Meijer KOOI-REACHFORK Series Technical reference manual

RG2, RGN2
TFG2
RG4, RG8
RGE2, RGEN2
RGE4
TRG2
Instruction and parts manual
Manual Nº: MA210314-12ENG Language: ENG
Publishing date: 11-12-2017 Revision: 12
Table of contents
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
Instructions for Replacement of Sleeve ............................ 8
Replacement of Hydraulic Parts ......................................... 10
Troubleshooting...................................................................... 12
Replacement parts list RG2, RGN2...................................... 14
Replacement parts list TFG2 ................................................ 15
Replacement parts list RG4.................................................. 16
Replacement parts list RG4.................................................. 18
Replacement parts list RG8.................................................. 20
Replacement parts list RG8 (cont’d) ................................... 21
Replacement parts list RGE2, RGEN2 ................................. 22
Replacement parts list RGE4................................................ 23
Replacement parts list TRG2................................................ 25

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 - 2014, 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-FDIS-ISO 3834-2 – Quality Requirements for Fusion Welding of Metallic Materials – Part 2: Comprehensive
Quality Requirements
• CE (2014/43/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.
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®.
Caution:
Retract the (loaded) 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
5Bleed 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. Operate the lever for about 30
seconds so that the KOOI-REACHFORKS® remain
retracted and they are ushed.
• 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 sys-
tem.
Type KOOI-RE- ACHFORKS® Recom- mended oil ow Recom- mended hose diameter Maximum operating pressure Connection
RG2 /
RGE2 /
RGN2 /
TFG2 /
TRG2
7,5-12,5 (L/
min)
2-3.3 (gal/
min) 3/8” 250 bar
(3626 psi)
12L /
7/16”
JIC
(USA)
/ 9/16”
(USA)
RG4 /
RGE4
12,5-20 (L/
min)
3.3-5.3
(gal/ min)

6
Working with KOOI-REACHFORKS®
The KOOI-REACHFORKS®, type RG, feature an integrated synchronising system that enables both forks to extend and
retract simultaneously. However, should the KOOI-REACHFORKS® fail to operate simultaneously, slide the KOOI-REACH-
FORKS® fully in and, whilst the sleeves are in the retracted position, operate the valve for another ±10 seconds. This
gives the hydraulic system a chance to reset both sleeves in their rearmost position.
To minimise wear, avoid allowing the KOOI-REACHFORKS® to come in contact with the ground during operation . In
order to reduce wear:
• The manufacturer can weld a wear-resistant plate under the sleeve which can be replaced when worn out.
• The chains in the forklift mast can be shortened so that the KOOI-REACHFORKS® cannot reach the ground.
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 sleeve for signs of wear, espe-
cially the heel side* (REE/REEN type also
wear plate)
5. Check for and remove any dirt in the
sleeve
6. Check for any cylinder head leaks
7. Check inner forks in accordance with
ISO 5057* standards
*See chapter on ‘Wear’.
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
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 in the
inner fork.
Applies only to: KOOI-REACHFORKS® type RGE and RGEN;
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 (2) must be replaced. If
there are signs of wear in the lower side of the sleeve (2)
then it must be replaced. See point 4 of the Maintenance
Schedule.
Wear Plate Welding Data:
• Process: MAG (135), 210A, 28 VDC
• Weld type: llet weld a4, 1 layer
• Cleaning: brush
• Wire: 1 mm, EN 12534 / Mn3Ni1CrMo
• Shielding gas: 80% Ar / 20% CO2, 15-16 L/min
• Weld in wear-plate grooves

8
1
2
3
Instructions for Replacement of Sleeve
2a 3a
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).
Applies only to: KOOI-REACHFORKS® type TRG2;
Unscrew the screws (3) and remove the stops (4) from the
outer sleeve (5) (on both sides of the sleeve).
Tools required: Allen key 4.
Pull the sleeve (1) off the fork.
Tap the spring pins (2) out of the sleeve (1).
Tools required: Hammer, punch10
Applies only to: KOOI-REACHFORKS® type TRG2;
Unscrew the screws (6) (on both sides) from the stops (7)
and remove the inner sleeve.
Tools required: Allen key 4.

