BT Electric Forklift SPE120XR SPE120XRD Repair manual 7605990

Description

BT Electric Forklift SPE120XR SPE120XRD Repair manual 7605990  – PDF DOWNLOAD

FILE DETAILS:

BT Electric Forklift SPE120XR SPE120XRD Repair manual 7605990  – PDF DOWNLOAD

Language : English
Pages :580
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Electric Forklift SPE120XR SPE120XRD Repair manual 7605990  – PDF DOWNLOAD

1 General introduction 9
11 Warning levels and symbols 9
12 Pictograms 9
13 Abbreviations 10
2 General safety rules 13
21 Authorised personnel 13
22 Work safety 13
23 Electrical system 14
231 Electrostatic risks 14
232 Battery handling 14
24 Safe lifting 15
25 Product modification 16
26 Software 16
27 Hydraulic system 16
3 Operating principle 19
31 Description 19
311 Battery is connected 19
312 Login via keypad 19
313 Login via “ID key” option 19
314 Tiller arm lowered for driving 20
315 Driving in fork direction 20
316 Driving in the drive wheel direction 20
317 Braking in neutral 20
318 Reverse braking 21
319 Mechanical braking 21
3110 Emergency reversal 21
32 Description 22
4 Parameters 25
41 Display/change parameters 25
42 Parameters in general 25
43 Parameter list 25
5 Installation 61
51 Transport 61
511 Transporting the mast 61
52 Lifting the truck 61
521 Lifting the truck 61
522 Lift using a jack 63
53 Commissioning 63
531 Parameters on commissioning 63
5311 Setting parameters 63
5312 Setting collision sensor parameters (option) 63
5313 Setting battery parameters 63
532 Battery 64
5321 Battery installation 64
6 Maintenance 69
61 Introduction 69
62 Maintenance instructions 69
621 Cleaning 69
622 High-pressure washers 69
623 Degreasing agents 70
624 Cleaning the exterior 70
625 Cleaning the chain 70
626 Cleaning the motor compartment 70
627 Electric components 70
628 Hydraulic system 71
629 Signs, warnings and adhesive labels 71
6291 Placement of signs 71
6292 Placement of signs 72
63 Lubricants specification 74
64 Periodic maintenance 74
7 Troubleshooting 89
71 Initial troubleshooting 89
72 Concluding troubleshooting 90
73 Auxiliary functions 91
731 Towing a defective truck 91
7311 Towing and transporting a defective truck 91
732 Emergency driving mode 91
7321 Emergency driving mode 91
733 Error code history 91
7331 Error code history 91
734 Extended error log 92
7341 Extended error log 92
735 Built-in test function for the tiller arm 92
7351 General 92
7352 Display test 93
7353 Speed control 93
7354 Safety reversing 93
7355 Controls for lifting/lowering 94
7356 Sensilift 94
7357 Keypad 95
736 Digital input/output status 95
7361 Test mode “9” 95
737 Service information 96
7371 Service information 96
74 Troubleshooting using error codes 97
741 List of error codes 97
8 Chassis C0000167
81 Overview167
82 Inspection of the rear chassis168
83 Frame, chassis C0300169
831 Inspection covers C0340169
8311 Motor compartment covers169
83111 Overview169
83112 Replacing a service cover170
831121 Removing a service cover170
831122 Installing a service cover170
83113 Replacing a side cover170
831131 Removing a side cover170
831132 Installing a side cover171
83114 Replacing an emblem cover171
831141 Removing an emblem cover171
831142 Installing an emblem cover172
83115 Replacing an upper cover172
831151 Removing an upper cover172
831152 Installing an upper cover173
83116 Replacing a cover174
831161 Removing a cover174
831162 Installing a cover174
832 Support arms, stabilizers C0350175
8321 Checking the support arms175
8322 Lubrication of the support arms175
833 Battery compartment parts C0390176
8331 Overview176
8332 Description176
83321 Battery lock, fixed176
8333 Checking the battery lock177
84 Frame/chassis components C0400177
841 Motor mount/brackets C0450177
8411 Checking the motor mounts177
8412 Drive unit mountings178
84121 Drive unit mountings 6/8 km/h178
841211 Overview178
85 Operator compartment, cab C0500179
851 Platform including fixing points C0560179
8511 Overview179
8512 Checking the function of the platform switches180
8513 Adjusting the position sensor [B120]180
8514 Checking the platform181
8515 Gas strut181
85151 Checking the gas strut181
