BT REFLEX RR B User manual

© BT Europe AB
Service Manual en
REFLEX RR B,E RR B,E CC
Valid from serial number: 713962-
Order number: 218920-040
Issued: 2005-09-09 ITS
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© BT Europe AB Service Manual REFLEX RR B,E RR B,E CC Approved by: K-G Andersson
This manual covers following truck models:
Some chapters in this manual covers only certain of the T-codes above.
Document revisions
Issue date Resp. Changes
2004-09-01 ITS Brand new version.
2005-06-01 ITS Updating: M4, P1, P2, P3, P4, 0840, 3550, 5000 (wiring diagram +
component list), 5110, 5710, 6000, 6620, 7100, 7400, 9390, 9420,
9500
2005-09-09 ITS Updating: M4, P2, P4, 3550.2 (new)
T-code Model Serial number
403 RR B1-3 713962-
404 RR B1-3C 713962-
405 RR B4-6 713962-
406 RR B4-6C 713962-
407 RR B7-8 713962-
408 RR B7-8C 713962-
409 RR E 1-3 713962-
410 RR E1-3C 713962-
411 RR E4-6 713962-
412 RR E4-6C 713962-
413 RR E7-8 713962-
414 RR E7-8C 713962-
669 RR E2-3CC 713962-
670 RR E4-6CC 713962-
671 RR E7-8CC 713962-
716 RR B2-3CC 713962-
717 RR B4-5CC 713962-
718 RR B7-8CC 713968-
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-1
Table of contents
1-Table of contents
General product information – M2 2-1
Presentation of the reach trucks................... 1
2.1.1 Application areas for the reach trucks ................ 1
2.1.2 Prohibited applications for the reach trucks ........ 1
Truck data..................................................... 2
Truck dimensions ......................................... 3
Identification plate, truck............................... 5
2.4.1 Capacity plate ..................................................... 5
2.4.2 Modification plate ............................................... 6
2.4.3 Identification plate, mast ..................................... 6
Main components RR B/E 1-8...................... 7
Main components RR B/E 2-8 CC................ 9
Warning and information plates and symbols
RR B/E 1-8 11
Warning and information plates and symbols
RR B/E 2-8 CC 13
Technical data – M4 3-1
General tightening torque............................. 5
3.1.1 Galvanised, non-oiled bolts ................................ 5
3.1.2 Untreated, oiled bolts ......................................... 5
Introduction, maintenance – P1 4-1
Safety regulations during maintenance work 1
Cleaning and washing .................................. 2
4.2.1 Cleaning the exterior .......................................... 3
4.2.2 Cleaning the motor compartment ....................... 3
4.2.3 Electrical components ........................................ 3
Safe lifting..................................................... 3
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-2 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Opening motor compartment........................ 4
4.4.1 RR B 1-8 ............................................................. 4
Cab tilting...................................................... 5
4.5.1 RR E 1-8 ............................................................. 5
4.5.2 RR E 2-8 CC ....................................................... 6
Preventive maintenance – P2 5-1
Maintenance Schedule................................. 1
5.1.1 RR B/E 1-8 .......................................................... 1
5.1.2 RR B/E 2-8 CC ................................................. 11
Oil and grease specification – P3 6-1
Tools – P4 7-1
Super Seal connector ................................... 1
7.1.1 AMP connector ................................................... 2
7.1.2 AMP microtimer .................................................. 3
7.1.3 Diverse tools ....................................................... 4
Cab heating/ventilation – 0630 8-1
General......................................................... 1
Air conditioning unit ...................................... 1
8.2.1 Ventilation ........................................................... 1
8.2.2 Main heater ......................................................... 1
8.2.3 Auxiliary heater ................................................... 1
8.2.4 Temperature ....................................................... 1
8.2.5 Air direction ......................................................... 2
8.2.6 Fuses .................................................................. 2
8.2.7 Air filter ................................................................ 2
8.2.8 Emergency exit (12) ............................................ 3
8.2.9 Lighting ............................................................... 3
Driver protection – 0840 9-1
General......................................................... 1
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-3
Table of contents
Tilt Stops....................................................... 2
9.2.1 Inspection and Adjustment ................................. 2
9.2.2 Removing the tilt stops ....................................... 3
Electric pump motor –1710 10-1
General......................................................... 1
Dismantling the pump motor......................... 1
Dismantling and assembling the pump motor 2
10.3.1 Dismantling ........................................................ 2
10.3.2 Assembling ......................................................... 2
Bearing replacement .................................... 3
10.4.1 Dismantling ........................................................ 3
10.4.2 Assembling ......................................................... 4
Installation instructions for external tempera-
ture sensor 5
Electric steering motor – 1730 11-1
General......................................................... 1
Replacing the steering motor........................ 1
11.2.1 Dismantling ........................................................ 1
11.2.2 Assembling ......................................................... 1
Dismantling and assembling the carbon brush-
es 2
Electric drive motor – 1760 12-1
