BT Forklift RR M12, M14, M16 Service Manual – PDF DOWNLOAD

Description

BT Forklift RR M12, M14, M16 Service Manual – PDF DOWNLOAD

FILE DETAILS:

BT Forklift RR M12, M14, M16 Service Manual – PDF DOWNLOAD

Language : English
Pages :424
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

BT Forklift RR M12, M14, M16 Service Manual – PDF DOWNLOAD

1 – Table of contents 3
2- Technical data – M4 17
21 General tightening torques 21
211 Galvanised, non-oiled bolts 21
212 Untreated, oiled bolts 21
3- Introduction, maintenance – P1 23
31 Safety regulations with maintenance work 23
32 Cleaning and washing 25
321 External cleaning 25
322 Cleaning the motor compartment 25
323 Electrical components 25
33 Safe lifting 26
4- Preventive Maintenance – P2 27
41 Maintenance schedule 27
5- Oil and grease specification – P3 37
6- Tools – P4 39
61 Super Seal contact 39
611 AMP connector 40
612 AMP microtimer 41
613 Various tools 42
7- Driver Protection – 0840 47
71 General 47
72 Tilt stops 48
711 Removing the tilt stops 49
8- Power electronics panel – 5660 51
81 General description 51
811 Terminal connections and pole bolts 52
812 Technical Data 53
813 Installing a new transistor panel 53
82 Diagnostics and trouble shooting 54
821 Displaying error codes, logging errors 54
822 Error codes, trouble shooting 54
823 Resetting an error 55
83 Maintenance 55
831 Safety 55
832 Cleaning 56
9- Electric Pump Motor – 1710 57
91 General 57
92 Dismantling the Pump Motor 57
921 Connection 57
93 Removing and replacing the pump motor 58
931 Dismantling 58
932 Assembling 59
94 Bearing replacement 59
941 Dismantling (D side) 60
942 Assembling 60
943 Dismantling (N side) 60
944 Assembling (N side) 60
945 Carbon brushes and brush holders 61
New carbon brushes should always be ground in 61
Commutator 61
Machining the commutator 61
10- Electric steering motor – 1730 63
101 General 63
102 Replacing the steering motor 63
1021 Dismantling 63
1022 Assembling 63
103 Removing and replacing the carbon brushes 64
11- Electric drive motor – 1760 65
111 General 65
112 Dismantling the drive motor 65
113 Dismantling and assembling the drive motor 66
1131 Dismantling the drive motor 66
Removing the gear wheel 66
Removing the brakes 66
1132 Assembling the drive motor 67
Assembling the brakes 67
Assembling the gear wheel 67
1133 Reset the truck 67
114 Bearing replacement 68
1141 Dismantling 68
D-side 68
1142 Assembling 69
N-side 69
D-side 69
115 Installation instructions for external temperature sensor 70
12- Mechanical drive gear unit – 2550 73
121 General 73
122 Components/data for the drive assembly/transmission 73
1221 Component placement 74
1222 Technical data 76
1223 Dismantling the transmission 76
123 Replacing the drive motor/drive transmission 76
1231 Dismantling the drive motor 77
Dismantling the gear wheel 77
1232 Dismantling the drive transmission 78
1233 Assembling the transmission 78
1234 Installing the drive motor 79
Assembling the gear wheel 79
1235 Reset the truck 79
124 Checking/replacing the oil 79
1241 Checking/refilling the oil 79
1242 Changing the Oil 80
125 Repairs 81
1251 Replacing the drive shaft sealing ring 81
Dismantling 81
Assembling 82
1252 Leakage from the upper cover 83
1253 Leakage from the lower cover 83
1254 Replacing wheel bolts 84
13- Travel brake system – 3100 85
131 General 85
132 Operating description 85
1321 Releasing the accelerator 86
1322 Travel direction selector 86
1323 Pressing down the brake pedal 87
1324 Parking brake 88
1325 Emergency brake 88
133 Electromechanical disc brake, drive motor 89
134 Disassembly 90
135 Inspection 90
136 Assembly 91
137 Maintenance 92
1371 Adjusting the play 92
1372 Wear 93