9
4
54a
5a
Tap the spring pin(s) (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
spring pin onto the bracket or piston rod!
Tools required: Hammer.
Slide the (new) sleeve (1) over the fork.
Applies only to: KOOI-REACHFORKS® type TRG2;
Slide the (new) inner sleeve (8) onto the fork. Tighten the
screws (6) (on both sides in the stops (7). Lock the screws
(6) with Loctite 2701.
Tools required: Allen key 4, Loctite 2701.
Applies only to: KOOI-REACHFORKS® type TRG2;
Place the stops (4) in the outer sleeve (5). Tighten the
screws (3) (on both sides od the sleeve). Lock the screws
(3) with Loctite 2701.
Tools required: Allen key 4, Loctite 2701.
1See www.loctite.com

10
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 22.
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 RE0058034).
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.
Even 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 24 (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 24, 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.

11
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 24 (11) to tighten the piston (9) onto the piston rod
(10) to a torque of 100 Nm.
Tools required: Loctite 2701, Loctite 70631, torque wrench
24.

12
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 values.
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 RE0058034).
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
Troubleshooting
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 cylinder head
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
Right sleeve extends faster
than left one. When the
right-hand fork has reached
its limit, the left one stops
approx. half way.
The left and right KOOI-
REACHFORKS® have been
mounted the wrong way
round
Swap the left and right
KOOI-REACHFORKS®
around and connect the
hoses correctly
Cylinder diameter (mm) Torque (Nm)
30 60
35 80
40 90

13
Forks not moving in unison
The left sleeve reaches its
end position rst. When the
left sleeve is at its end posi-
tion, the right one reaches
3/4 of its stroke
KOOI-REACHFORKS® have
been connected the wrong
way round
Connect the KOOI-REACH-
FORKS® as indicated in the
instructions in the chapter
on ‘Assembly’
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’
Difference in stroke length
becomes increasingly great
and one sleeve fails to
retract fully.
Pistons cannot return to
their rear position meaning
the KOOI-REACHFORKS®
hydraulic system cannot be
ushed and reset
Slide the sleeves in fully
and operate the lever for
another 30 sec. (in the same
direction as when retract-
ing)
Check that the rear of the
sleeve(s) does not come
into contact with the car-
riage plate. If so, please
contact your supplier
Dismantle sleeves and
remove any dirt that has ac-
cumulated in the front ends.
One or both sleeves move
without being operated
Leak in the forklift’s control
valve Inform your forklift supplier.
One sleeve remains station-
ary when retracting and
then suddenly retracts
quickly Spring pin(s) broken Replace the spring pin(s)
One of the sleeves fails to
retract
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 (100
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

14
Replacement parts list RG2, RGN2
Pos. Nº Description Article Nº Number of parts per set and type of forks
RG2-20 RG2-30 RGN2-30 RGN2-35
1 Cylinder head spanner1RE0058034 - - - -
2 Straight male coupling 12L RE2017001 4 4 4 4
3Piston30 (for piston rod18)2RE2008009 1 1 1 1
Piston35 (for piston rod18)3RE2008011 1 1 1 1
4 Inner fork 42 2 2 2
5 Wear strip PA6 RE0020000 4 4 4 4
6Piston rod 18 42 2 2 2
7Cylinder Head30 (for piston rod18)2RE2009002 1 1 1 1
Cylinder Head35 (for piston rod18)3RE2009003 1 1 1 1
8 Sleeve 42 2 2 2
9 Spring pin 55 mm RE0033015 2 2 - -
Spring pin 65 mm RE0033014 - - 2 2
A Type plate
B Engraved type information and serial number
1Available separately from KOOI-REACHFORKS® supplier, is not supplied a standard with KOOI-REACHFORKS®.
2Parts from left fork
3Parts from right fork.
4Article Nº depending on specic model. Please provide serial number when ordering.

15
Replacement parts list TFG2
Pos. Nº Description Article Nº Number of parts per set and type of forks
TFG2-20
1 Cylinder head spanner1RE0058034 -
2 Straight male coupling 12L RE2017001 4
3Piston35 (for piston rod20)2RE2008011 1
Piston40 (for piston rod20)3RE2008014 1
4 Inner fork 42
5 Wear strip PA6 RE0020000 4
6Piston rod 20 42
7Cylinder Head35 (for piston rod20)2RE2009004 1
Cylinder Head40 (for piston rod20)3RE2009006 1
8 Sleeve 42
9 Spring pin 65 mm RE0033015 2
A Type plate
B Engraved type information and serial number
1Available separately from KOOI-REACHFORKS® supplier, is not supplied a standard with KOOI-REACHFORKS®.
2Parts from left fork
3Parts from right fork.
4Article Nº depending on specic model. Please provide serial number when ordering.

