BT REFLEX RR B-E, RR B-E CC Service Manual 232808-040

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BT REFLEX RR B-E, RR B-E CC Service Manual 232808-040

$30.00

Type Of Manual: Service Manual
Manual ID: 232808-040
: Service Manual PDF
Number of Pages: 482
Size: 16.0MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- REFLEX RR B-E, RR B-E CC

1. Contents
2. Technical data – M4
2.1. General tightening torque
2.1.1. Galvanised, non-oiled bolts
2.1.2. Untreated, oiled bolts
3. Introduction, maintenance – P1
3.1. Safety regulations during maintenance work
3.2. Cleaning and washing
3.2.1. Cleaning the exterior
3.2.2. Cleaning the motor compartment
3.2.3. Electrical components
3.3. Safe lifting
3.4. Opening motor compartment
3.4.1. RR B 1-8
3.5. Cab tilting
3.5.1. RR E 1-8
3.5.2. RR E 2-8 CC
4. Preventive maintenance – P2
4.1. Maintenance Schedule
4.1.1. RR B/E 1-8
4.1.2. RR B/E 2-8 CC
5. Oil and grease specification – P3
6. Tools – P4
6.1. Super Seal connector
6.1.1. AMP connector
6.1.2. AMP microtimer
6.1.3. Diverse tools
7. Cab heating/ventilation – 0630
7.1. General
7.2. Air conditioning unit
7.2.1. Ventilation
7.2.2. Main heater
7.2.3. Auxiliary heater
7.2.4. Temperature
7.2.5. Air direction
7.2.6. Fuses
7.2.7. Air filter
7.2.8. Emergency exit (12)
7.2.9. Lighting
8. Driver protection – 0840
8.1. General
8.2. Tilt Stops
8.2.1. Inspection and Adjustment
8.2.2. Removing the tilt stops
9. Electric pump motor -1710
9.1. General
9.2. Dismantling the pump motor
9.3. Dismantling and assembling the pump motor
9.3.1. Dismantling
9.3.2. Assembling
9.4. Bearing replacement
9.4.1. Dismantling
9.4.2. Assembling
9.5. Installation instructions for external temperature sensor
10. Electric steering motor – 1730
10.1. General
10.2. Replacing the steering motor
10.2.1. Dismantling
10.2.2. Assembling
10.3. Dismantling and assembling the carbon brushes
11. Electric drive motor – 1760
11.1. General
11.2. Dismantling the drive motor
11.3. Dismantling and assembling the drive motor
11.3.1. Dismantling the drive motor
11.3.2. Assembling the drive motor
11.4. Bearing replacement
11.4.1. Dismantling
11.4.2. N-side
11.4.3. Assembling
11.5. Installation instructions for external temperature sensor
12. Mechanical drive gear unit – 2550
12.1. General
12.2. Components/data for the drive assembly/transmission
12.2.1. Component placement
12.2.2. Technical data
12.2.3. Dismantling the transmission
12.3. Replacing the drive motor/drive transmission
12.3.1. Dismantling the drive motor
12.3.2. Dismantling the gear wheel
12.3.3. Dismantling the drive transmission
12.3.4. Assembling the transmission
12.3.5. Installing the drive motor
12.3.6. Assembling the gear wheel
12.4. Checking/replacing the oil
12.4.1. Checking/refilling the oil
12.4.2. Changing the Oil
12.5. Repairs
12.5.1. Replacing the drive shaft sealing ring
12.5.2. Leakage from the upper cover
12.5.3. Leakage from the lower cover
12.5.4. Replacing wheel bolts
13. Travel brake system – 3100.1
13.1. Without support arm brakes
13.2. General
13.3. Operating description
13.3.1. Releasing the accelerator
13.3.2. Travel direction selector
13.3.3. Pressing down the brake pedal
13.3.4. Parking brake
13.3.5. Emergency brake
13.4. Electromechanical disc brake, drive motor
13.5. Disassembly
13.6. Inspection
13.7. Assembly
13.8. Maintenance
13.8.1. Adjusting the play
13.8.2. Wear
13.8.3. Checking the braking force
14. Travel brake system – 3100.2
14.1. With support arm brake
14.2. General
14.3. Operating description
14.3.1. Releasing the accelerator
14.3.2. Travel direction selector
14.3.3. Pressing down the brake pedal
14.3.4. Parking brake
14.3.5. Emergency braking
14.4. Electromechanical disc brake, drive motor
14.5. Removal
14.6. Inspection
14.7. Assembly
14.8. Maintenance
14.8.1. Adjusting the play
14.8.2. Wear
14.8.3. Checking the braking force
14.9. Multiple disc brake, support arm
