TOYOTA MATERIAL HANDLING EUROPE

Safety Bulletin/BSB: 1033

RRE: Risk of cracks, inspection and re-inspection of reach
carriages
Note!
This safety bulletin deals with a safety measure that must continually be carried out within the
time requirements as stated below. Translation into other standard languages will follow.
However, allocation of resources and parts ordering must commence promptly upon receipt
of this English issue.

Model T Code C Code Serial Number

RRE140-250 900 mm,
8FBRE 14-25 900 mm, 815, 816 7190 6051503 - 6137212
R314-320 900 mm

1. General
BSB1031 requires immediate inspection of the reach carriage on all RREs.
This BSB informs of how the work is to proceed on RRE/8FBRE/R314-320
with 900 mm width between the support arms.
All RRE140-250/8FBRE14-25/R314-320 with 900 mm between the support
arms must be checked at 500 B-hours and thereafter at every 500 B-hour.
All checks and reported trucks according to BSB1031 (even trucks reported
with less than 500 B-hours) are included in this BSB.
The exceptions are trucks that have had their reach carriage replaced. They
do not need to be inspected (unless a BTP should later require this).

Directive from and including 3rd December:

Trucks that have passed 500 B-hours and have not yet been inspected
are issued with an immediate driving ban. Trucks that been used >500
B-hours since the last inspection are also issued with an immediate
driving ban. This applies until BSB1033 has been carried out.

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Safety Bulletin - RRE: Risk of cracks, inspection and re-inspection of
reach carriages

2. Procedure
The methods are planned for two persons, where at least one must be trained
for crack indication.

2.1 Disassembly
1. Park the truck on a level floor.
2. Remove the reach carriage stop (3) located on the support arm.

3. Run out the reach carriage so that the cover plate for the valve block can
be removed.
4. Remove the screws (2) that support the cover plate (1) and the screw by
the reach cylinder (2) so that the valve block can be pushed back.
2

5. Disconnect the hose (6) that runs from the valve block to the reach
cylinder’s rear connection.
9

6. Make sure that no dirt gets into the hose/valve.

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Safety Bulletin - RRE: Risk of cracks, inspection and re-inspection of
reach carriages

7. Remove the measuring rule (8) from the pin under the motor plate and
push it into the front part.
8. Raise the mast so that the forks come into the main lift range.

8
9. Remove the safety ring and remove the reach cylinder (7) from the front
pin.

10. Remove the two screws (9) that hold the valve block in the reach
carriage.
11. Place a jack under the front edge of the mast or under the support arms
and carefully lift the truck.
12. Supports of a stable material (5) of the same height are placed under
both mast beam so that the reach carriage rests on them when the truck
is run back.

13. Lower the truck so that it rests on the supports.

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Safety Bulletin - RRE: Risk of cracks, inspection and re-inspection of
reach carriages

14. The mast may need to be secured at the top with a traverse or another
truck.
15. Drive the truck in the drive wheel direction so that the reach carriage’s
front part is accessible.
16. Make sure that the valve block, hoses and/or the measuring rule do not
get stuck in anything when the reach carriage is made accessible.
17. Disconnect the electrical power in the truck so that the brake is applied.
18. Check both sides of the mast anchorage (the thick plate at position (4)
marked below) according to point 2.2 or 2.3 for any indication of cracks.
4

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Safety Bulletin - RRE: Risk of cracks, inspection and re-inspection of
reach carriages

2.2 Crack indication using a penetrator

1. Clean around the area in question (type Bycotest C10).
2. Apply the penetrator (type Bycotest RP20)
3. Penetration time 20 minutes.
4. Wipe away the penetrator with a remover.
5. Apply a developer (type Bycotest D30A)
6. Developing time approx. 10 minutes.
7. Crack indication.
8. Scratch a horizontal line at the crack point according to the figure below.
9. Special reporting according to 2.5.

2.3 Crack indication using a magnetic yoke

1. Clean around the area in question.
2. Apply the magnetic yoke.
3. Apply the magnetic powder fluid (type Bycotest C101)
4. Inspect using a UV lamp.
5. Scratch a horizontal line at the crack point according to the figure below.
6. Special reporting according to 2.5.

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Safety Bulletin - RRE: Risk of cracks, inspection and re-inspection of
reach carriages

2.4 Reassembly
1. Switch on the electrical power in the truck and drive the truck forward so
that the reach cylinder reaches the pin and the reach carriage enters the
support arms.
2. Make sure that no hydraulic function is active and connect the hydraulic
hose to the valve block.
3. Fine adjustment of the cylinder’s position can be done with the hydraulic
lever.
4. Fit the cylinder on the pin.
5. Fit the safety ring on the pin.
6. Fit the measuring rule.
7. Raise the mast so that the supports can be removed.
8. Fit the reach carriage stop in the support arms.
9. Screw back the screws that support the cover plate and its locking screw.
10. Refit the screws for the valve block.
11. Fit the cover plate.

2.5 Special reporting

Reporting is as previously with one difference; the customer and town must
be included. Only numbers are allowed in all other fields. It is not allowed to
write things such as etc, h, N/A, ' in the reporting matrix. Only date format
YYYY-MM-DD is allowed.
Every inspection must be reported as follows:
2.5.1 Truck
• Machinery serial number
• Mast number
• B-hours
2.5.2 Application
• Average load
• Max. load
• Max. lift height
• Floor (1 Good, 2 OK, 3 Poor)
2.5.3 Crack
• Crack in mm on each side respectively.
If no crack has been identified it must be reported as 0 mm.

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Safety Bulletin - RRE: Risk of cracks, inspection and re-inspection of
reach carriages

2.6 Handling of trucks with an identified crack

• Size 0,1-20 mm:
1. Mark the end of the crack
2. Report via "Special reporting" (2.5) to BTP.
BTP will via the "Special reporting" get knowledge of the need to ship a new
reach carriage according to pre-determined prioritization.
3. 3. Re-inspect within 500 B-hours.
• Size 20-40 mm:
1. Mark the end of the crack
2. Report via "Special reporting" (2.5) to BTP.
BTP will via the "Special reporting" get knowledge of the need to ship a new
reach carriage according to pre-determined prioritization.
3. 3. Re-inspect within 500 B-hours.
• Size >40 mm:
A driving ban is immediate imposed on the truck. Contact the local
administrator who reports to Mjölby.

3. Parts
When BTP require an exchange the correct Reach Carriage will be received
from BTP. Communication needs to be through:
RREreachcarriage@toyota-industries.eu.
If the truck is opposed with a driving ban, the Reach Carriage will be sent by
express delivery to the customer. Reach Carriages for planned exchanges
will delivered by normal transportation from BT Mjölby.

4. Realisation
4.1 Warranty
Yes, reimbursement will be possible for maximum 3 hours working time.

4.2 Completion
The measure must be performed and reported no later than 2011-09-30.

4.3 Reporting
1. Report continually by filling out the Excel matrix (special reporting)
according to 2.5. It must be mailed continually to:
RREreachcarriage@toyota-industries.eu
2. The reporting shall be done via BT Claims on project number 52194 and
C-code 7190.

- End of Message -

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