General......................................................... 1
Dismantling the drive motor.......................... 1
Dismantling and assembling the drive motor 2
12.3.1 Dismantling the drive motor ............................... 2
Removing the gear wheel ................................... 2
Removing the brakes ......................................... 2
12.3.2 Assembling the drive motor ................................ 3
Assembling the brakes ....................................... 3
Assembling the gear wheel ................................ 3
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-4 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Bearing replacement..................................... 4
12.4.1 Dismantling ......................................................... 4
12.4.2 N-side ................................................................. 4
D-side ................................................................. 4
12.4.3 Assembling ......................................................... 5
N-side ................................................................. 5
D-side ................................................................. 5
Installation instructions for external tempera-
ture sensor 6
Mechanical drive gear unit – 2550 13-1
General......................................................... 1
Components/data for the drive assembly/
transmission 1
13.2.1 Component placement ....................................... 2
13.2.2 Technical data .................................................... 4
13.2.3 Dismantling the transmission ............................. 4
Replacing the drive motor/drive transmission.. 5
13.3.1 Dismantling the drive motor ................................ 5
13.3.2 Dismantling the gear wheel ................................ 5
13.3.3 Dismantling the drive transmission ..................... 6
13.3.4 Assembling the transmission .............................. 6
13.3.5 Installing the drive motor .................................... 7
13.3.6 Assembling the gear wheel ................................ 7
Checking/replacing the oil............................. 8
13.4.1 Checking/refilling the oil ..................................... 8
13.4.2 Changing the Oil ................................................. 8
Repairs ......................................................... 9
13.5.1 Replacing the drive shaft sealing ring ................ 9
Dismantling ......................................................... 9
Assembling ....................................................... 10
13.5.2 Leakage from the upper cover ......................... 11
13.5.3 Leakage from the lower cover .......................... 11
13.5.4 Replacing wheel bolts ...................................... 12
Travel brake system – 3100.1 14-1
Without support arm brakes ................................ 1
General......................................................... 1
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-5
Table of contents
Operating description ................................... 1
14.2.1 Releasing the accelerator .................................. 2
14.2.2 Travel direction selector ..................................... 2
14.2.3 Pressing down the brake pedal .......................... 3
14.2.4 Parking brake ..................................................... 4
14.2.5 Emergency brake ............................................... 4
Electromechanical disc brake, drive motor... 5
14.3.1 Assembling ......................................................... 5
14.3.2 Dismantling ........................................................ 6
14.3.3 Inspection ........................................................... 6
14.3.4 Assembling ......................................................... 6
Maintenance................................................. 7
14.4.1 Adjusting the play ............................................... 7
14.4.2 Wear ................................................................... 7
14.4.3 Check the braking force ..................................... 8
Travel brake system – 3100.2 15-9
With support arm brake ...................................... 9
General......................................................... 9
Operating description ................................... 9
15.2.1 Releasing the accelerator ................................ 10
15.2.2 Travel direction selector ................................... 10
15.2.3 Pressing down the brake pedal ........................ 11
15.2.4 Parking brake ................................................... 12
15.2.5 Emergency braking .......................................... 12
Electromechanical disc brake, drive motor.. 13
15.3.1 Assembling ....................................................... 13
15.3.2 Dismantling ...................................................... 14
15.3.3 Inspection ......................................................... 14
15.3.4 Assembling ....................................................... 14
Maintenance................................................ 15
15.4.1 Adjusting the play ............................................. 15
15.4.2 Wear ................................................................. 15
15.4.3 Check the braking force ................................... 16
Multiple disc brake, support arm.................. 17
15.5.1 Assembling ....................................................... 17
15.5.2 Dismantling ...................................................... 18
15.5.3 Inspection ......................................................... 19
15.5.4 Assembling ....................................................... 19
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-6 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Maintenance................................................ 19
15.6.1 Adjusting the play ............................................. 20
Drive wheel – 3530 16-1
General......................................................... 1