14.9.1. Assembling
14.9.2. Dismantling
14.9.3. Inspection
14.9.4. Assembling
14.10. Maintenance
14.10.1. Adjusting the play
15. Drive wheel – 3530
15.1. General
15.2. Dismantling the drive wheel
15.3. Assembling the drive wheel
16. Fork/support arm wheel – 3550.1
16.1. General
16.2. Dismantling the wheel
16.3. Assembling the wheel
16.4. Dismantling/assembling the wheel bearings
16.4.1. mm wheel and 300 mm wheel without brakes
16.4.2. mm wheel with brake and 350 mm wheel
17. Fork/support arm wheel – 3550.2
17.1. Valid for T-code 403-404
17.2. General
17.3. Dismantling the wheel
17.4. Assembling the drive wheel
17.5. Dismantling the wheel bearings
17.6. Assembling the wheel bearings
18. Mechanical steering system – 4100
18.1. General
18.2. Replacing the steering generator
18.2.1. Dismantling
18.2.2. Assembling
19. Steering angle sensor – 4350
19.1. General
19.2. Procedure
19.2.1. Adjustment of the steering angle sensor
20. Electrical system – 5000
20.1. Electrical Panel
20.2. List of symbols and wiring diagrams
20.2.1. List of symbols
20.2.2. Wiring diagram
20.3. Component list
20.3.1. Figure 1
20.3.2. Figure 2
20.3.3. Figure 3
20.3.4. Figure 4
20.3.5. Figure 5
20.3.6. Figure 6
20.3.7. Figure 7
20.3.8. Figure 8
20.3.9. Figure 9
20.3.10. Figure 10
20.3.11. Figure 11
20.3.12. Figure 12
20.4. Functional description
20.4.1. Truck not started up
20.4.2. Truck started up
20.4.3. Selection of travel direction
20.4.4. Driving
20.4.5. Steering
20.4.6. Steering wheel indicator
20.4.7. Braking
20.4.8. Fork lift
20.4.9. Maximum height
20.4.10. Maximum height
20.4.11. Fork lowering
20.4.12. Mast out/in
20.4.13. Fork tilt up/down
20.4.14. Hydraulic function 4
20.4.15. Hydraulic function 5
20.4.16. Cab tilt
20.4.17. Height indication
20.4.18. Height pre-set
20.4.19. Weighing
20.4.20. Driver identification
21. Battery – 5110
21.1. Battery dimensions
21.2. Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries
21.2.1. General
21.2.2. Battery recommendation
21.2.3. Battery installation
21.2.4. Recommended parameter setting for ventilation regulated batteries
21.2.5. Instructions for verifying the parameter setting
22. Transistor panel – 5460
22.1. Frequency converter
22.1.1. General description
22.1.2. Terminal connections and pole bolts
22.1.3. Technical data
22.1.4. Programming
23. Electronic card – 5710
23.1. General description
23.2. Terminal connections and voltages on A5
23.2.1.
23.2.2.
23.2.3.
23.2.4.
23.2.5.
23.2.6.
23.2.7.
23.2.8.
23.2.9.
23.3. Adjusting the lowering speed
23.4. Display and programming
23.4.1. Keyboard
23.5. Parameter settings for all parameters
23.5.1. Parameters
23.5.2. Parameter 1
23.5.3. Parameter 2
23.5.4. Parameter 3
23.5.5. Parameter 4
23.5.6. Parameter 5
23.5.7. Parameters 6 and 7
23.5.8. Parameter 11
23.5.9. Parameter 12
23.5.10. Parameters 13 to 14
23.5.11. Parameters 15 and 16
23.5.12. Parameters 17 and 18
23.5.13. Parameter 19
23.5.14. Parameter 20
23.5.15. Parameter 21
23.5.16. Parameter 22
23.5.17. Parameter 23
23.5.18. Parameter 24
23.5.19. Parameter 25
23.5.20. Parameter 26
23.5.21. Parameter 27
23.5.22. Parameter 28
23.5.23. Parameter 29
23.5.24. Parameter 30
23.5.25. Parameter 31
23.5.26. Parameter 37
23.5.27. Parameter 38
23.5.28. Parameter 39
23.5.29. Parameters 40 to 42
23.5.30. Other parameters
23.6. Operating Time
23.6.1. Installing a new card in the truck.
23.7. Warning Codes
23.8. Error codes
23.8.1. Error mode
23.8.2. Safety logic
23.9. Warning codes without registration
23.10. Warning codes with registration
23.11. Error codes
23.11.1. Error codes with registration
24. Keyboard
24.1. General
24.2. Display
24.2.1. Description of the keyboard symbols
24.3. Function
24.3.1. Function 0
24.3.2. Function 1
24.3.3. Function 2
24.3.4. Function 3
24.4. Programming
24.4.1. LED status.
24.4.2. Driver codes
25. Hydraulics – 6000
25.1. General
25.2. Symbols
25.2.1. Hydraulics diagram 1 (4)
