Meijer KOOI-REACHFORK REE2-17 Technical reference manual

REE2-17, 24
RIE2-17, 19
REE4-17
IKEA
Instruction and parts manual
Manual Nº: WO19021504ENG Language: ENG
Publishing date: 22-06-2017 (original manual) Revision: 04
Index
Denitions ............................................................................... 2
Note.......................................................................................... 2
Quality Standards/Norms and Directives .......................... 2
Safety....................................................................................... 3
Identication........................................................................... 4
Assembly................................................................................. 5
Working with KOOI-REACHFORKS® .................................. 6
Maintenance Schedule......................................................... 6
Wear......................................................................................... 7
Taking goods from the racking ............................................ 8
Loading goods into the racking ........................................... 9
Instructions for Replacement of Sleeve ............................ 10
Replacement of Hydraulic Parts ......................................... 11
Troubleshooting...................................................................... 14
Replacement parts list REE2 ................................................ 15
Replacement parts list sleeves REE2 ................................. 16

2
Warning:
Text blocks marked by a “Warning” icon (as shown on the left) and starting with the text “Warning:” provide
information on actions which may result in serious injury.
Caution:
Text blocks marked by a “Caution” icon (as shown on the left) and starting with the text “Caution:” provide
information on actions which may result in damage to the KOOI-REACHFORKS®, parts of the KOOI-REACH-
FORKS® or goods.
“Only applies to:” texts (italics) indicate that a text only applies to a certain situation or certain type of KOOI-REACH-
FORKS®.
Note
© Copyright 2006 - 2015, Meijer Handling Solutions B.V. All rights reserved.
Unless otherwise indicated, information provided in this manual, including but not limited to illustrations and text, may
not be reproduced without the prior written permission of Meijer Handling Solutions.
The information in this manual is provided without any form of guarantee. Under no circumstances shall Meijer Handling
Solutions B.V. be held liable for accidents or damages arising from the use of this manual.
Please note that information in this manual may be changed at any time without prior notice and that it may contain tech-
nical inaccuracies and typing errors. Meijer Handling Solutions B.V. makes every effort to avoid errors in this manual, but
cannot guarantee this. Please let us know if you encounter any typing errors or technical inaccuracies, or if you have
any suggestions.
KOOI-REACHFORKS® is a registered trademark of Meijer Handling Solutions. (Gebr. Meijer).
Other trade or product names used in this manual, but not mentioned here, are the trademarks of their respective hold-
ers.
Denitions
Quality Standards/Norms and Directives
Meijer Handling Solutions B.V. complies with the following quality standards: ISO 9001
KOOI-REACHFORKS® comply with the following norms/directives:
• ISO 13284 – Fork Arm Extensions and Telescopic Fork Arms;
• ISO 4406 – Hydraulic Fluid Power – Fluids – Method for Coding the Level of Contamination by Solid Particles
• ISO 2328 – Forklift Trucks – Hook-On Type Fork Arms and Fork Arm Carriages
• CE (2006/42/EC) – Machinery Directive
• ISO 3834-2 Quality Requirements for Fusion Welding of Metalic Materials - Part2: Compressive Quality Require-
ments
• CE (94/9/EC) – ATEX (only applies to forks with an ATEX name plate!)
KOOI-REACHFORKS® are randomly subjected to dynamic testing in accordance with ISO 2330.

3
Safety
Warning:
Do not ride on the KOOI-REACHFORKS® or on
the load.
Warning:
Do no walk or stand under the KOOI-REACH-
FORKS®.
Warning:
Do not reach through the mast of the forklift
truck.
Warning:
Do not load the KOOI-REACHFORKS® beyond
the limits of the lifting capacities and load centre
stipulated by the manufacturer.
Warning:
Do not weld anything onto the KOOI-REACH-
FORKS® without the express permission of the
supplier. Welding carried out without permission
shall void any warranty.
Warning:
Do not use faulty KOOI-REACHFORKS® before
they have been either professionally repaired or
replaced.
Warning:
Do not carry out maintenance work on the
KOOI-REACHFORKS® whilst there is pressure
in the hydraulic system (remove key from forklift
ignition switch).
Warning:
Do not place limbs between pallet stops and the
inner fork (vertical section) of the KOOI-REACH-
FORKS®. If the load shifts, limbs can become
trapped which can result in serious injury.
Warning:
Do not use the KOOI-REACHFORKS® in areas
where the temperature is below -30ºC (-22ºF) un-
less otherwise agreed with the manufacturer.
Warning:
Do not extend or retract KOOI-REACHFORKS® of
types ‘REE’ and ‘RGE’ with load. These types are
extension forks only.
Caution:
When leaving the forklift the engine must be
switched off and the handbrake applied.
Caution:
Bear in mind the space above and beneath the
KOOI-REACHFORKS®.
Caution:
The load must be distributed as evenly as pos-
sible on the KOOI-REACHFORKS® and may
consist of one or multiple pallets.
Caution:
Retract the KOOI-REACHFORKS® as soon as
possible.
Caution:
If possible, retract the KOOI-REACHFORKS®
before driving.
Caution:
Always drive with the KOOI-REACHFORKS® in
the lowest possible position.