Dismantling the drive wheel.......................... 1
Assembling the drive wheel.......................... 1
Fork/support arm wheel – 3550.1 17-1
General......................................................... 1
Dismantling the wheel................................... 2
Assembling the wheel................................... 3
Dismantling/assembling the wheel bearings. 5
17.4.1 265 mm wheel and 300 mm wheel without
brakes. 5
Dismantling the bearing ...................................... 5
Assembling bearings .......................................... 5
17.4.2 300 mm wheel with brake and 350 mm wheel ... 6
Dismantling the bearing ...................................... 6
Assembling bearings .......................................... 6
Fork/support arm wheel – 3550.2 18-1
General......................................................... 1
Dismantling the wheel................................... 1
Assembling the drive wheel.......................... 2
Dismantling the wheel bearing...................... 2
Assembling the wheel bearing...................... 2
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-7
Table of contents
Mechanical steering system – 4100 19-1
General......................................................... 1
Replacing the steering generator.................. 1
19.2.1 Dismantling ........................................................ 1
19.2.2 Assembling ......................................................... 1
Steering angle sensor – 4350 20-1
General......................................................... 1
Procedure..................................................... 1
20.1.1 Adjustment of the steering angle sensor ............ 2
Electrical system – 5000 21-1
General......................................................... 1
21.1.1 Electrical panel ................................................... 1
Symbol list and wiring diagrams ................... 2
21.2.1 List of symbols ................................................... 2
21.2.2 Wiring diagram (1/16) ......................................... 5
21.2.3 Wiring diagram (2/16) ......................................... 6
21.2.4 Wiring diagram (3/16) ......................................... 7
21.2.5 Wiring diagram (4/16) ......................................... 8
21.2.6 Wiring diagram (5/16) ......................................... 9
21.2.7 Wiring diagram (6/16) ....................................... 10
21.2.8 Wiring diagram (7/16) ....................................... 11
21.2.9 Wiring diagram (8/16) ....................................... 12
21.2.10 Wiring diagram (9/16) ..................................... 13
21.2.11 Wiring diagram (10/16) ................................... 14
21.2.12 Wiring diagram (11/16) ................................... 15
21.2.13 Wiring diagram (12/16) ................................... 16
21.2.14 Wiring diagram (13/16) ................................... 17
21.2.15 Wiring diagram (14/16) ................................... 18
21.2.16 Wiring diagram (15/16) ................................... 19
21.2.17 Wiring diagram (16/16) ................................... 20
Component list............................................. 21
21.3.1 Figure 1 ............................................................ 27
21.3.2 Figure 2 ............................................................ 27
21.3.3 Figure 3 ............................................................ 28
21.3.4 Figure 4 ............................................................ 28
21.3.5 Figure 5 ............................................................ 29
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-8 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
21.3.6 Figure 6 ............................................................ 30
21.3.7 Figure 7 ............................................................ 30
21.3.8 Figure 8 ............................................................ 31
21.3.9 Figure 9 ............................................................ 32
21.3.10 Figure 10 ........................................................ 33
21.3.11 Figure 11 ........................................................ 34
21.3.12 Figure 12 ........................................................ 34
Functional description.................................. 35
21.4.1 Truck not started up ......................................... 35
21.4.2 Truck started up ............................................... 36
21.4.3 Choice of travel direction .................................. 37
On the control console ...................................... 37
On the left-hand handle .................................... 37
On the accelerator ............................................ 37
21.4.4 Driving .............................................................. 38
21.4.5 Steering ............................................................ 39
21.4.6 Steering wheel indicator ................................... 39
21.4.7 Braking ............................................................. 40
Auto-brakes ...................................................... 40
Motor brakes (electric) ...................................... 40
Foot brake ......................................................... 40
Parking brake .................................................... 40
21.4.8 Fork lift .............................................................. 41
21.4.9 Maximum height ............................................... 41
21.4.10 Maximum height ............................................. 42
21.4.11 Fork lowering .................................................. 42
21.4.12 Mast out/in ...................................................... 43
21.4.13 Fork tilt up/down ............................................. 43
21.4.14 Hydraulic function 4 ........................................ 43
21.4.15 Hydraulic function 5 ........................................ 44
21.4.16 Cab tilt ............................................................ 44