25.2.2. Hydraulics diagram 2 (4)
25.2.3. Hydraulics diagram 3 (4)
25.2.4. Hydraulics diagram 4 (4)
25.3. List of symbols
25.3.1. Component placement 1 (3)
25.3.2. Component placement 2 (3)
25.3.3. Component placement 3 (3)
25.4. Adjusting fork lowering
25.5. Adjusting the maximum lifting capacity
26. Hydraulic pump – 6140
26.1. General
26.2. Replacing the hydraulic pump
26.2.1. Dismantling
26.2.2. Assembling
27. Hydraulic connections – 6230
27.1. General
27.2. Tightening torque for hydraulic connections
27.2.1. Conical connection with O-ring
27.2.2. Tredo seal
27.2.3. Pipe coupling
27.2.4. Connection screwed into aluminium
27.2.5. Connection screwed into steel
28. Mast mounted hose reel – 6370
28.1. General
28.2. Assembling
28.3. Check after assembly
29. Main lift cylinder – 6610
29.1. General
29.2. Tools
29.3. Dismantling the lift cylinders from the mast
29.4. Dismantling the cylinder
29.4.1. Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder
29.4.2. Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder
29.4.3. Dismantling and assembling the hose rupture valve
29.5. Assembling the cylinder
29.5.1. Assembling the cylinder in the mast
30. Free lift cylinder – 6620
30.1. General
30.2. Tools
30.3. Dismantling
30.3.1. Dismantling the cylinder
30.4. Dismantle the rod seal and support ring
30.4.1. Assembling the rod seal and support ring
30.5. Dismantling the piston
30.5.1. Fitting the piston in the free lift cylinder
30.6. Dismantling and assembling the hose rupture valve
30.7. Assembling the cylinder
30.8. Assembly
31. Reach cylinder – 6650
31.1. General
31.2. Assembling and dismantling the reach cylinder
31.3. Dismantling
31.3.1. Dismantling the cylinder
31.3.2. Dismantle the rod seal and the support ring
31.3.3. Assembling the rod seal and the support ring
31.3.4. Dismantling the ram
31.3.5. Assembling the ram
31.3.6. Assembling the cylinder
31.4. Assembling
32. Tilt cylinder – 6660.1
32.1. General
32.2. Mast with valve on the fork carriage
32.2.1. Dismantling the fork carriage
32.2.2. Dismantling the cylinder
32.2.3. Dismantling the rod seal
32.2.4. Dismantling the ram
32.2.5. Assembling the ram
32.2.6. Assembling the rod seal
32.2.7. Assembling the cylinder
32.2.8. Assembling the fork carriage
32.3. Mast without valve on the fork carriage
32.3.1. Dismantling the fork carriage
32.3.2. Dismantling the cylinder
32.3.3. Dismantling the rod seal
32.3.4. Dismantling the ram
32.3.5. Assembling the ram
32.3.6. Assembling the rod seal
32.3.7. Assembling the cylinder
32.3.8. Assembling the fork carriage
33. Tilt cylinder – 6660.2
33.1. General
33.2. Dismantling the cylinder from the truck
33.3. Dismantling and assembling the cylinder
33.3.1. Dismantling the cylinder
33.3.2. Dismantle the seals and the support ring
33.3.3. Assembling the rod seal and the support ring
33.3.4. Dismantling the ram
33.3.5. Assembling the ram
33.3.6. Assembling the cylinder
33.4. Refitting the cylinder in the truck
34. Main mast -7100
34.1. General
34.2. List of tools
34.3. Transporting the truck
34.4. Assembling the mast
34.5. Dismantling the mast
34.6. Adjusting the play
34.6.1. Adjusting the mast play.
34.6.2. Radial play
34.7. Assembly
34.8. Problem with the mast rollers
34.9. Adjusting the distance between the forks and floor
35. Main lift chain system – 7120
35.1. General
35.2. Checking the chain setting
35.3. Chain inspection
35.3.1. Noise
35.3.2. Surface rust
35.3.3. Rusty links
35.3.4. Stiff links
35.3.5. Bolt rotation
35.3.6. Loose bolts
35.3.7. Outline wear
35.3.8. Stretching
35.3.9. Damage
35.3.10. Damaged discs
35.3.11. Damaged bolts
35.3.12. Dirty chain
35.4. Cleaning
35.5. Lubrication
36. Lifting devices – 7400
36.1. General
36.1.1. Inspection intervals
36.1.2. Inspection
36.1.3. Surface cracks
36.1.4. Difference in height between the fork tips

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