85152 Replacing a gas strut181
851521 Removing a gas strut181
851522 Installing a gas strut184
8516 Platform suspension185
85161 Adjusting platform suspension185
85162 Replacing the platform suspension186
851621 Removing the platform suspension186
851622 Fitting the platform suspension187
8517 Safety switch, platform [B119]188
85171 Adjusting the position sensor play [B119]188
85172 Checking the position sensor [B119]189
8518 Safety switch, platform [B119]/[B120]189
85181 Measuring the detection distance [B120]189
85182 Replacing sensor [B119]190
851821 Removing the platform position sensor [B119]190
851822 Fitting the platform position sensor [B119]191
85183 Replacing sensor [B120]191
851831 Removing the platform position sensor [B120]191
851832 Fitting the platform position sensor [B120]192
8519 Replacing the platform192
85191 Removing the platform192
85192 Installing the platform195
86 Safety equipment C0800198
861 Operator protection C0840198
8611 Gate198
86111 198
86112 Checking the gate bar198
86113 Replacing a gas strut199
861131 Removing the gate damper199
861132 Fitting the gate damper200
86114 Replacing the pad200
861141 200
861142 201
86115 Replacing the gate202
861151 202
861152 203
86116 Replacing the gate bar204
861161 204
861162 205
862 Signs, warnings, labels C0850205
8621 Checking signs and labels205
8622 Placement of signs205
8623 Placement of signs207
9 Motors C1000211
91 Electric motors C1700211
911 Electric pump motor C1710211
9111 Overview211
9112 Replacing the pump motor211
91121 Removing a pump motor211
91122 Installing a pump motor212
912 Electric steering motor C1730213
9121 Overview213
9122 Description213
91221 Design213
9123 Cleaning the ring gear214
9124 Checking the electrical connections214
9125 Checking the steering motor gears214
9126 Checking the steering motor214
9127 Lubricating the ring gear214
9128 Check the drive gear’s attachment214
9129 Replacing the steering motor214
91291 Removing the steering motor [M6]214
91292 Installing the steering motor [M6]216
913 Electric fan motor/fan C1740217
9131 Overview217
9132 Description217
91321 Design217
9133 Replacing the motor control fan217
91331 Removing a motor control fan217
91332 Installing a motor control fan219
914 Electric drive motor C1760220
9141 Overview 18 kW220
9142 Description220
91421 Design220
9143 Checking the electrical connections221
9144 Checking the drive motor221
9145 Listen for any abnormal noise in the drive motor bearings221
9146 Check the drive motor mountings222
9147 Checking the rotational speed sensor222
9148 Check the rotational speed sensor fitting223
9149 Replacing the drive motor223
91491 Removing the drive motor [M1]223
91492 Removing the drive motor [M1]226
91493 Removing the drive motor [M1]228
91494 Installing the drive motor [M1]231
91495 Installing the drive motor [M1]234
91496 Installing the drive motor [M1]236
91410 Replacing the temperature sensor239
914101 Installing the temperature sensor239
91411 Replacing the rotational speed sensor240
914111 Removing a rotational speed sensor240
914112 Installing a rotational speed sensor242
91412 Replacing the toothed wheel243
914121 Removing a toothed wheel243
914122 Installing a toothed wheel244
10 Transmission/Drive gear C2000247
101 Drive unit, final gear C2500247
1011 Drive unit/gear C2550 247
10111 Overview247
10112 Description 247
101121 Design247
101122 Technical data248
10113 Check the drive gear’s attachment 248
10114 Checking for leaks in the drive gear248
10115 Checking for noise in the drive gear248
10116 Replacing the drive gear 249
101161 Removing the drive gear249
101162 Installing the drive gear251
10117 Replacing the wheel hub seal 253
101171 Removing the wheel hub seal253
101172 Installing the wheel hub seal254
10118 Drive gear oil change255
101181 Empty the drive gear oil256
101182 Filling oil in the drive gear257
10119 Drive gear oil change258
101191 Empty the drive gear oil258
101192 Filling oil in the drive gear259
101110 Replacing the drive gear steering bearing 260
1011101 Removing the drive gear steering bearing260
1011102 Installing the drive gear steering bearing261
