BT REFLEX RR B1-3

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T-code Valid from serial number

403-414, 669-671, 716-718 713962-

Date Order number

2005-06-01 218920-040

Mechanical steering system – 4100

Replacing the steering generator

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1- Table of contents3
2- General product information - M227
- 2.1 Presentation of the reach trucks27
  - 2.1.1 Application areas for the reach trucks27
  - 2.1.2 Prohibited applications for the reach trucks27
- 2.2 Truck data28
- 2.3 Truck dimensions29
- 2.4 Identification plate, truck31
- 2.5 Main components RR B/E 1-833
- 2.6 Main components RR B/E 2-8 CC35
- 2.7 Warning and information plates and symbols RR B/E 1-837
- 2.8 Warning and information plates and symbols RR B/E 2-8 CC39
3- Technical data - M441
- 3.1 General tightening torque45
  - 3.1.1 Galvanised, non-oiled bolts45
  - 3.1.2 Untreated, oiled bolts45
4- Introduction, maintenance - P147
- 4.1 Safety regulations during maintenance work47
- 4.2 Cleaning and washing48
- 4.3 Safe lifting49
- 4.4 Opening motor compartment50
  - 4.4.1 RR B 1-850
- 4.5 Cab tilting51
  - 4.5.1 RR E 1-851
  - 4.5.2 RR E 2-8 CC52
5- Preventive maintenance - P255
- 5.1 Maintenance Schedule55
  - 5.1.1 RR B/E 1-855
  - 5.1.2 RR B/E 2-8 CC65
6- Oil and grease specification - P375
7- Tools - P477
- 7.1 Super Seal connector77
8- Cab heating/ventilation - 063087
- 8.1 General87
- 8.2 Air conditioning unit87
9- Driver protection - 084091
- 9.1 General91
- 9.2 Tilt Stops92
  - 9.2.1 Inspection and Adjustment92
  - 9.2.2 Removing the tilt stops93
10- Electric pump motor -171095
- 10.1 General95
- 10.2 Dismantling the pump motor95
- 10.3 Dismantling and assembling the pump motor96
  - 10.3.1 Dismantling96
  - 10.3.2 Assembling96
- 10.4 Bearing replacement97
  - 10.4.1 Dismantling97
  - 10.4.2 Assembling98
- 10.5 Installation instructions for external temperature sensor99
11- Electric steering motor - 1730103
- 11.1 General103
- 11.2 Replacing the steering motor103
  - 11.2.1 Dismantling103
  - 11.2.2 Assembling103
- 11.3 Dismantling and assembling the carbon brushes104
12- Electric drive motor - 1760105
- 12.1 General105
- 12.2 Dismantling the drive motor105
- 12.3 Dismantling and assembling the drive motor106
  - 12.3.1 Dismantling the drive motor106
    - Removing the gear wheel106
    - Removing the brakes106
  - 12.3.2 Assembling the drive motor107
    - Assembling the brakes107
    - Assembling the gear wheel107
- 12.4 Bearing replacement108
- 12.5 Installation instructions for external temperature sensor110
13- Mechanical drive gear unit - 2550113
- 13.1 General113
- 13.2 Components/data for the drive assembly/transmission113
- 13.3 Replacing the drive motor/drive transmission117
- 13.4 Checking/replacing the oil120
  - 13.4.1 Checking/refilling the oil120
  - 13.4.2 Changing the Oil120
- 13.5 Repairs121
14- Travel brake system - 3100.1125
- Without support arm brakes125
- 14.1 General125
- 14.2 Operating description125
- 14.3 Electromechanical disc brake, drive motor129
- 14.4 Maintenance131
15- Travel brake system - 3100.2133
- With support arm brake133
- 15.1 General133
- 15.2 Operating description133
- 15.3 Electromechanical disc brake, drive motor137
- 15.4 Maintenance139
- 15.5 Multiple disc brake, support arm141
- 15.6 Maintenance143
  - 15.6.1 Adjusting the play144
16- Drive wheel - 3530145
- 16.1 General145
- 16.2 Dismantling the drive wheel145
- 16.3 Assembling the drive wheel145
17- Fork/support arm wheel - 3550.1147
- 17.1 General147
- 17.2 Dismantling the wheel148
- 17.3 Assembling the wheel149
- 17.4 Dismantling/assembling the wheel bearings151
  - 17.4.1 265 mm wheel and 300 mm wheel without brakes.151
    - Dismantling the bearing151
    - Assembling bearings151
  - 17.4.2 300 mm wheel with brake and 350 mm wheel152
    - Dismantling the bearing152
    - Assembling bearings152
18- Fork/support arm wheel - 3550.2153
- 18.1 General153
- 18.2 Dismantling the wheel153
- 18.3 Assembling the drive wheel154
- 18.4 Dismantling the wheel bearing154
- 18.5 Assembling the wheel bearing154
19- Mechanical steering system - 4100155
- 19.1 General155
- 19.2 Replacing the steering generator155
  - 19.2.1 Dismantling155
  - 19.2.2 Assembling155
20- Steering angle sensor - 4350157
- 20.1 General157