21.4.17 Height indication ............................................. 45
21.4.18 Height pre-set ................................................. 45
21.4.19 Weighing ........................................................ 45
21.4.20 Driver identification ......................................... 46
Without pin code ............................................... 46
With pin code .................................................... 46
Battery – 5110 22-1
Battery dimensions....................................... 1
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-9
Table of contents
Setting the battery parameters on RR trucks fit-
ted with Hawker Evolution gel batteries 2
22.2.1 General .............................................................. 2
22.2.2 Battery recommendation .................................... 2
22.2.3 Battery installation .............................................. 2
22.2.4 Recommended parameter setting for ventilation
regulated batteries 3
22.2.5 Instructions for verifying the parameter setting .. 3
Transistor panel – 5460 23-1
Frequency converter..................................... 1
23.1.1 Terminal connections and pole bolts .................. 2
23.1.2 Technical Data ................................................... 3
23.1.3 Installation of new frequency converter on truck 3
23.1.4 Programming ...................................................... 3
Electronic card – 5710 24-1
General description ...................................... 1
Terminal connections and voltages on A5.... 2
24.2.1 10X ..................................................................... 2
24.2.2 20X ..................................................................... 3
24.2.3 30X ..................................................................... 3
24.2.4 40X ..................................................................... 4
24.2.5 50X ..................................................................... 4
24.2.6 60X ..................................................................... 5
24.2.7 70X ..................................................................... 5
24.2.8 80X ..................................................................... 6
24.2.9 90X ..................................................................... 6
Adjusting the lowering speed........................ 7
Displaying and programming........................ 8
24.4.1 Keypad ............................................................... 8
Clock .................................................................. 9
Driver parameters 1-7 ......................................... 9
Parameter settingof all parameters.............. 10
Clock ................................................................ 10
Parameters ....................................................... 11
24.5.1 Parameter 1 ..................................................... 15
24.5.2 Parameter 2 ..................................................... 15
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-10 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
24.5.3 Parameter 3 ...................................................... 15
24.5.4 Parameter 4 ...................................................... 15
24.5.5 Parameter 5 ...................................................... 15
24.5.6 Parameters 6 and 7 .......................................... 15
24.5.7 Parameter 11 .................................................... 15
24.5.8 Parameter 12 .................................................... 15
24.5.9 Parameters 13 and 14 ...................................... 15
24.5.10 Parameters 15 and 16 .................................... 16
24.5.11 Parameters 17 and 18 .................................... 16
24.5.12 Parameter 19 .................................................. 17
24.5.13 Parameter 20 .................................................. 17
24.5.14 Parameter 21 .................................................. 17
24.5.15 Parameter 22 .................................................. 19
24.5.16 Parameter 23 .................................................. 19
24.5.17 Parameter 24 .................................................. 19
24.5.18 Parameter 25 .................................................. 19
24.5.19 Parameter 26 .................................................. 19
24.5.20 Parameter 27 .................................................. 19
24.5.21 Parameter 28 .................................................. 20
24.5.22 Parameter 29 .................................................. 20
24.5.23 Parameter 30 .................................................. 20
24.5.24 Parameter 37 .................................................. 20
24.5.25 Parameter 38 .................................................. 21
24.5.26 Parameter 39 .................................................. 22
24.5.27 Parameters 40 to 42 ....................................... 22
24.5.28 Miscellaneous parameters ............................. 22
Operating hours........................................... 23
24.6.1 Installing a new electronic card in the truck ...... 23
Warning codes............................................. 24
Error Codes ................................................. 25
24.8.1 Error mode ....................................................... 25
24.8.2 Safety logic ....................................................... 26
Warning Codes without registration ................ 26
Warning codes with registration................... 47
Error Codes ................................................. 66
24.10.1 Error codes with registration ........................... 67
Keypad 25-99
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-11
Table of contents
General........................................................ 99
Display......................................................... 99
25.2.1 Description of the keypad symboles .............. 100
Function..................................................... 101