4
Identication
Type plate legend:
Mounting type description of KOOI-REACHFORKS®:

5
1
2
3
4
5
L R
Bleed the hydraulic system:
• Tilt the forklift truck mast forwards and back-
wards several times.
• Tilt the forklift mast forwards and slide the KOOI-
REACHFORKS® in.
• Extend and retract the KOOI-REACHFORKS®
several times.
Check that hydraulic hoses are unobstructed and that
there are no oil leakages.
The KOOI-REACHFORKS® type plates are
stamped with an ‘L’ and an ‘R’. Mount the KOOI-
REACHFORKS® on the left (L) and right (R) as
viewed from the forklift operator’s seat.
Assembly
Slide the KOOI-REACHFORKS® onto the carriage plate.
Make sure that each of the KOOI-REACHFORK® lock-
ing pins (2) drops into one of the notches on the carriage
plate. Use catch (1) before operating.
Connect the KOOI-REACHFORKS® to the hydraulic system
via the ow divider (1).
Type KOOI-RE- ACHFORKS® Recom- mended oil ow Recom- mended hose diameter Maximum operating pressure Connection
REE2 7,5-12,5 (L/
min)
2-3.3 (gal/
min) 3/8” 250 bar
(3626 psi)
12L /
10L / 8L
/ 7/16”
JIC
(USA)
/ 9/16”
(USA)

6
1 4 5 3
2
6
Working with KOOI-REACHFORKS®
To minimise wear, avoid allowing the KOOI-REACHFORKS® to come in contact with the ground during operation . In
order to reduce wear:
• The chains in the forklift mast can be shortened so that the KOOI-REACHFORKS® cannot reach the ground.
• The manufacturer can replace the wear-resistant plate under the sleeve when worn out.
Maintenance Schedule
Nº Description Weekly Monthly 6 months or
every 1000
hours
Annually or
every 2000
hours
1. Grease the underside and topside of the
inner fork
2. Check inner fork for leaks
3. Check wear strips for any sign of wear
4. Check for and remove any dirt in the
sleeve
5. Check for any cylinder head leaks
6. Check inner forks in accordance with
ISO 5057 standards
Notes on ‘Maintenance Schedule’
• Recommended lubricating grease: Nova-
tex EP2 (point 1).
• In the event of leakage, immediately
remove the forks from the forklift and
contact your supplier (point 2).
• If defects are detected, solve the problem
/ replace parts before proceeding to work
with the KOOI-REACHFORKS®.
• See chapter on ‘Instructions for Re-
placement of Sleeve’ and ‘Instructions
for Replacement of Hydraulic Parts’ for
further explanation about replacing parts
and required tools.

7
1A
B
Wear
The thickness of Wear Strips (1) may not be less than
1.5 mm (1/16”). When Wear Strips (1) have worn to this
thickness, replace them or ll with spacers (2) (Art. Nº
RE0092002). See point 3 of the Maintenance Schedule.
The inner fork must be replaced when S1 is 5% thinner
than S2. See point 7 of the Maintenance Schedule.
When surface A (dark grey, integrated wear plate) is
worn to the extent that it is level with or below surface B
(light grey), then the sleeve (1) must be replaced or tted
with a welded-on wear plate. For more information about
welded-on wear plates, please contact your fork supplier.
See point 4 of the Maintenance Schedule.
Caution:
The sleeves must be removed from the KOOI-
REACHFORKS® before welding work can
proceed.
Pistons, piston rods and cylinder heads must
be removed before welding is carried out at the
inner fork.

