BT REFLEX RR B1-3 - 37.6.1 Instructions for replacing hydraulic parts

Valid from serial number T-code
713962- 403-414, 669-671, 716-718
Order number Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B,E RR B,E CC 37- 15
Lifting devices – 7400
Troubleshooting
37.6.1 Instructions for replacing hydraulic
parts
1. Level the forks to hip height, tilt the mast to its forward posi-
tion and remove the ignition key from the contact The battery
plug must also be removed.
2. Take the outer fork off by removing the special M10 bolt from
the piston rod on the underside of the fork nose.
3. Unscrew the couplings on top of the back of the fork, so the
piston rods will not create a vacuum while disassembling.
4. Remove the Loctite from the thread of the coupling.
5. Unscrew the fixing screw in between the two cylinder heads.
6. Place a reservoir under the forks. Use the cylinder head span-
ner to unscrew the cylinder head. The right cylinder head (as
seen from the position of the driver) must always be un
-
screwed first because of the plastic plug under the fixing
screw.
7. Pull the piston rods out carefully. Note that there are two loose
support rings, with a piston rod seal on the piston rod in be
-
tween. They must be replaced before the piston rod is inserted
back into the fork.
8. The piston can be unscrewed now. To prevent damage to the
piston rod while unscrewing the piston, it must be fixed at the
clamp.
9. The cylinder head can be removed from the piston rod.
10. Replace parts.
11. Remove the Loctite from the thread of the piston rod.
12. Clean the piston rod and the thread with Loctite 7063.
13. The cylinder head can be replaced on the piston rod.
14. When screwing the pistons on the piston rod, the pistons
must be locked with Loctite 542.
15. Keep the piston rod (together with the piston and cylinder
head) in line with the cylinders and tap it in carefully.
16. Put copper paste on the thread of the cylinder head.
17. Insert the cylinder head again using the cylinder head span-
ner.
18. Once all piston rods are in, the fixing screw has to be tight-
ened again.
19. Now the couplings have to be tightened (lock with Loctite
542).
20. Extend the forks about 150 mm.
21. The outer forks can now be mounted. Clean the thread of the
special M10 bolt. Put the first washer between the piston rod
and the hole in the vertical plate on the outer fork. Then put the
second washer on the other side of the vertical plate. Apply
Loctite 542 to the special M10 bolt and then insert it first
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