16
Replacement parts list RG4
Pos. Nº Description Article Nº Number of parts per set and type of forks
RG4-25 RG4-35 RG4-45 RG4-58
1 Cylinder head spanner1RE0058034 - - - -
2 Straight male coupling 12L RE2017001 4 4 4 4
3Piston30 (for piston rod18)2RE2008009 1 1 1 1
Piston30 (for piston rod18)2RE2008010 1 1 1 1
Piston35 (for piston rod18)3RE2008011 1 1 1 1
Piston35 (for piston rod18)3RE2008012 1 1 1 1
4 Inner fork 42 2 2 2
5 Wear strip PA6 RE0020000 4 4 - -
Wear strip AMPCO RE0020001 - - 4 4
6Piston rod 18 44 4 4 4
7Cylinder Head30 (for piston rod18)2RE2009002 2 2 2 2
Cylinder Head35 (for piston rod18)3RE2009003 2 2 2 2
8 Sleeve 42 2 2 2
9 Spring pin 55 mm RE0033015 4 4 4 -
Spring pin 65 mm RE0033014 - - - 4
A Type plate
B Engraved type information and serial number
1Available separately from KOOI-REACHFORKS® supplier, is not supplied a standard with KOOI-REACHFORKS®.

2Parts from left fork
3Parts from right fork.
4Article Nº depending on specic model. Please provide serial number when ordering.

18
Replacement parts list RG4
Pos. Nº Description Article Nº Number of parts per set and type of forks
RG4-77 RG4-105
1 Cylinder head spanner1RE0058034 - -
2 Straight male coupling 12L RE2017001 4 4
3Piston35 (for piston rod20)2RE2008011 1 1
Piston35 (for piston rod20)2RE2008012 1 1
Piston40 (for piston rod20)3RE2008014 1 1
Piston40 (for piston rod20)3RE2008015 1 1
4 Inner fork 42 2
5 Wear strip AMPCO RE0020001 4 4
6Piston rod 20 44 4
7Cylinder Head35 (for piston rod20)2RE2009004 2 2
Cylinder Head40 (for piston rod20)3RE2009006 2 2
8 Sleeve 42 2
9 Spring pin 65 mm RE0033014 4 -
Spring pin 75 mm RE0033023 - 4
A Type plate
B Engraved type information and serial number
1Available separately from KOOI-REACHFORKS® supplier, is not supplied a standard with KOOI-REACHFORKS®.
2Parts from left fork

3Parts from right fork.
4Article Nº depending on specic model. Please provide serial number when ordering.

20
Replacement parts list RG8
Pos. Nº Description Article Nº Number of parts per set and type of forks
RG8-90 RG8-116 RG8-154 RG8-210
1 Cylinder head spanner1RE0058034 - - - -
2 Straight male coupling 12L RE2017001 8 8 8 8
3Piston30 (for piston rod18)2RE2008009 4 4 - -
Piston30 (for piston rod18)2RE2008010 4 4 - -
Piston35 (for piston rod18)3RE2008011 4 4 - -
Piston35 (for piston rod18)3RE2008012 4 4 - -
Piston35 (for piston rod20)2RE2008011 - - 4 4
Piston35 (for piston rod20)2RE2008012 - - 4 4
Piston40 (for piston rod20)3RE2008014 - - 4 4
Piston40 (for piston rod20)3RE2008015 - - 4 4
4 Inner fork 42 2 2 2
5 Wear strip AMPCO RE0020001 8 8 8 8
6Piston rod 18 48 8 - -
Piston rod 20 4- - 8 8
7Cylinder Head30 (for piston rod18)2RE2009002 8 8 - -
Cylinder Head35 (for piston rod18)3RE2009003 8 8 - -
Cylinder Head35 (for piston rod20)2RE2009004 - - 8 8
Cylinder Head40 (for piston rod20)3RE2009006 - - 8 8
8 Sleeve 42 2 2 2