101111 Stud replacement 262
1011111 Removing a stud262
1011112 Installing a stud262
11 Brake/wheel/track system C3000265
111 Travel brake system C3100265
1111 Description265
11111 Brake types265
111111 Travel brake265
111112 Emergency brake265
111113 Parking brake265
112 Parking brake details C3300266
1121 Electrical parking brake, magnet brake C3370266
11211 Overview266
11212 Description267
112121 Technical data267
11213 Cleaning the parking brake267
11214 Adjusting the parking brake gap268
11215 Tighten the parking brake mounting bolts268
11216 Checking the parking brake269
11217 Replacing the brake hub269
112171 Disassembling the brake hub269
112172 Installing a brake hub270
11218 Replacing the friction disc270
112181 Removing the friction disc270
112182 Fitting the friction disc271
113 Wheels C3500273
1131 Drive wheel C3530273
11311 Overview273
11312 Description274
113121 Wheel wear274
11313 Measuring the drive wheel tread274
11314 Check the drive wheel mountings274
11315 Replacing the drive wheel275
113151 Disassembling the drive wheel275
113152 Installing a drive wheel277
1132 Support arm wheels/castor wheels C3540278
11321 Replacing the castor wheel278
113211 Removing the castor278
113212 Removing the castor279
113213 Installing a castor wheel280
113214 Installing a castor wheel281
11322 Replacing the castor wheel assembly282
113221 Removing the castor wheel assembly282
113222 Installing the castor wheel assembly283
1133 Fork wheels/support arm wheels C3550283
11331 Replacing the support arm wheels283
113311 Removing the support arm wheels283
113312 Fitting the support arm wheel285
12 Steering system C4000291
121 Description291
1211 Power steering291
122 Mechanical steering system C4100291
1221 Steering arm/wheel/lever C4110291
12211 Overview tiller arm291
12212 Operating panel293
122121 Overview operating panel293
122122 Controls294
1221221 Replacing the signal button/switch294
12212211 Removing the signal button/switch294
12212212 Fitting the signal button/switch295
1221222 Replacing the lift/lower button297
12212221 Removing the lift/lower button297
12212222 Fitting the lift/lower button298
12212223 Checking the hydraulic functions299
1221223 Replacing the stomach button299
12212231 Removing the stomach button299
12212232 Installing a stomach button300
12212233 Checking the stomach button301
1221224 Replacing the sensilift301
12212241 Removing the sensilift301
12212242 Installing sensilift302
1221225 Changing the position of the controls – support arm lift/fork lift302
1221226 Replacing the keypad303
12212261 Removing the keypad303
12212262 Installing a keypad303
122123 Replacing the operating panel303
1221231 Removing the operating panel303
1221232 Installing an operating panel304
1221233 Checking the speed control306
122124 Replacing the logic card306
1221241 Removing the logic card306
1221242 Installing a logic card307
1221243 Logic card [A5]309
12213 Tiller arm handle309
122131 Replacing the handle to the tiller arm309
1221311 Removing the tiller arm handle309
1221312 Fitting the handle to the tiller arm310
12214 Tiller arm311
122141 Replacing the tiller arm311
1221411 Removing the tiller arm311
1221412 Fitting tiller arm313
122142 Checking the brake microswitches315
122143 Checking the play and the return travel316
122144 Replacing the tiller arm cover316
1221441 Removing the tiller arm cover316
1221442 Installing the tiller arm cover317
12215 Steering yoke318
122151 Overview steering servo318
122152 Replacing the steering yoke319
1221521 Removing the steering yoke319
1221522 Installing a steering yoke320
122153 Changing the tiller arm spring320
1221531 Removing the tiller arm spring320
1221532 Installing the tiller arm spring321
122154 Replacing the safety switch321
1221541 Removing the safety switch [B60]321
1221542 Installing the safety switch [B60]323
12216 Steering adapter324
122161 Overview steering servo324
122162 Replacing the steering adapter325
1221621 Removing the steering adapter325
1221622 Installing a steering adapter326
122163 Replacing the steering adapter cover328
1221631 Removing the steering adapter cover328