1373 Checking the braking force 93
14- Drive wheel – 3530 95
141 General 95
142 Dismantling the drive wheel 95
143 Assembling the drive wheel 95
15- Fork/support arm wheel – 3550 97
151 General 97
152 Dismantling the wheel 97
153 Assembling the drive wheel 98
154 Dismantling the wheel bearing 98
155 Assembling the wheel bearing 98
16- Mechanical steering system – 4100 99
161 General 99
162 Replacing the steering generator 99
1621 Dismantling 99
1622 Assembling 99
17- Steering angle sensor – 4350101
171 General101
172 Procedure101
1711 Adjustment of the steering angle sensor102
18- Electrical System – 5000103
181 General103
1811 Electrical Panel103
182 Symbol List and Electrical Diagrams104
1821 Symbol List104
1822 Electrical Diagrams107
1823 Component List118
1824 Figure 1121
1825 Figure 2122
1826 Figure 3122
1827 Figure 4123
1828 Figure 5124
1829 Figure 6125
18210 Figure 7125
18211 Figure 8126
183 Functional Description127
1831 Key in Position 0127
1832 Key in Position I128
1833 Choice of travel direction128
On the control console129
On the accelerator129
1834 Driving129
1835 Steering130
1836 Steering wheel indicator131
1837 Braking131
Auto-brakes131
Motor brakes (electric)131
Foot brakes131
Parking brake131
1838 Fork lifting132
1839 Maximum height132
18310 Maximum height132
18311 Fork lowering133
18312 Mast out/in133
18313 Fork tilt up/down133
18314 Hydraulic function 4134
18315 Hydraulic function 5134
18316 Height indicator134
18317 Preset height135
18318 Driver identification135
Without pin code135
With pin code135
19- Battery – 5110137
191 Battery dimensions137
192 Setting the battery parameters on RR trucks fitted with Hawker Evolution gel batteries138
1921 General138
1922 Battery recommendation138
1923 Battery installation138
1924 Recommended parameter setting for ventilation regulated batteries139
1925 Instructions for verifying the parameter setting139
20- Transistor panel – 5460141
201 Frequency converter141
2011 Terminal connections and pole bolts142
2012 Technical Data143
2013 Programming143
21- Electronic card – 5710145
211 General description145
212 Terminal connections and voltages on A5146
2121 10X146
2122 20X147
2123 30X147
2124 40X148
2125 50X148
2126 60X149
2127 70X149
2128 80X150
2129 90X151
213 Adjusting the lowering speed151
214 Show152
215 Programming153
2111 Driver parameters (1-7)154
212 Warning Codes155
213 Error Codes156
2111 Safety logic157
2112 Warning Codes without registration157
212 Warning codes with registration179
213 Error Codes199
2131 Error codes with registration200
214 Operating Time225
215 Parameter Settings226
2151 Parameter 1228
2152 Parameter 2228
2153 Parameter 3228
2154 Parameter 4228
2155 Parameter 5228
2156 Parameter 10228
2157 Parameter 11229
2158 Parameter 12229
2159 Parameters 13 to 14229
21510 Parameters 15 and 16229
21511 Parameters 17 and 18229
21512 Parameter 19230
21513 Parameter 20230
21514 Parameter 21230
21515 Parameter 23231
21516 Parameter 24231
21517 Parameter 25232
21518 Parameter 26232
21519 Parameter 27232
21520 Parameter 28232
21521 Parameter 29232
21522 Parameter 38232
21523 Parameter 39233
21524 Parameters 40 to 42233
21525 Other parameters233
21526 Installing a new card in the truck234
22- Hydraulic system – 6000235
221 General235
222 Symbols235
2221 Hydraulic chart 1 (3)237
2222 Hydraulic chart 2 (3)238
2223 Hydraulic chart 3 (3)239
223 List of symbols240
2231 Component placement 1 (2)242
2232 Component placement 2 (2)243
224 Adjusting fork lowering244
225 Setting the max lifting capacity245
23- Hydraulic pump – 6140247
231 General247
232 Replacing the hydraulic pump247
2321 Dismantling247
2322 Assembling248
24- Hydraulic connections – 6230249
