BT RR M12, RR M14, RR M16 Service Manual 232809-040
BT RR M12, RR M14, RR M16 Service Manual 232809-040 - Image 2
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BT RR M12, RR M14, RR M16 Service Manual 232809-040 - Image 5

BT RR M12, RR M14, RR M16 Service Manual 232809-040

$30.00

  • Type Of Manual: Service Manual
  • Manual ID: 232809-040
  • : Service Manual PDF
  • Number of Pages: 424
  • Size: 13.5MB
  • Format: PDF
Category:

Product details

  • Model List:

    • RR M12, RR M14, RR M16
  • 1. Return To HomePage
  • 2. Table of contents
  • 3. Technical data – M4
  • 3.1. General tightening torques
  • 3.1.1. Galvanised, non-oiled bolts
  • 3.1.2. Untreated, oiled bolts
  • 4. Introduction, maintenance – P1
  • 4.1. Safety regulations with maintenance work
  • 4.2. Cleaning and washing
  • 4.2.1. External cleaning
  • 4.2.2. Cleaning the motor compartment
  • 4.2.3. Electrical components
  • 4.3. Safe lifting
  • 5. Preventive Maintenance – P2
  • 5.1. Maintenance schedule
  • 6. Oil and grease specification – P3
  • 7. Tools – P4
  • 7.1. Super Seal contact
  • 7.1.1. AMP connector
  • 7.1.2. AMP microtimer
  • 7.1.3. Various tools
  • 8. Driver Protection – 0840
  • 8.1. General
  • 8.2. Tilt stops
  • 8.2.1. Removing the tilt stops
  • 9. Power electronics panel – 5660
  • 9.1. General description
  • 9.1.1. Terminal connections and pole bolts
  • 9.1.2. Technical Data
  • 9.1.3. Installing a new transistor panel
  • 9.2. Diagnostics and trouble shooting
  • 9.2.1. Displaying error codes, logging errors
  • 9.2.2. Error codes, trouble shooting
  • 9.2.3. Resetting an error
  • 9.3. Maintenance
  • 9.3.1. Safety
  • 9.3.2. Cleaning
  • 10. Electric Pump Motor – 1710
  • 10.1. General
  • 10.2. Dismantling the Pump Motor
  • 10.2.1. Connection
  • 10.3. Removing and replacing the pump motor
  • 10.3.1. Dismantling
  • 10.3.2. Assembling
  • 10.4. Bearing replacement
  • 10.4.1. Dismantling (D side)
  • 10.4.2. Assembling
  • 10.4.3. Dismantling (N side)
  • 10.4.4. Assembling (N side)
  • 10.4.5. Carbon brushes and brush holders
  • 11. Electric steering motor – 1730
  • 11.1. General
  • 11.2. Replacing the steering motor
  • 11.2.1. Dismantling
  • 11.2.2. Assembling
  • 11.3. Removing and replacing the carbon brushes
  • 12. Electric drive motor – 1760
  • 12.1. General
  • 12.2. Dismantling the drive motor
  • 12.3. Dismantling and assembling the drive motor
  • 12.3.1. Dismantling the drive motor
  • 12.3.2. Assembling the drive motor
  • 12.3.3. Reset the truck
  • 12.4. Bearing replacement
  • 12.4.1. Dismantling
  • 12.4.2. Assembling
  • 12.5. Installation instructions for external temperature sensor
  • 13. Mechanical drive gear unit – 2550
  • 13.1. General
  • 13.2. Components/data for the drive assembly/transmission
  • 13.2.1. Component placement
  • 13.2.2. Technical data
  • 13.2.3. Dismantling the transmission
  • 13.3. Replacing the drive motor/drive transmission
  • 13.3.1. Dismantling the drive motor
  • 13.3.2. Dismantling the drive transmission
  • 13.3.3. Assembling the transmission
