15 – 42 Repair Manual RRE140/160/180/200/250 © BT
Mast/Lift system 7000
Hydraulic telescopic forks
T-code Valid from serial number Date Publication No.
815, 816 6051502 2008-08-21 261828-040
15.9.4 Dismantling telescopic forks
IMPORTANT!
Whenever the telescopic forks are serviced, the truck must be turned
off and the battery disconnected.
During maintenance, the hydraulic system must be depressurised.
If the telescopic forks are removed, the forks’ couplings must be
sealed to prevent dirt from entering the hydraulic system.
1. Operate the forks to waist height and tilt the mast to its forward po-
sition.
2. Switch off the truck and then withdraw the battery cut out connec-
tor.
3. Remove the outer fork by removing the attachment bushings for
the spirals. Be careful not to damage the piston rods.
4. Unscrew the couplings on the back of the fork, so that the piston
rods do not create a vacuum when removed.
5. Remove all Loctite from the coupling threads.
6. Undo the fixing screw between the two cylinder heads.
7. Place a collection vessel under the forks. Undo the cylinder head
using the cylinder head spanner. The right cylinder head (as
viewed by the operator) must always be unscrewed first, as there is
a plastic plug underneath the fixing screw.
8. Carefully remove the piston rods. Note that there are two loose
support rings on each side of the piston ring seal. Remember to re
-
place these when installing the piston rod on the fork.
9. The piston can now be unscrewed. To prevent the piston rod being
damaged while the piston is being unscrewed, it must be secured
in position to prevent the piston rotating. Due to the presence of
Loctite sealant, the pistons on forks with integrated flow dividers
must be heated with a burner before they can be unscrewed.
10. The cylinder head can now be removed from the piston rod.
11. Replace the parts.
12. Remove all Loctite from the piston rod thread.
13. Clean the piston rod and thread with Loctite 7063.
14. The cylinder head can now be reinstalled on the piston rod.
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