- 20.2 Procedure157
  - 20.1.1 Adjustment of the steering angle sensor158
21- Electrical system - 5000159
- 21.1 General159
  - 21.1.1 Electrical panel159
- 21.2 Symbol list and wiring diagrams160
- 21.3 Component list179
- 21.4 Functional description193
22- Battery - 5110205
- 22.1 Battery dimensions205
- 22.2 Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries206
23- Transistor panel - 5460209
- 23.1 Frequency converter209
24- Electronic card - 5710213
- 24.1 General description213
- 24.2 Terminal connections and voltages on A5214
- 24.3 Adjusting the lowering speed219
- 24.4 Displaying and programming220
  - 24.4.1 Keypad220
    - Clock221
    - Driver parameters 1-7221
- 24.5 Parameter setting of all parameters222
- 24.6 Operating hours235
  - 24.6.1 Installing a new electronic card in the truck235
- 24.7 Warning codes236
- 24.8 Error Codes237
  - 24.8.1 Error mode237
  - 24.8.2 Safety logic238
- 24.9 Warning Codes without registration238
- 24.10 Warning codes with registration259
- 24.11 Error Codes278
  - 24.11.1 Error codes with registration279
25- Keypad311
- 25.1 General311
- 25.2 Display311
  - 25.2.1 Description of the keypad symboles312
- 25.3 Function313
- 25.4 Programming314
  - 25.4.1 LED status314
  - 25.4.2 Driver PIN-codes315
26- Hydraulics - 6000317
- 26.1 General317
- 26.2 Symbols317
- 26.3 List of symbols323
- 26.4 Adjusting fork lowering328
- 26.5 Adjusting the maximum lifting capacity329
27- Hydraulic pump - 6140331
- 27.1 General331
- 27.2 Replacing the hydraulic pump331
  - 27.2.1 Dismantling331
  - 27.2.2 Assembling332
28- Hydraulic connections - 6230333
- 28.1 General333
- 28.2 Tightening torque for hydraulic connections333
29- Mast mounted hose reel - 6370337
- 29.1 General337
- 29.2 Assembling337
- 29.3 Check after assembly338
30- Main lift cylinder - 6610339
- 30.1 General339
- 30.2 Tools339
- 30.3 Dismantling the lift cylinders from the mast340
- 30.4 Dismantling the cylinder340
- 30.5 Assembling the cylinder342
  - 30.5.1 Assembling the cylinder in the mast342
31- Free lift cylinder - 6620343
- 31.1 General343
- 31.2 Tools343
- 31.3 Dismantling344
  - 31.3.1 Dismantling the cylinder345
- 31.4 Dismantle the rod seal and support ring345
  - 31.4.1 Assembling the rod seal and support ring345
- 31.5 Dismantling the piston346
  - 31.5.1 Fitting the piston in the free lift cylinder346
- 31.6 Dismantling and assembling the hose rupture valve346
- 31.7 Assembling the cylinder347
- 31.8 Assembly347
32- Reach cylinder - 6650349
- 32.1 General349
- 32.2 Assembling and dismantling the reach cylinder349
- 32.3 Dismantling349
- 32.4 Assembling351
33- Tilt cylinder - 6660.1353
- 33.1 General353
- 33.2 Mast with valve on the fork carriage354
- 33.3 Mast without valve on the fork carriage357
34- Tilt cylinder - 6660.2361
- 34.1 General361
- 34.2 Dismantling the cylinder from the truck361
- 34.3 Dismantling and assembling the cylinder362
- 34.4 Refitting the cylinder in the truck364
35- Main mast -7100365
- 35.1 General365
- 35.2 List of tools365
- 35.3 Transporting the truck366
- 35.4 Assembling the mast367
- 35.5 Dismantling the mast372
- 35.6 Adjusting the play373
  - 35.6.1 Adjusting the mast play.376
    - Lateral play376
  - 35.6.2 Radial play377
- 35.7 Assembly377
36- Main lift chain system - 7120379
- 36.1 General379
- 36.2 Checking the chain setting379
- 36.3 Chain inspection379
- 36.4 Cleaning383
- 36.5 Lubrication383
37- Lifting devices - 7400385
- 37.1 General385
- 37.2 Checking the fork carriage’s wearing strips388
- 37.3 Fork spread unit390
  - 37.3.1 Servicing of fork spread unit390
- 37.4 Telescopic forks391
  - 37.4.1 Telescopic forks391
  - 37.4.2 Putting the telescopic forks into operation:392
- 37.5 Maintenance392
- 37.6 Troubleshooting397
  - 37.6.1 Instructions for replacing hydraulic parts399
- 37.7 Extended forks401
38- Battery charger - 8340403
- 38.1 General403
- 38.2 Installation404
- 38.3 Functional description404
- 38.4 Service and maintenance414
39- Control/computer equipment - 8700423
- 39.1 General423
- 39.2 Connection423
- 39.3 Layout424
- 39.4 Function for connection427
- 39.5 Function for disconnecting427
- 39.6 Function for program downloading427
- 39.7 Function for truck report429
- 39.8 Function for parameters430
- 39.9 Function for diagnostics432
- 39.10 Other menu functions436