  • 13.3.4. Installing the drive motor
  • 13.3.5. Reset the truck
  • 13.4. Checking/replacing the oil
  • 13.4.1. Checking/refilling the oil
  • 13.4.2. Changing the Oil
  • 13.5. Repairs
  • 13.5.1. Replacing the drive shaft sealing ring
  • 13.5.2. Leakage from the upper cover
  • 13.5.3. Leakage from the lower cover
  • 13.5.4. Replacing wheel bolts
  • 14. Travel brake system – 3100
  • 14.1. General
  • 14.2. Operating description
  • 14.2.1. Releasing the accelerator
  • 14.2.2. Travel direction selector
  • 14.2.3. Pressing down the brake pedal
  • 14.2.4. Parking brake
  • 14.2.5. Emergency brake
  • 14.3. Electromechanical disc brake, drive motor
  • 14.4. Disassembly
  • 14.5. Inspection
  • 14.6. Assembly
  • 14.7. Maintenance
  • 14.7.1. Adjusting the play
  • 14.7.2. Wear
  • 14.7.3. Checking the braking force
  • 15. Drive wheel – 3530
  • 15.1. General
  • 15.2. Dismantling the drive wheel
  • 15.3. Assembling the drive wheel
  • 16. Fork/support arm wheel – 3550
  • 16.1. General
  • 16.2. Dismantling the wheel
  • 16.3. Assembling the drive wheel
  • 16.4. Dismantling the wheel bearing
  • 16.5. Assembling the wheel bearing
  • 17. Mechanical steering system – 4100
  • 17.1. General
  • 17.2. Replacing the steering generator
  • 17.2.1. Dismantling
  • 17.2.2. Assembling
  • 18. Steering angle sensor – 4350
  • 18.1. General
  • 18.2. Procedure
  • 18.2.1. Adjustment of the steering angle sensor
  • 19. Electrical System – 5000
  • 19.1. General
  • 19.1.1. Electrical Panel
  • 19.2. Symbol List and Electrical Diagrams
  • 19.2.1. Symbol List
  • 19.2.2. Electrical Diagrams
  • 19.2.3. Component List
  • 19.2.4. Figure 1
  • 19.2.5. Figure 2
  • 19.2.6. Figure 3
  • 19.2.7. Figure 4
  • 19.2.8. Figure 5
  • 19.2.9. Figure 6
  • 19.2.10. Figure 7
  • 19.2.11. Figure 8
  • 19.3. Functional Description
  • 19.3.1. Key in Position 0
  • 19.3.2. Key in Position I
  • 19.3.3. Choice of travel direction
  • 19.3.4. Driving
  • 19.3.5. Steering
  • 19.3.6. Steering wheel indicator
  • 19.3.7. Braking
  • 19.3.8. Fork lifting
  • 19.3.9. Maximum height
  • 19.3.10. Maximum height
  • 19.3.11. Fork lowering
  • 19.3.12. Mast out/in
  • 19.3.13. Fork tilt up/down
  • 19.3.14. Hydraulic function 4
  • 19.3.15. Hydraulic function 5
  • 19.3.16. Height indicator
  • 19.3.17. Preset height
  • 19.3.18. Driver identification
  • 20. Battery – 5110
  • 20.1. Battery dimensions
  • 20.2. Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries
  • 20.2.1. General
  • 20.2.2. Battery recommendation
  • 20.2.3. Battery installation
  • 20.2.4. Recommended parameter setting for ventilation regulated batteries
  • 20.2.5. Instructions for verifying the parameter setting
  • 21. Transistor panel – 5460
  • 21.1. Frequency converter
  • 21.1.1. Terminal connections and pole bolts
  • 21.1.2. Technical Data
  • 21.1.3. Programming
  • 22. Electronic card – 5710
  • 22.1. General description
  • 22.2. Terminal connections and voltages on A5
  • 22.2.1.
  • 22.2.2.
  • 22.2.3.
  • 22.2.4.
  • 22.2.5.
  • 22.2.6.
  • 22.2.7.
  • 22.2.8.
  • 22.2.9.