25.3.1 Function 0 ...................................................... 101
25.3.2 Function 1 ...................................................... 101
25.3.3 Function 2 ...................................................... 101
25.3.4 Function 3 ...................................................... 102
Programming............................................. 102
25.4.1 LED status ...................................................... 102
25.4.2 Driver PIN-codes ............................................ 103
Hydraulics – 6000 26-1
General......................................................... 1
Symbols........................................................ 1
26.2.1 Hydraulics diagram 1 (4) .................................... 3
26.2.2 Hydraulics diagram 2 (4) .................................... 4
26.2.3 Hydraulics diagram 3 (4) .................................... 5
26.2.4 Hydraulics diagram 4 (4) .................................... 6
List of symbols.............................................. 7
26.3.1 Component placement 1 (3) ............................... 9
26.3.2 Component placement 2 (3) ............................. 10
26.3.3 Component placement 3 (3) ............................. 11
Adjusting fork lowering................................. 12
Adjusting the maximum lifting capacity........ 13
Hydraulic pump – 6140 27-1
General......................................................... 1
Replacing the hydraulic pump ...................... 1
27.2.1 Dismantling ........................................................ 1
27.2.2 Assembling ......................................................... 2
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-12 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Hydraulic connections – 6230 28-1
General......................................................... 1
Tightening torque for hydraulic connections . 1
28.2.1 Conical connection with O-ring ........................... 1
28.2.2 Tredo seal .......................................................... 2
28.2.3 Pipe coupling ...................................................... 2
28.2.4 Connection screwed into aluminium ................... 2
28.2.5 Connection screwed into steel ........................... 3
Pressure class L ................................................. 3
Mast mounted hose reel – 6370 29-1
General......................................................... 1
Assembling................................................... 1
Check after assembly ................................... 2
Main lift cylinder – 6610 30-1
General......................................................... 1
Tools............................................................. 1
Dismantling the lift cylinders from the mast... 2
Dismantling the cylinder................................ 2
30.4.1 Dismantling the rod seal, guide ring, guide ring
holder and locking ring in lift cylinder .................. 3
30.4.2 Fit the locking ring, rod seal, guide ring and guide
ring holder in the lift cylinder ............................... 3
30.4.3 Dismantling and assembling
the hose rupture valve......................................... 4
Assembling the cylinder................................ 4
30.5.1 Assembling the cylinder in the mast ................... 4
Free lift cylinder – 6620 31-1
General......................................................... 1
Tools............................................................. 1
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-13
Table of contents
Dismantling................................................... 2
31.3.1 Dismantling the cylinder ..................................... 3
Dismantle the rod seal and support ring. ...... 3
31.4.1 Assembling the rod seal and support ring. ......... 3
Dismantling the piston .................................. 4
31.5.1 Fitting the piston in the free lift cylinder .............. 4
Dismantling and assembling the hose rupture
valve 4
Assembling the cylinder................................ 5
Assembly...................................................... 5
Reach cylinder – 6650 32-1
General......................................................... 1
Assembling and dismantling
the reach cylinder..................................... 1
Dismantling................................................... 1
32.3.1 Dismantling the cylinder ..................................... 2
32.3.2 Dismantle the rod seal and the support ring. ..... 2
32.3.3 Assembling the rod seal and the support ring. ... 2
32.3.4 Dismantling the ram ........................................... 3
32.3.5 Assembling the ram ........................................... 3
32.3.6 Assembling the cylinder ..................................... 3
Assembling................................................... 3
Tilt cylinder – 6660.1 33-1
General......................................................... 1
Mast with valve on the fork carriage.............. 2
33.2.1 Dismantling the fork carriage ............................. 2
33.2.2 Dismantling the cylinder ..................................... 3
33.2.3 Dismantling the rod seal ..................................... 3
33.2.4 Dismantling the ram ........................................... 3
33.2.5 Assembling the ram ........................................... 3
33.2.6 Assembling the rod seal ..................................... 4
33.2.7 Assembling the cylinder ..................................... 4
33.2.8 Assembling the fork carriage .............................. 4
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-14 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Mast without valve on the fork carriage......... 5
33.3.1 Dismantling the fork carriage .............................. 5
33.3.2 Dismantling the cylinder ..................................... 6
33.3.3 Dismantling the rod seal ..................................... 6
33.3.4 Dismantling the ram ........................................... 6
33.3.5 Assembling the ram ............................................ 6