241 General249
242 Tightening torque for hydraulic connections249
2421 Conical connection with O-ring249
2422 Tredo seal250
2423 Pipe coupling250
2424 Connection screwed into aluminium250
2425 Connection screwed into steel251
Pressure class L251
25- Hydraulic cylinder – 6600253
251 General253
252 Duplex mast253
2521 Dismantling the lift cylinders from the mast253
2522 Dismantling the cylinder254
2523 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder254
2524 Assembling the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder255
2525 Dismantling and assembling the lower brake valve255
2526 Assembling the cylinder255
2527 Assembling the cylinder in the mast256
253 Triplex mast256
2531 Dismantling the free lift cylinder from the mast256
2532 Dismantling the mast lift cylinders from the mast256
254 Cylinder seals257
255 Replacing wear parts in the cylinder257
2551 Securing257
2552 Dismantling the cylinder257
2553 Replacing the lower support ring258
2554 Replacing the O-ring on the top sleeve258
2555 Replacing the internal wear parts in the top sleeve259
2556 Assembling the cylinder259
2557 Assembling the free lift cylinder in the mast260
2558 Assembling the mast lift cylinder260
26- Mast mounted hose reel – 6370261
261 General261
262 Assembling261
263 Check after assembly262
27- Main lift cylinder – 6610263
271 General263
272 Tools263
273 Dismantling the lift cylinders from the mast264
274 Dismantling the cylinder265
2741 Dismantling the rod seal, guide ring, guide ring holder and locking ring in lift cylinder265
2742 Fit the locking ring, rod seal, guide ring and guide ring holder in the lift cylinder266
2743 Dismantling and assembling the hose rupture valve266
275 Assembling the cylinder267
2751 Assembling the cylinder in the mast267
28- Free lift cylinder – 6620269
281 General269
282 Tools269
283 Dismantling270
2831 Dismantling the cylinder271
284 Dismantle the rod seal and the support rin271
2841 Assembling the rod seal and the support ring272
285 Dismantling the ram272
2851 Assembling the ram in the free lift cylinder272
286 Dismantling and assembling the hose rupture valve272
287 Assembling the cylinder273
288 Assembling273
29- Reach cylinder – 6650275
291 General275
292 Assembling and dismantling the reach cylinder275
2921 Dismantling the cylinder276
2922 Dismantling the rod277
2923 Dismantle the to sleeve seals277
2924 Assembling the top sleeve277
2925 Fit the ram seal277
2926 Dismantling the rod278
2927 Assembling the cylinder278
293 Assembling278
30- Tilt cylinder – 66601279
301 General279
302 Assembling and dismantling the tilt cylinder279
3021 Dismantling the cylinder280
3022 Dismantling the rod281
3023 Dismantling the ram seals281
3024 Dismantle the top sleeve seals281
3025 Assembling the top sleeve281
3026 Assembling the ram seal281
3027 Dismantling the rod282
3028 Assembling the cylinder282
303 Assembling282
31- Tilt cylinder – 66602283
311 General283
312 Mast with valve on the fork carriage284
3121 Dismantling the fork carriage284
3122 Dismantling the cylinder285
3123 Dismantling the rod seal285
3124 Dismantling the ram285
3125 Assembling the ram285
3126 Assembling the rod seal286
3127 Assembling the cylinder286
3128 Assembling the fork carriage286
313 Mast without valve on the fork carriage287
3131 Dismantling the fork carriage287
3132 Dismantling the cylinder288
3133 Dismantling the rod seal288
3134 Dismantling the ram288
3135 Assembling the ram288
3136 Assembling the rod seal289
3137 Assembling the cylinder289
3138 Assembling the fork carriage289
32- Main mast – 71001291
321 General291
322 List of tools291
323 Transporting the truck292
324 Assembling the mast293
325 Dismantling the mast297