8
1
2
3
Taking goods from the racking
1
2
1
2
1. Position the lift truck straight in front of the racking
2. Lift the forks to the right position to take out the goods.
3. drive straight backwards and only then lower the goods
in the lowest possible position.
4. Then turn the lift truck into a new driving direction
4

9
1
2
1
2
1. Position the lift truck straight in front of the racking with
the load still in the lowest position.
2. Lift the load and place the goods inside the racking.
3. Drive straight backwards and only then lower the forks
in the lowest possible position.
4. Then turn the lift truck into a new driving direction
Loading goods into the racking

10
1
2
3
Instructions for Replacement of Sleeve
4
5
1
2
1
2
1
1
Tap the clamping bush (2) into the (new) sleeve (1).
Caution:
Ensure that the holes in the sleeve (1) are aligned
with the opening in the bracket(s) that are
welded onto the piston rod(s). DO NOT tap the
clamping bush onto the bracket or piston rod!
Tools required: Hammer.
Position the KOOI-REACHFORKS® at hip height,
tilt the mast of the forklift slightly forward and
remover the key from the ignition switch of the
forklift.
Warning:
Do not carry out maintenance work on the
KOOI-REACHFORKS® whilst there is pressure
in the hydraulic system (remove key from forklift
ignition switch).
Pull the sleeve (1) off the fork.
Tap the clamping bush (2) out of the sleeve (1).
Tools required: Hammer, punch Ø10
Slide the (new) sleeve (1) over the fork.

11
1
2
3
4
5
Follow steps 1 to 3 in chapter on ‘Instructions for
Replacement of Sleeve’.
Replacement of Hydraulic Parts
Loosen the hose connectors (3) slightly so that the pistons
do not create a vacuum when removing the hydraulic
parts.
Tools required: Open-ended spanner size 19.
Place a drip tray below the fork. Unscrew the cylinder
head(s) (5) using a cylinder head spanner (4) and a
ratchet.
Tools required: Cylinder head spanner, 1/2’’ ratchet.
*Cylinder head spanners are only available from Meijer
Handling Solutions B.V. (Art. Nº RE0058049).
Pull the entire hydraulics set (6) consisting of the piston,
cylinder head and piston rod out of the fork.
Caution:
Take care with the surface of the piston rod.
Minor damage to surface can cause leaks.
Clamp the piston rod at the rod end (7), not on the piston
rod itself to prevent damage (see step 4 in this chapter).
Use a size 19 (8) open-ended spanner to loosen the piston
(9). If the piston cannot be loosened, heat the piston with
a burner.
Tools required: Open-ended spanner size 19, clamp.
Note: When heating the piston with a burner, it must be re-
placed due to the damage to the seals caused by heating.
Warning:
Do not use a burner in an area not equipped/in-
tended for his purpose because of re hazard.
Warning:
Do not carry out maintenance work on the
KOOI-REACHFORKS® whilst there is pressure
in the hydraulic system (remove key from forklift
ignition switch).

12
6
7
8
9
When piston (9) is removed, the cylinder head (5) can be
removed, should it need to be replaced.
Remove remaining adhesive residue from the piston rod
thread (10), then clean the piston rod and thread (10) using
Loctite 70631.
Tools required: Loctite 70631.
Slide the (new) cylinder head (5) onto the piston rod (10).
Caution:
Do not damage the cylinder head seals (5) during
assembly as this can result in leakage. Pay par-
ticular attention when the sliding cylinder head
(5) over the thread (10) of the piston rod.
Apply Loctite 270 to the thread (10) of the piston rod 1.
Clamp the piston rod at the rod end (7), not on the piston
rod itself to prevent damage (see step 4 in this chapter).
Clean the piston thread with Loctite 70631. Use a torque
wrench 19 (11) to tighten the piston (9) onto the piston rod
(10) to a torque of 40 Nm.
Tools required: Loctite 2701, Loctite 70631, torque wrench
19.

13
10 11
12
13
Smear Copaslip2onto the thread of the cylinder head (5).
Line up the hydraulic set (6) with the cylinder and use a
hammer to tap it carefully into the bore. Screw the cylin-
der head tight using the cylinder head spanner (4) and a
torque wrench. See table below for torque value.
Tools required: Hammer, Copaslip2, cylinder head span-
ner*, 1/2” ratchet.
*Cylinder head spanners are only available from Meijer
Handling Solutions B.V. (Art. Nº RE0058049).
Caution:
Do not damage the piston or cylinder head seals
during assembly as this can result in leakage.
Follow steps 4 to 5 in chapter on ‘Instructions for
Replacement of Sleeve’.
Screw the hose connectors (3) tight.
Tools required: Open-ended spanner 22.
Finally, follow step 5 of the chapter on ‘Assem-
bly’.
1See www.loctite.com
2See www.kroon-oil.com
Cylinder diameter (mm) Torque (Nm)
25 30