1221632 Installing the steering adapter cover329
122164 Replacing a gas strut – height adjuster329
1221641 Removing a gas strut – height adjuster329
1221642 Installing a gas strut – height adjuster330
122165 Replacing the height adjustment lock330
1221651 Removing the height adjustment lock330
1221652 Installing the height adjustment lock331
1221653 Checking the height adjustment lock331
122166 Replacing the mechanical stop of the steering shaft332
1221661 Removing the mechanical stop of the steering shaft (power steering)332
1221662 Fitting the mechanical stop of the steering shaft (power steering)333
12217 Tiller arm wiring harness335
122171 Replacing the tiller arm wiring harness335
1221711 Removing the tiller arm wiring harness335
1221712 Fitting the tiller arm wiring harness339
12218 Replacing the steering bearing344
122181 Removing the steering bearing344
122182 Fitting the steering bearing346
12219 Replacing the rubber seals347
122191 Removing rubber seals347
122192 Installing rubber seals348
123 Electric steering system C4300350
1231 Overview350
1232 Steering angle sensor C4350350
12321 Description350
123211 Design350
12322 Replacing the steering angle sensor servo unit351
123221 Removing the steering angle sensor351
123222 Installing steering angle sensor352
12323 Checking the reference sensor353
13 Electrical system C5000359
131 Description359
1311 Using the anti-static carpet359
132 Programming tools359
1321 TruckCom359
13211 Connect the CAN interface to the truck359
133 General electric equipment C5100360
1331 Battery C5110360
13311 Description360
133111 Mast dimensions360
13312 Cleaning the battery360
13313 Checking the connections360
13314 Checking the battery cables360
13315 Checking the battery361
13316 Checking cell and terminal protectors361
13317 Checking the level of the electrolyte361
13318 Checking the electrolyte density362
13319 Checking the battery parameters362
133110 Checking the battery voltage362
133111 Resetting/restarting the battery362
133112 Charging the battery363
133113 Replacing a battery using a lifting device364
1331131 Removing a battery using a lifting device364
133114 Replacing a battery using a battery changing table364
1331141 Removing a battery using a battery changing table364
1332 General alarm signals (audible/visual) C5160365
13321 Horn365
133211 Overview365
133212 Checking the horn function365
1333 Battery charger (built-in) C5170365
13331 Checking the battery charger cables365
13332 Checking the battery charger parameters365
1334 Battery cut out switch, main contactor C5190366
13341 Main contactor366
133411 Replacing the main contactor366
1334111 Removing the main contactor366
1334112 Fitting the main contactor369
134 Instrument panel, display C5200371
1341 Menu371
13411 Menus371
13412 Menu navigation371
13413 Menu overview372
13414 Menu list373
13415 Menu information373
13416 Show hour meter values373
13417 Show error codes374
13418 Show part numbers for software/hardware374
13419 Built-in test ICH374
134110 Show collisions374
134111 Show/change parameters375
134112 Emergency driving mode375
134113 Calibration375
134114 Show/change PIN code375
134115 PIN codes376
1341151 General376
1341152 PIN code for resetting the truck376
1341153 Programming PIN codes376
1341154 PIN code defaults378
1342 Hour counter, tachograph C5290378
13421 Checking error log and operating hours378
135 Control system travel function C5300379
1351 Direction selector/speed regulator379
1352 Pressure equalization379
1353 Weighing system379
1354 Display379
1355 Symbols on keypad and display379
1356 Option buttons379
1357 Signal buttons380
1358 Lifting and lowering control380
1359 Hour meter380
13510 Battery indicator380
13511 Safety reversing380
136 Power system travel function C5400381
1361 Overview381
1362 Transistor panel C5460381
13621 Description381
136211 General381
13622 Checking the contactors382
13623 Checking the cable connections382
13624 Checking the electric panel mounting382
13625 Cleaning the electric panel heatsink383
13626 Replacing the motor control panel383
136261 Removing the motor control panel383
136262 Installing the motor control panel384