3251 Chains, cylinders and hoses298
3252 Dismantling the runner299
3253 Inner guide300
326 Assembling Duplex mast303
3261 Assembly-shimming the side play303
3262 Inner guide304
3263 Chains, cylinders and hoses304
3264 Fork carriage304
3265 Docking the mast in the truck304
327 Assembling the Triplex mast305
3271 Assembly-shimming the side play305
3272 Inner guide306
3273 Chains, cylinders and hoses306
3274 Fork carriage306
328 Problem with the mast rollers307
329 Adjusting the distance between the forks and floor308
33- Main mast – 71002309
331 General309
332 List of tools309
333 Transporting the truck310
334 Assembling the mast311
335 Dismantling the mast315
336 Adjust the play316
3361 Adjusting the mast play319
Lateral play319
3362 Radial play320
337 Assembling320
338 Problem with the mast rollers321
339 Adjusting the distance between the forks and floor322
34- Main lift chain system – 7120323
341 General323
342 Checking the chain setting323
343 Chain inspection323
3431 Noise323
3432 Surface rust323
3433 Rusty links323
3434 Stiff links324
3435 Bolt rotation324
3436 Loose bolts324
3437 Outline wear325
3438 Stretching326
3439 Damage326
34310 Damaged discs327
34311 Damaged bolts327
34312 Dirty chain327
344 Cleaning327
345 Lubrication328
35- Lifting devices – 7400329
351 General329
3511 Inspection intervals329
3512 Inspection329
3513 Surface cracks329
3514 Difference in height of fork tips329
3515 Positioning lock329
3516 Legibility of marking330
3517 Fork arm blade and shank330
3518 Fork arm mountings330
3519 Repair and testing330
Repair330
Yield test330
Fork331
Extended fork331
352 Checking the fork carriage’s wearing strips332
353 Fork spread unit334
3531 Servicing of fork spread unit334
Replacing bearings336
36- Battery charger – 8340337
361 General337
362 Installation337
363 Functional description338
3631 Display functions338
3632 Charging process338
3633 Shutdown conditions339
3634 Delayed power on and charging339
3635 Extra charging339
3636 Equalised charging339
3637 Current and voltage characteristics339
3638 Safety shutdowns340
3639 Display and keyboard340
Reading of analogue measurement values341
Error indication and error messages341
Reading statistics from the previous charge342
Reading of long term statistics343
Storing parameters344
Reading parameters344
Battery specific parameters345
Charger specific parameters345
Mains voltage codes346
Other functions346
Changing parameters346
36310 Acid circulation347
General347
BTM with acid circulation347
Pump type APE, VPM347
Pump type API348
364 Service and maintenance348
3641 Basic programming, code 30348
3642 Resetting the statistics, code 31348
3643 Calibrating the measurement value348
Calibrating the current’s zero value and temperatures, code 21349
Calibrating the battery voltage’s measurement value, code 20349
Calibrating the charging current, code 25349
Calibrating the mains voltage display, code 26349
3644 Calibrating and programming API350
Calibrating zero pressure350
Calibrating the pressure350
Programming the alarm limits350
Programming the API function350
3645 Adjusting the charging characteristics351
3646 Trouble shooting351
Error message, analysis and action351
Errors without indication352
3647 Trouble shooting acid circulation353
3648 Service measures353
Switching to the timer charger353
Replacing the display card354
Replacing the computer board354
Replacing the mother board354
Replacing the diodes355
3649 Preventive maintenance355
37- Extra Lighting – 9360357
38- Extra warning lights/alarm – 9370359
381 General359
39- Position sensors/TV-Equipment – 9390361
391 General361
392 Height indication361
393 Operation362
394 Display363
