BT REFLEX RR E7-8 - 21.3.5 Figure 5

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Valid from serial number T-code

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

Order number Date

218920-040 2005-06-01

Electrical system – 5000

Component list

21.3.5 Figure 5

K10

A5 A2A1

U11

U12

F1 F3

F63

F62

F61

F60

M10

M12

S65

S66

S131S133S134

X32

X33

X34

X30

X31

X18

X36

X19

X35

Y21

Y20

X42

R102

X12

X13

X26X27

RR E1-8

R101

X14

X15

X37

X38

X20

X21

X24

X23

X48

S132

X47

X49

X46

X55

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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 E7-8 - 21.3.5 Figure 5

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