137 Control system, working function C5500385
1371 Work function harnesses/fuse C5590385
13711 Checking the wiring harnesses385
138 Protective sensors, position sensors C5800385
1381 Description385
13811 Inductive sensors385
138111 Position sensors385
138112 Steering reference sensor386
13812 Pressure sensor386
13813 Pulse transducer387
1382 Safety probes/sensors C5830387
13821 Emergency switch off387
138211 Description387
1382111 Task and function387
138212 Checking the emergency switch function388
13822 Gate switches [B121]/[B122]388
138221 Replacing the gate switch [B120]388
1382211 388
1382212 389
138222 Replacing the gate switch [B122]390
1382221 390
1382222 391
139 Calibrations391
1391 Steering angle calibration391
1392 Hydraulic valve calibration392
13921 Proportional valve calibration392
13922 Calibrating the tilt sensor393
1393 Pressure sensor calibration393
13931 Weight measuring calibration393
13932 Weight measuring calibration394
13933 Calibrating the reach sensor394
13934 Overload calibration395
13935 Overload calibration396
14 Hydraulics/Pneumatics C6000399
141 Overview399
142 Description399
1421 Hydraulic hygiene399
14211 Inside cleaning399
14212 Packaging399
14213 Handling400
14214 Storage400
14215 Work procedures400
14216 Definitions – hydraulic parts400
1422 Erroneous hydraulic system pressure400
143 Quick change connectors401
1431 Overview quick change connectors401
1432 Removing female quick change connectors401
1433 Installing female quick change connectors402
1434 Removing a quick change connector (male)403
1435 Installing a quick change connector (male)403
144 Hydraulic unit C6100404
1441 Description404
14411 Pressure limiting valve404
1442 Hydraulic oil tank C6110405
14421 Tank405
14422 Description405
144221 Design405
14423 Cleaning the tank406
14424 Cleaning the tank406
14425 Checking the tank406
14426 Oil change407
144261 Topping up with oil407
14427 Replacing the tank408
144271 Removing the tank408
144272 Fitting the tank409
1443 Filter, filter housing C6130409
14431 Air filter409
144311 Cleaning the air filter409
14432 409
144321 Replacing the suction filter409
1443211 Removing suction filter409
1443212 Installing the suction filter410
14433 Oil filter replacement411
144331 Removing oil filter411
144332 Installing the oil filter411
144333 Oil filter replacement412
144334 Oil filter replacement412
1444 412
14441 Description412
144411 Checking the pressure limiting valve412
14442 Replacing the flow control valve413
144421 Removing the flow control valve413
144422 Fitting the flow control valve414
14443 Replacing the pressure limiting valve415
144431 Removing the pressure limiting valve415
144432 Fitting the pressure limiting valve415
1445 Replacing the valve coil415
14451 Removing the valve coil415
14452 Fitting the valve coil416
1446 Replacing the pressure sensor417
14461 Removing the pressure sensor417
14462 Fitting the pressure sensor418
145 Hydraulic system, fitted on the mast C6300418
1451 Mast hydraulic conduits C6320418
14511 Replacing the hose rupture valve418
145111 Disassembly of the hose rupture valve418
145112 Assembling the hose rupture valve418
14512 Checks for leaks from hydraulic conduits and connections, hydraulic unit418
146 Hydraulic cylinder C6600419
1461 Main lift cylinders C6610419
14611 Checking for leaks in the lift cylinder419
14612 Replacing the main lift cylinders419
146121 Removing the lift cylinder419
146122 Fitting the lift cylinder421
1462 Reach/telescoping cylinder C6650423
14621 Lubricate the reach cylinder attachment points423
14622 Replacing the reach cylinder423
146221 Removing the reach cylinder423
146222 Installing the reach cylinder426
15 Work function – lifting masts C7000431
151 Description431
1511 Ordering a replacement mast431
152 Chain system, general431
1521 General431
1522 Adjusting the chain431
1523 Lubrication432
1524 Checking the chains432
15241 Noise432
15242 Surface rust432
15243 Rusty links432
15244 Stiff links432
15245 Bolt rotation433
15246 Loose bolts433
15247 Outline wear433
15248 Chain gauge434
15249 Stretching434
152410 Damaged plates435
152411 Damaged bolts435