33.3.6 Assembling the rod seal ..................................... 7
33.3.7 Assembling the cylinder ..................................... 7
33.3.8 Assembling the fork carriage .............................. 7
Tilt cylinder – 6660.2 34-1
General......................................................... 1
Dismantling the cylinder from the truck......... 1
Dismantling and assembling the cylinder...... 2
34.3.1 Dismantling the cylinder ..................................... 2
34.3.2 Dismantle the seals and the support ring ........... 2
34.3.3 Assembling the rod seal and the support ring .... 3
34.3.4 Dismantling the ram ........................................... 3
34.3.5 Assembling the ram ............................................ 3
34.3.6 Assembling the cylinder ..................................... 3
Refitting the cylinder in the truck................... 4
Main mast –7100 35-1
General......................................................... 1
List of tools.................................................... 1
Transporting the truck................................... 2
Assembling the mast .................................... 3
Dismantling the mast .................................... 8
Adjusting the play ......................................... 9
35.6.1 Adjusting the mast play. ................................... 12
Lateral play ....................................................... 12
35.6.2 Radial play ........................................................ 13
Assembly..................................................... 13
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-15
Table of contents
Main lift chain system – 7120 36-1
General......................................................... 1
Checking the chain setting............................ 1
Chain inspection........................................... 1
36.3.1 Noise .................................................................. 1
36.3.2 Surface rust ........................................................ 1
36.3.3 Rusty links .......................................................... 1
36.3.4 Stiff links ............................................................. 2
36.3.5 Bolt rotation ........................................................ 2
36.3.6 Loose bolts ......................................................... 2
36.3.7 Outline wear ....................................................... 3
36.3.8 Stretching ........................................................... 3
36.3.9 Damage .............................................................. 4
36.3.10 Damaged discs ................................................ 4
36.3.11 Damaged bolts ................................................. 5
36.3.12 Dirty chain ........................................................ 5
Cleaning ....................................................... 5
Lubrication.................................................... 5
Lifting devices – 7400 37-1
General......................................................... 1
37.1.1 Inspection intervals ............................................ 1
37.1.2 Inspection ........................................................... 1
37.1.3 Surface cracks ................................................... 1
37.1.4 Difference in height of fork tips ........................... 1
37.1.5 Positioning lock .................................................. 1
37.1.6 Legibility of marking ........................................... 2
37.1.7 Fork arm blade and shank ................................. 2
37.1.8 Fork arm mountings ........................................... 2
37.1.9 Repair and testing .............................................. 2
Repair ................................................................. 2
Yield test ............................................................. 2
Fork .................................................................... 3
Extended fork ..................................................... 3
Checking the fork carriage’s wearing strips.. 4
Fork spread unit............................................ 6
37.3.1 Servicing of fork spread unit ............................... 6
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-16 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Telescopic forks............................................ 7
37.4.1 Telescopic forks ................................................. 7
37.4.2 Putting the telescopic forks into operation: ......... 8
Maintenance................................................. 8
How to remove the outer fork ............................. 8
How to mount the outer fork ............................... 8
37.5.1 Maintenance ..................................................... 12
Troubleshooting........................................... 13
37.6.1 Instructions for replacing hydraulic parts .......... 15
Extended forks............................................. 17
Battery charger – 8340 38-1
General......................................................... 1
Installation .................................................... 2
Functional description................................... 2
38.3.1 Display functions ................................................ 2
38.3.2 Charging process ............................................... 2
38.3.3 Shutdown conditions .......................................... 3
38.3.4 Delayed power on and charging ......................... 3
38.3.5 Extra charging .................................................... 3
38.3.6 Equalised charging ............................................. 4
38.3.7 Current and voltage characteristics .................... 4
38.3.8 Safety shutdowns ............................................... 4
38.3.9 Display and keyboard ......................................... 5
Reading of analogue measurement values ........ 5
Error indication and error messages ................... 6
Reading statistics from the previous charge ....... 7