14
Difference in length be-
tween the sleeves Stroke length difference
Piston rods are not same
length.
Please contact your sup-
plier.
Loose piston
Dismantle outer fork,
remove hydraulic set from
fork and tighten piston (40
Nm)
Difference in height be-
tween forks
One fork point hangs lower
than the other
One of the KOOI-REACH-
FORKS® has been perma-
nently deformed as a result
of overloading.
Remove KOOI-REACH-
FORKS® from carriage
immediately and contact
supplier
One of the KOOI-REACH-
FORKS® is not hanging on
the carriage plate
Hang the KOOI-REACH-
FORK® properly onto the
carriage plate (check lock-
ing mechanism)
Carriage plate is not com-
pletely horizontal
Please do contact your
forklift truck supplier.
The forks do not match
(forks belong to different
sets)
Check serial Nºs.
Wear strips on one KOOI-
REACHFORK® are more
worn than the other Replace wear strips
Excessive play between
fork blade and sleeve
Wear strips worn out
Sleeves worn out Replace sleeves
Observation Symptom Possible Cause Possible Solution
Oil leak
Oil leak between cylinder
head and piston rod
Bent piston rod Replace piston rod and
cylinder head
Scratched/damaged piston
rod
Leaking piston seal Replace cylinder head
Oil leak between cylinder
head and fork blade. Leaking O-Ring Replace O-ring
Oil leak at connector Leaking copper ring Replace copper ring
Loose connector Tighten connector
Forks leaking oil One or both KOOI-REACH-
FORKS® are cracked
Remove KOOI-REACH-
FORKS® from carriage
immediately and contact
supplier.
Forks not moving in unison
Sleeves not moving in
unison A piston seal is leaking Replace the piston with the leaking seal
Left or right sleeve extends
without operating lever be-
ing used.
Air in hydraulic system Follow step 5 of the chapter
on ‘Assembly’
Troubleshooting

15
Replacement parts list REE2 / RIE2 / REE4
Pos. Nº Description Article Nº Number of parts per set and
type of forks
REE4-17 REE2-17 REE2-24
1 Cylinder head spanner REE2 RE0058049 - - -
2 Piston with sealing RE Ø25 (for piston rod Ø16) RE2008000 2 1 1
2APiston seal RE Ø25 (for piston rod Ø16) RE0015000 2 1 1
3 Wear strip plastic 80x25x4.5 RE0020000 4 4 4
4 Piston rod RE Ø16 stroke 800 mm1RE20100000900 4 2 2
5 Cylinder head incl. seal Ø25 (for piston rod Ø16) RE2009023 2 1 1
6 Sleeve * 2 2 2
7 Clamping bush 12x40 mm RE0033018 4 2 2
8 Wiper ring Ø16 RE0014000 4 2 2
9 O-ring 20x2.5 Ø25 RE0012000 4 2 2
Flowdivider 6-12ltr (Metric) RE0100044 1 1 1
Flowdivider 6-12ltr (JIC) RE0100045 1 1 1
A Type plate
B Engraved type information and serial number
*For type of sleeve see chapter: replacements parts list sleeves REE2
1 - If fork length is unequal to 1200 and/or if the stroke is unequal to 800 than attach the serial number in de spare part re-
quest.

16
Replacement parts list sleeves REE2 / RIE2 / REE4
REE 24 type II
REE 17 type II
REE 17 type I
REE 24 type I
Wear plates REE types
A B
C
RIE 17 / 19 type I
RIE 17 / 19 type II
Description Article Nº Retracted fork length
REE 17 type I 1BV00029657 1200
REE 24 type I 1BV00037485 1200
REE 17 type II 1M00028013 1200
REE 24 type II 1M00008510 1200
Wear plate A 1M00012315 1200
Wear plate B * 1M00014882 1200
Wear plateC ** 1M00028014 1200
RIE 17 / 19 type I *** 1M00030127 1200
RIE 17 / 19 type II *** 110088397 1150
*Wear plate only supplied with type I forks
**Wear plate only supplied with type II forks
***Only RIE: Outer sleeve contains integrated, external wear plate (underside) - when
wear plate is worn down outer sleeve should be replaced. The base fork does not
contain a seperate wear plate.
1 - If fork length is unequal to 1200 and/or if the stroke is unequal to 800 than attach
the serial number in de spare part request.