152412 Other damage435
152413 Dirty chain435
153 Checking the chains436
154 Lubricating the chains436
155 Checking the split pins437
156 Check-tighten the locking nuts437
157 Main mast C7100438
1571 Check for cracks/damages to the mast438
1572 Checking the 18 meter sensor438
1573 Lubrication of the mast roller guides 438
1574 Adjusting the slide pad439
1575 Adjusting the slide pad440
1576 Replacement of the mast442
15761 Disassembling the mast442
15762 Mounting the mast447
1577 Main mast suspension C7190448
15771 Reach carriage448
157711 Checking the reach movement sensor448
157712 Check the reach carriage rollers448
157713 Checking the reach/tilt cylinder bracket448
157714 Replacing the idler roller448
1577141 Removing the reach carriage rollers448
1577142 Installing the reach carriage rollers449
15772 Mast strut449
157721 Check the bolts to the scissor cross strut449
15773 Scissors450
157731 Overview450
157732 Checking the play between bushings and shafts450
157733 Checking the mast pivot bushing451
157734 Checking the wiring harnesses, scissors451
157735 Checking the valve unit, scissors451
157736 Replacing the mast pivot bushing452
1577361 Removing the mast pivot bushing452
158 Auxiliary mast/mast C7200454
1581 Replacing the auxiliary mast454
15811 Removing the auxiliary mast454
15812 Installing the auxiliary mast456
1582 Auxiliary mast struts C7210458
15821 Adjusting the angle of the auxiliary mast458
1583 Auxiliary mast yoke carriage C7230458
15831 Fork yoke458
158311 Replacing forks458
1583111 Removing the forks458
1583112 Fitting the forks460
158312 Replacing the fork yoke461
1583121 Removing the fork yoke461
1583122 Fitting the fork yoke462
158313 Adjusting the fork yoke464
159 Lifting/carrying/clamping devices C7400465
1591 Fork carriage unit/with integrated sideshift/fork spread C7420465
15911 Measuring the fork-to-floor distance465
16 Auxiliary equipment, installation equipment C8000469
17 Optional equipment/Extra equipment C9000473
171 Overview473
172 Extra electrical equipment C9400474
1721 Extra power socket474
17211 Overview474
17212 Description474
172121 DC/DC converter474
1722 Truck log equipment, code lock C9420475
17221 Overview475
17222 I_Site475
172221 Description475
1722211 I_Site475
17223 Impact Manager476
172231 Impact sensor476
172232 Description476
1722321 Impact sensor476
172233 Checking the impact sensor parameters476
172234 Checking DHU/I-site [K110]476
173 Other extra equipment C9500476
1731 Ground strap476
17311 Replacing the ground strap476
173111 Removing the ground strap476
173112 Installing a ground strap477
1732 Fire extinguisher478
17321 Description478
173211 Fire extinguisher478
1733 Horizontal E-bar479
17331 Description479
173311 E-bar479
1734 Spider expansion unit480
17341 Description480
173411 Spider expansion unit480
18 Instructions for disposal485
181 General485
182 Marking of plastics485
1821 General marking of products and packaging485
1822 Marking according to the manufacturer’s standards485
18221 Abbreviations485
18222 Marking examples486
183 Pressure vessels486
1831 Gas struts486
184 Sorting categories487
19 Wiring diagram491
191 Colour code table491
192 Diagram491
1921 Component list491
1922 Explanation S112-115, the functions controlled by the switch depend on what options the truck is fitted with497
1923 Component placement498
1924 General diagram517
1925 Detailed diagrams518
20 Hydraulics schematics547
201 List of symbols547
202 Diagram549
2021 Component list549
2022 Component placement550
2023 Detailed diagrams553
203 Diagram554
2031 Component list554
2032 Component placement555
2033 Detailed diagrams557
21 Tools561
211 Tools for electric connectors561
2111 AMP connectors561
2112 MQS connectors561
2113 CPC connectors562
2114 AMP Seal connectors563
212 Special tools563
22 Service data and grease specifications569
221 General tightening torques569
2211 Galvanised, non-oiled screws569
2212 Untreated, oiled screws569
222 Lubricants specification570
23 Technical data573
231 Truck Dimensions573
232 Truck Dimensions574
233 Truck data575
24 Index577

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