395 Preset height364
396 Operation365
397 Display366
3971 Description of the display symbols367
398 Assembly of height preset368
399 Programming368
3991 Programming a level368
Collection level368
Leaving level368
3992 Erasing programmed levels369
3910 Automatic operations369
39101 Collect load369
39102 Leaving a load370
39103 Control370
3911 Parameters370
39111 Parameter 1371
39112 Parameter 2371
39113 Parameter 3371
39114 Parameter 4371
39115 Parameter 5372
39116 Parameter 7372
39117 Parameter 8372
39118 Parameter 9372
3912 Programming parameters373
3913 Error codes375
40- Truck log system, code lock – 9420377
401 General377
BT TLS truck logging system377
402 EV 1 and S 16 keyboard version377
4021 Log-in with code (5-digit)377
4022 Logout377
4023 Log-in with fault reporting (5+1 digit)378
Only applies to S 16378
Login378
4024 Log-in with extra code (5+3 digits)378
Only applies to S 16378
4025 Log-in with extra code and fault reporting (5+3+1 digits)379
Only applies to S 16379
4026 Changing the three-digit personal code379
Only applies to S 16379
403 EV 1 and S 16 code card version379
4031 Login379
4032 Logout379
4033 Wiring diagram381
404 Collision sensor382
Only applies to S 16383
4041 Wiring diagram385
405 Trouble shooting387
4051 EV 1387
4052 S 16387
41- Extra equipment – 9500389
411 Dry powder extinguisher389
In the event of fire, the powder extinguisher should be employed as follows:389
4111 Regular checks of the powder extinguisher – truck driver389
4112 Inspection of powder extinguisher in service inspection of the truck390
42- Instructions for destruction391
421 General391
422 Procedure391
423 Abbreviations392
424 Sorting392
425 Frame/chassis (0300)393
4251 Dismantling393
4252 Material handling393
426 Operator’s seat, cushion (0620)394
4261 Dismantling394
4262 Material handling394
427 Driver controls (0640)395
4271 Dismantling395
4272 Material handling395
428 Interior fittings (0680)396
4281 Dismantling396
4282 Material handling396
429 Rollover guard/head guard (0810)397
4291 Dismantling397
4292 Material handling397
4210 Finger protectors (0820)398
42101 Dismantling398
42102 Material handling398
4211 Electric motors (1700)399
42111 Dismantling399
42112 Material handling399
4212 Electric fan motor (1740)400
42121 Dismantling400
42122 Material handling400
4213 Drive unit, final gear (2500)401
42131 Dismantling401
42132 Material handling401
4214 Wheels (3500)402
42141 Dismantling402
42142 Material handling402
4215 Electric steering system (4300)403
42151 Dismantling404
42152 Material handling404
4216 General electric equipment (5100)405
42161 Dismantling405
42162 Material handling405
4217 Power system, drive function (5400)406
42171 Dismantling406
42172 Material handling406
4218 Control system, operation function (5500)407
42181 Dismantling407
42182 Material handling407
4219 Steering/protective electronics (5700)408
42191 Dismantling408
42192 Material handling408
4220 Hydraulic unit (6100)409
42201 Dismantling410
42202 Material handling410
4221 Hydraulic system, fitted on the chassis (6200)411
42211 Dismantling412
42212 Material handling412
4222 Hydraulic system, fitted on the mast (6300)413
42221 Dismantling413
42222 Material handling413
4223 Hydraulic cylinders (6600)414
42231 Dismantling416
42232 Material handling416
4224 Main mast and mast (7100)417
42241 Dismantling417
42242 Material handling417
4225 Lift fork (7410)418
42251 Dismantling418
42252 Material handling418
4226 Optional electric equipment (9300)419
42261 Dismantling419
42262 Material handling419
4227 Optional electric equipment (9400)420
42271 Dismantling420
42272 Material handling420

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