- 39.11 Specifications437
- 39.12 Installation438
40- Extra warning lights/alarm - 9370441
- 40.1 General441
41- Positioning equipment - 9390443
- 41.1 General443
- 41.2 Height indication444
- 41.3 Function445
- 41.4 Display445
- 41.5 Height pre-set447
- 41.6 Function448
- 41.7 Display449
  - 41.7.1 Description of the display symbols450
- 41.8 Assembly of height pre-set451
- 41.9 Programming451
  - 41.9.1 Programming a level451
    - Collect level451
    - Leave level452
  - 41.9.2 Deleting programmed levels452
- 41.10 Automatic driving453
- 41.11 Parameters455
- 41.12 Programming parameters458
- 41.13 Error codes460
42- TV equipment - 9390461
- 42.1 General461
- 42.2 Camera mounted on fork461
43- Truck log system, code lock - 9420465
- 43.1 General465
- 43.2 SD 16465
  - 43.2.1 Login with code (5-digit)465
  - 43.2.2 Logout465
- 43.3 Components466
  - If the truck does not start:468
- 43.4 I/O Module468
44- Extra equipment - 9500469
- 44.1 Dry powder extinguisher469
45- Instructions for destruction471
- 45.1 General471
- 45.2 Procedure471
- 45.3 Abbreviations472
- 45.4 Sorting472
- 45.5 Frame/chassis (0300)473
  - 45.5.1 Dismantling473
    - Material handling473
- 45.6 Operator's seat, cushion (0620)474
  - 45.6.1 Dismantling474
    - Material handling474
- 45.7 Cab heating/ventilation (0630)475
  - 45.7.1 Dismantling475
    - Material handling475
- 45.8 Driver controls (0640)476
  - 45.8.1 Dismantling476
    - Material handling476
- 45.9 Interior fittings RR-B (0680)477
  - 45.9.1 Dismantling477
    - Material handling478
- 45.10 Interior fittings RR-E (0680)479
  - 45.10.1 Dismantling479
    - Material handling480
- 45.11 Interior fittings RR-B-CC (0680)481
  - 45.11.1 Dismantling481
    - Material handling482
- 45.12 Interior fittings RR-E-CC (0680)483
  - 45.12.1 Dismantling483
    - Material handling484
- 45.13 Rollover guard/head guard (0810)485
  - 45.13.1 Dismantling485
    - Material handling485
- 45.14 Finger protectors (0820)485
  - 45.14.1 Dismantling485
    - Material handling485
- 45.15 Finger/foot protectors (0820)486
  - 45.15.1 Dismantling486
    - Material handling486
- 45.16 Finger/foot protectors (0820)487
  - 45.16.1 Dismantling487
    - Material handling487
- 45.17 Electric motors (1700)488
  - 45.17.1 Dismantling488
    - Material handling488
- 45.18 Electric fan motor (1740)489
  - 45.18.1 Dismantling489
    - Material handling489
- 45.19 Drive unit, final gear (2500)490
  - 45.19.1 Dismantling490
    - Material handling490
- 45.20 Wheels (3500)491
  - 45.20.1 Dismantling491
    - Material handling491
- 45.21 Electric steering system (4300)492
  - 45.21.1 Dismantling493
    - Material handling493
- 45.22 General electric equipment (5100)494
  - 45.22.1 Dismantling494
    - Material handling494
- 45.23 Manöversystem, körfunktion (5300)495
  - 45.23.1 Dismantling495
    - Material handling495
- 45.24 Power system, drive function (5400)496
  - 45.24.1 Dismantling496
    - Material handling496
- 45.25 Control system, operation function (5500)497
  - 45.25.1 Dismantling497
    - Material handling497
- 45.26 Steering/protective electronics (5700)498
  - 45.26.1 Dismantling498
    - Material handling498
- 45.27 Hydraulic unit (6100)499
  - 45.27.1 Dismantling500
    - Material handling500
- 45.28 Hydraulic system, fitted on the chassis (6200)501
  - 45.28.1 Dismantling502
    - Material handling502
- 45.29 Hydraulic system, fitted on the mast (6300)503
  - 45.29.1 Dismantling503
    - Material handling503
- 45.30 Hydraulcylindrar (6600)504
  - 45.30.1 Dismantling505
    - Material handling505
- 45.31 Main mast (7100)506
  - 45.31.1 Dismantling506
    - Material handling506
- 45.32 Lift fork (7410)507
  - 45.32.1 Dismantling507
    - Material handling507
- 45.33 Optional electric equipment (9300)507
  - 45.33.1 Dismantling507
    - Material handling507
- 45.34 Radio/CD player (9330)508
  - 45.34.1 Dismantling508
    - Material handling508
- 45.35 Extra work light (9360)509
  - 45.35.1 Dismantling509
    - Material handling509
- 45.36 Optional electric equipment (9400)510
  - 45.36.1 Dismantling510
    - Material handling510
- 45.37 Optional electric equipment (9400)511
  - 45.37.1 Dismantling511
    - Material handling512

BT REFLEX RR B1-3 - Page 156

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