  • 22.3. Adjusting the lowering speed
  • 22.4. Show
  • 22.5. Programming
  • 22.5.1. Driver parameters (1-7)
  • 22.6. Warning Codes
  • 22.7. Error Codes
  • 22.7.1. Safety logic
  • 22.7.2. Warning Codes without registration
  • 22.8. Warning codes with registration
  • 22.9. Error Codes
  • 22.9.1. Error codes with registration
  • 22.10. Operating Time
  • 22.11. Parameter Settings
  • 22.11.1. Parameter 1
  • 22.11.2. Parameter 2
  • 22.11.3. Parameter 3
  • 22.11.4. Parameter 4
  • 22.11.5. Parameter 5
  • 22.11.6. Parameter 10
  • 22.11.7. Parameter 11
  • 22.11.8. Parameter 12
  • 22.11.9. Parameters 13 to 14
  • 22.11.10. Parameters 15 and 16
  • 22.11.11. Parameters 17 and 18
  • 22.11.12. Parameter 19
  • 22.11.13. Parameter 20
  • 22.11.14. Parameter 21
  • 22.11.15. Parameter 23
  • 22.11.16. Parameter 24
  • 22.11.17. Parameter 25
  • 22.11.18. Parameter 26
  • 22.11.19. Parameter 27
  • 22.11.20. Parameter 28
  • 22.11.21. Parameter 29
  • 22.11.22. Parameter 38
  • 22.11.23. Parameter 39
  • 22.11.24. Parameters 40 to 42
  • 22.11.25. Other parameters
  • 22.11.26. Installing a new card in the truck
  • 23. Hydraulic system – 6000
  • 23.1. General
  • 23.2. Symbols
  • 23.2.1. Hydraulic chart 1 (3)
  • 23.2.2. Hydraulic chart 2 (3)
  • 23.2.3. Hydraulic chart 3 (3)
  • 23.3. List of symbols
  • 23.3.1. Component placement 1 (2)
  • 23.3.2. Component placement 2 (2)
  • 23.4. Adjusting fork lowering
  • 23.5. Setting the max lifting capacity
  • 24. Hydraulic pump – 6140
  • 24.1. General
  • 24.2. Replacing the hydraulic pump
  • 24.2.1. Dismantling
  • 24.2.2. Assembling
  • 25. Hydraulic connections – 6230
  • 25.1. General
  • 25.2. Tightening torque for hydraulic connections
  • 25.2.1. Conical connection with O-ring
  • 25.2.2. Tredo seal
  • 25.2.3. Pipe coupling
  • 25.2.4. Connection screwed into aluminium
  • 25.2.5. Connection screwed into steel
  • 26. Hydraulic cylinder – 6600
  • 26.1. General
  • 26.2. Duplex mast
  • 26.2.1. Dismantling the lift cylinders from the mast
  • 26.2.2. Dismantling the cylinder
  • 26.2.3. Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder
  • 26.2.4. Assembling the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder
  • 26.2.5. Dismantling and assembling the lower brake valve
  • 26.2.6. Assembling the cylinder
  • 26.2.7. Assembling the cylinder in the mast
  • 26.3. Triplex mast
  • 26.3.1. Dismantling the free lift cylinder from the mast
  • 26.3.2. Dismantling the mast lift cylinders from the mast
  • 26.4. Cylinder seals
  • 26.5. Replacing wear parts in the cylinder
  • 26.5.1. Securing
  • 26.5.2. Dismantling the cylinder
  • 26.5.3. Replacing the lower support ring
  • 26.5.4. Replacing the O-ring on the top sleeve
  • 26.5.5. Replacing the internal wear parts in the top sleeve
  • 26.5.6. Assembling the cylinder
  • 26.5.7. Assembling the free lift cylinder in the mast
  • 26.5.8. Assembling the mast lift cylinder
  • 27. Mast mounted hose reel – 6370
  • 27.1. General
  • 27.2. Assembling
  • 27.3. Check after assembly
  • 28. Main lift cylinder – 6610
  • 28.1. General
  • 28.2. Tools
  • 28.3. Dismantling the lift cylinders from the mast
  • 28.4. Dismantling the cylinder
  • 28.4.1. Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder
  • 28.4.2. Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder
  • 28.4.3. Dismantling and assembling the hose rupture valve
  • 28.5. Assembling the cylinder
  • 28.5.1. Assembling the cylinder in the mast
  • 29. Free lift cylinder – 6620
  • 29.1. General
  • 29.2. Tools
  • 29.3. Dismantling
  • 29.3.1. Dismantling the cylinder
  • 29.4. Dismantle the rod seal and the support rin
  • 29.4.1. Assembling the rod seal and the support ring.
