423
	39.1 General............................................................................................423
	39.2 Connection.........................................................................................423
	39.3 Layout.............................................................................................424
		39.3.1 Main window..................................................................................424
		39.3.2 Nodes........................................................................................424
		39.3.3 Icons........................................................................................425
		39.3.4 Tool buttons and menu list...................................................................426
		39.3.5 Information window...........................................................................426
		39.3.6 Status row...................................................................................426
	39.4 Function for connection............................................................................427
	39.5 Function for disconnecting.........................................................................427
	39.6 Function for program downloading...................................................................427
		39.6.1 Normal loading...............................................................................428
		39.6.2 Loading in old versions of the electronic card...............................................428
		39.6.3 Emergency loading............................................................................428
	39.7 Function for truck report..........................................................................429
	39.8 Function for parameters............................................................................430
	39.9 Function for diagnostics...........................................................................432
		39.9.1 Signal colours...............................................................................432
		39.9.2 Tab for “Analogue”...........................................................................433
		39.9.3 Tab for “Temperature”........................................................................434
		39.9.4 Tab for “Digital”............................................................................435
	39.10 Other menu functions..............................................................................436
		39.10.1 Save to file................................................................................436
		39.10.2 Loading from a file.........................................................................436
		39.10.3 Resetting the CAN adapter...................................................................436
		39.10.4 Deleting the fault code log.................................................................436
		39.10.5 Resetting the hour meter....................................................................436
		39.10.6 Reading the fault code log..................................................................436
		39.10.7 Adjusting the date/time.....................................................................436
		39.10.8 Adjusting the hour meter on older cards.....................................................437
		39.10.9 Help........................................................................................437
			About TruckCom..................................................................................437
		39.10.10 Conclude...................................................................................437
	39.11 Specifications....................................................................................437
	39.12 Installation......................................................................................438
		39.12.1 Installation on a PC with Windows XP/ 2000/NT...............................................438
		39.12.2 IInstallation on a PC with Windows 95/ 98...................................................438
		39.12.3 In the event of any problems with communication with CAN....................................439
		39.12.4 Uninstallation..............................................................................439
40- Extra warning lights/alarm - 9370.......................................................................441
	40.1 General............................................................................................441
41- Positioning equipment - 9390............................................................................443
	41.1 General............................................................................................443
	41.2 Height indication..................................................................................444
	41.3 Function...........................................................................................445
	41.4 Display............................................................................................445
	41.5 Height pre-set.....................................................................................447
	41.6 Function...........................................................................................448
	41.7 Display............................................................................................449
		41.7.1 Description of the display symbols...........................................................450
	41.8 Assembly of height pre-set.........................................................................451
	41.9 Programming........................................................................................451
		41.9.1 Programming a level..........................................................................451
			Collect level...................................................................................451
			Leave level.....................................................................................452
		41.9.2 Deleting programmed levels...................................................................452
	41.10 Automatic driving.................................................................................453
		41.10.1 Collect load................................................................................453
		41.10.2 Depositing a load...........................................................................454
		41.10.3 Inspection..................................................................................454
	41.11 Parameters........................................................................................455
		41.11.1 Parameter 1.................................................................................455
		41.11.2 Parameter 2.................................................................................455
		41.11.3 Parameter 3.................................................................................456
		41.11.4 Parameter 4.................................................................................456
		41.11.5 Parameter 5.................................................................................456
		41.11.6 Parameter 7.................................................................................457
		41.11.7 Parameter 8.................................................................................457
		41.11.8 Parameter 9.................................................................................457
	41.12 Programming parameters............................................................................458
	41.13 Error codes.......................................................................................460
42- TV equipment - 9390.....................................................................................461
	42.1 General............................................................................................461
	42.2 Camera mounted on fork.............................................................................461
		42.2.1 Colour camera A51............................................................................462
		42.2.2 Colour monitor A50...........................................................................462
		42.2.3 Voltage converter A10........................................................................464
43- Truck log system, code lock - 9420......................................................................465
	43.1 General............................................................................................465
	43.2 SD 16..............................................................................................465
		43.2.1 Login with code (5-digit)....................................................................465
		43.2.2 Logout.......................................................................................465
	43.3 Components.........................................................................................466
		If the truck does not start:........................................................................468
	43.4 I/O Module.........................................................................................468
44- Extra equipment - 9500..................................................................................469
	44.1 Dry powder extinguisher............................................................................469
		In the event of fire, the powder extinguisher should be employed as follows:........................469
		44.1.1 Regular checks of the powder extinguisher - truck driver.....................................470
		44.1.2 Inspection of powder extinguisher in service inspection of the truck.........................470
45- Instructions for destruction............................................................................471
	45.1 General............................................................................................471
	45.2 Procedure..........................................................................................471
	45.3 Abbreviations......................................................................................472
	45.4 Sorting............................................................................................472
	45.5 Frame/chassis (0300)...............................................................................473