Reading of long term statistics ............................ 8
Storing parameters ............................................. 8
Reading parameters ........................................... 9
Battery specific parameters ................................ 9
Charger specific parameters ............................. 10
Mains voltage codes ......................................... 10
Other functions ................................................. 10
Changing parameters ....................................... 11
38.3.10 Acid circulation ............................................... 11
General ............................................................. 11
BTM with acid circulation .................................. 11
Pump type APE, VPM ....................................... 12
Pump type API .................................................. 12
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Applies from machine no. T-code
713962- 403-414, 669-671, 716-718
Order no. Date
218920-040 2005-06-01
© BT Europe AB Service Manual REFLEX RR B/E, RR B/E CC 1-17
Table of contents
Service and maintenance............................ 12
38.4.1 Basic programming, code 30 ........................... 12
38.4.2 Resetting the statistics, code 31 ...................... 12
38.4.3 Calibrating the measurement value ................. 13
Calibrating the current’s zero value and tempera-
tures, code 21 ................................................... 13
Calibrating the battery voltage’s measurement val-
ue, code 20 ....................................................... 13
Calibrating the charging current, code 25 ......... 14
Calibrating the mains voltage display, code 26 ... 14
38.4.4 Calibrating and programming API .................... 14
Calibrating zero pressure ................................. 14
Calibrating the pressure ................................... 14
Programming the alarm limits ........................... 14
Programming the API function ......................... 15
38.4.5 Adjusting the charging characteristics .............. 15
38.4.6 Trouble shooting .............................................. 16
Error message, analysis and action ................. 16
Errors without indication ................................... 17
38.4.7 Trouble shooting acid circulation ...................... 17
38.4.8 Service measures ............................................ 17
Switching to the timer charger .......................... 18
Replacing the display card ............................... 18
Replacing the computer board ......................... 19
Replacing the mother board ............................. 19
Replacing the diodes ........................................ 19
38.4.9 Preventive maintenance ................................... 19
Control/computer equipment – 8700 39-1
General......................................................... 1
Connection ................................................... 1
Layout........................................................... 2
39.3.1 Main window ...................................................... 2
39.3.2 Nodes ................................................................. 2
39.3.3 Icons ................................................................... 3
39.3.4 Tool buttons and menu list ................................. 4
39.3.5 Information window ............................................ 4
39.3.6 Status row .......................................................... 4
Function for connection ............................... 5
Function for disconnecting............................ 5
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T-code Applies from machine no.
403-414, 669-671, 716-718 713962-
Date Order no.
2005-06-01 218920-040
1-18 Service Manual REFLEX RR B/E, RR B/E CC © BT Europe AB
Table of contents
Function for program downloading ............... 5
39.6.1 Normal loading ................................................... 6
39.6.2 Loading in old versions of the electronic card .... 6
39.6.3 Emergency loading ............................................. 6
Function for truck report................................ 7
Function for parameters................................ 8
Function for diagnostics............................... 10
39.9.1 Signal colours ................................................... 10
39.9.2 Tab for “Analogue” ........................................... 11
39.9.3 Tab for “Temperature” ...................................... 12
39.9.4 Tab for “Digital” ................................................. 13
Other menu functions .................................. 14
39.10.1 Save to file ...................................................... 14
39.10.2 Loading from a file .......................................... 14
39.10.3 Resetting the CAN adapter ............................ 14
39.10.4 Deleting the fault code log .............................. 14
39.10.5 Resetting the hour meter ................................ 14
39.10.6 Reading the fault code log .............................. 14
39.10.7 Adjusting the date/time ................................... 14
39.10.8 Adjusting the hour meter on older cards ........ 15
39.10.9 Help ................................................................ 15
About TruckCom ............................................... 15
39.10.10 Conclude ...................................................... 15
Specifications .............................................. 15
Installation ................................................... 16
39.12.1 Installation on a PC
with Windows XP/2000/NT 16
39.12.2 IInstallation on a PC with Windows 95/98 ...... 16
39.12.3 In the event of any problems with communication
with CAN ........................................................... 17
39.12.4 Uninstallation .................................................. 17
Extra warning lights/alarm – 9370 40-1
General......................................................... 1
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