  • 29.5. Dismantling the ram
  • 29.5.1. Assembling the ram in the free lift cylinder
  • 29.6. Dismantling and assembling the hose rupture valve
  • 29.7. Assembling the cylinder
  • 29.8. Assembling
  • 30. Reach cylinder – 6650
  • 30.1. General
  • 30.2. Assembling and dismantling the reach cylinder
  • 30.2.1. Dismantling the cylinder
  • 30.2.2. Dismantling the rod
  • 30.2.3. Dismantle the to sleeve seals
  • 30.2.4. Assembling the top sleeve
  • 30.2.5. Fit the ram seal
  • 30.2.6. Dismantling the rod
  • 30.2.7. Assembling the cylinder
  • 30.3. Assembling
  • 31. Tilt cylinder – 6660.1
  • 31.1. General
  • 31.2. Assembling and dismantling the tilt cylinder
  • 31.2.1. Dismantling the cylinder
  • 31.2.2. Dismantling the rod
  • 31.2.3. Dismantling the ram seals
  • 31.2.4. Dismantle the top sleeve seals
  • 31.2.5. Assembling the top sleeve
  • 31.2.6. Assembling the ram seal
  • 31.2.7. Dismantling the rod
  • 31.2.8. Assembling the cylinder
  • 31.3. Assembling
  • 32. Tilt cylinder – 6660.2
  • 32.1. General
  • 32.2. Mast with valve on the fork carriage
  • 32.2.1. Dismantling the fork carriage
  • 32.2.2. Dismantling the cylinder
  • 32.2.3. Dismantling the rod seal
  • 32.2.4. Dismantling the ram
  • 32.2.5. Assembling the ram
  • 32.2.6. Assembling the rod seal
  • 32.2.7. Assembling the cylinder
  • 32.2.8. Assembling the fork carriage
  • 32.3. Mast without valve on the fork carriage
  • 32.3.1. Dismantling the fork carriage
  • 32.3.2. Dismantling the cylinder
  • 32.3.3. Dismantling the rod seal
  • 32.3.4. Dismantling the ram
  • 32.3.5. Assembling the ram
  • 32.3.6. Assembling the rod seal
  • 32.3.7. Assembling the cylinder
  • 32.3.8. Assembling the fork carriage
  • 33. Main mast – 7100.1
  • 33.1. General
  • 33.2. List of tools
  • 33.3. Transporting the truck
  • 33.4. Assembling the mast
  • 33.5. Dismantling the mast
  • 33.5.1. Chains, cylinders and hoses
  • 33.5.2. Dismantling the runner
  • 33.5.3. Inner guide
  • 33.6. Assembling Duplex mast
  • 33.6.1. Assembly-shimming the side play
  • 33.6.2. Inner guide
  • 33.6.3. Chains, cylinders and hoses
  • 33.6.4. Fork carriage
  • 33.6.5. Docking the mast in the truck
  • 33.7. Assembling the Triplex mast
  • 33.7.1. Assembly-shimming the side play
  • 33.7.2. Inner guide
  • 33.7.3. Chains, cylinders and hoses
  • 33.7.4. Fork carriage
  • 33.8. Problem with the mast rollers
  • 33.9. Adjusting the distance between the forks and floor
  • 34. Main mast – 7100.2
  • 34.1. General
  • 34.2. List of tools
  • 34.3. Transporting the truck
  • 34.4. Assembling the mast
  • 34.5. Dismantling the mast
  • 34.6. Adjust the play
  • 34.6.1. Adjusting the mast play
  • 34.6.2. Radial play
  • 34.7. Assembling
  • 34.8. Problem with the mast rollers
  • 34.9. Adjusting the distance between the forks and floor
  • 35. Main lift chain system – 7120
  • 35.1. General
  • 35.2. Checking the chain setting
  • 35.3. Chain inspection
  • 35.3.1. Noise
  • 35.3.2. Surface rust
  • 35.3.3. Rusty links
  • 35.3.4. Stiff links
  • 35.3.5. Bolt rotation
  • 35.3.6. Loose bolts
  • 35.3.7. Outline wear
  • 35.3.8. Stretching
  • 35.3.9. Damage
  • 35.3.10. Damaged discs
  • 35.3.11. Damaged bolts
  • 35.3.12. Dirty chain
  • 35.4. Cleaning
  • 35.5. Lubrication
  • 36. Lifting devices – 7400
  • 36.1. General
  • 36.1.1. Inspection intervals
  • 36.1.2. Inspection
  • 36.1.3. Surface cracks
  • 36.1.4. Difference in height of fork tips
  • 36.1.5. Positioning lock
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