		45.5.1 Dismantling..................................................................................473
			Material handling...............................................................................473
	45.6 Operator's seat, cushion (0620)....................................................................474
		45.6.1 Dismantling..................................................................................474
			Material handling...............................................................................474
	45.7 Cab heating/ventilation (0630).....................................................................475
		45.7.1 Dismantling..................................................................................475
			Material handling...............................................................................475
	45.8 Driver controls (0640).............................................................................476
		45.8.1 Dismantling..................................................................................476
			Material handling...............................................................................476
	45.9 Interior fittings RR-B (0680)......................................................................477
		45.9.1 Dismantling..................................................................................477
			Material handling...............................................................................478
	45.10 Interior fittings RR-E (0680).....................................................................479
		45.10.1 Dismantling.................................................................................479
			Material handling...............................................................................480
	45.11 Interior fittings RR-B-CC (0680)..................................................................481
		45.11.1 Dismantling.................................................................................481
			Material handling...............................................................................482
	45.12 Interior fittings RR-E-CC (0680)..................................................................483
		45.12.1 Dismantling.................................................................................483
			Material handling...............................................................................484
	45.13 Rollover guard/head guard (0810)..................................................................485
		45.13.1 Dismantling.................................................................................485
			Material handling...............................................................................485
	45.14 Finger protectors (0820)..........................................................................485
		45.14.1 Dismantling.................................................................................485
			Material handling...............................................................................485
	45.15 Finger/foot protectors (0820).....................................................................486
		45.15.1 Dismantling.................................................................................486
			Material handling...............................................................................486
	45.16 Finger/foot protectors (0820).....................................................................487
		45.16.1 Dismantling.................................................................................487
			Material handling...............................................................................487
	45.17 Electric motors (1700)............................................................................488
		45.17.1 Dismantling.................................................................................488
			Material handling...............................................................................488
	45.18 Electric fan motor (1740).........................................................................489
		45.18.1 Dismantling.................................................................................489
			Material handling...............................................................................489
	45.19 Drive unit, final gear (2500).....................................................................490
		45.19.1 Dismantling.................................................................................490
			Material handling...............................................................................490
	45.20 Wheels (3500).....................................................................................491
		45.20.1 Dismantling.................................................................................491
			Material handling...............................................................................491
	45.21 Electric steering system (4300)...................................................................492
		45.21.1 Dismantling.................................................................................493
			Material handling...............................................................................493
	45.22 General electric equipment (5100).................................................................494
		45.22.1 Dismantling.................................................................................494
			Material handling...............................................................................494
	45.23 Manöversystem, körfunktion (5300).................................................................495
		45.23.1 Dismantling.................................................................................495
			Material handling...............................................................................495
	45.24 Power system, drive function (5400)...............................................................496
		45.24.1 Dismantling.................................................................................496
			Material handling...............................................................................496
	45.25 Control system, operation function (5500).........................................................497
		45.25.1 Dismantling.................................................................................497
			Material handling...............................................................................497
	45.26 Steering/protective electronics (5700)............................................................498
		45.26.1 Dismantling.................................................................................498
			Material handling...............................................................................498
	45.27 Hydraulic unit (6100).............................................................................499
		45.27.1 Dismantling.................................................................................500
			Material handling...............................................................................500
	45.28 Hydraulic system, fitted on the chassis (6200)....................................................501
		45.28.1 Dismantling.................................................................................502
			Material handling...............................................................................502
	45.29 Hydraulic system, fitted on the mast (6300).......................................................503
		45.29.1 Dismantling.................................................................................503
			Material handling...............................................................................503
	45.30 Hydraulcylindrar (6600)...........................................................................504
		45.30.1 Dismantling.................................................................................505
			Material handling...............................................................................505
	45.31 Main mast (7100)..................................................................................506
		45.31.1 Dismantling.................................................................................506
			Material handling...............................................................................506
	45.32 Lift fork (7410)..................................................................................507
		45.32.1 Dismantling.................................................................................507
			Material handling...............................................................................507
	45.33 Optional electric equipment (9300)................................................................507
		45.33.1 Dismantling.................................................................................507
			Material handling...............................................................................507
	45.34 Radio/CD player (9330)............................................................................508
		45.34.1 Dismantling.................................................................................508
			Material handling...............................................................................508
	45.35 Extra work light (9360)...........................................................................509
		45.35.1 Dismantling.................................................................................509
			Material handling...............................................................................509
	45.36 Optional electric equipment (9400)................................................................510
		45.36.1 Dismantling.................................................................................510
			Material handling...............................................................................510
	45.37 Optional electric equipment (9400)................................................................511
		45.37.1 Dismantling.................................................................................511
			Material handling...............................................................................512

DESCRIPTION:

BT FORKLIFT REFLEX RR B,E RR B,E CC SERVICE MANUAL 218920-040 – PDF DOWNLOAD

S.S 05/01/2025