BT REFLEX RR B-E, RR B-E CC Service Manual 232808-040
BT REFLEX RR B-E, RR B-E CC Service Manual 232808-040 - Image 2
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BT REFLEX RR B-E, RR B-E CC Service Manual 232808-040 - Image 4
BT REFLEX RR B-E, RR B-E CC Service Manual 232808-040 - Image 5

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:

Product details

  • 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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