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

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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: BT Service Manual PDF

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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