BT FORKLIFT SPE120XR SPE120XRD Repair manual 7605990 – PDF DOWNLOAD

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BT FORKLIFT SPE120XR SPE120XRD Repair manual 7605990 – PDF DOWNLOAD

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BT FORKLIFT SPE120XR SPE120XRD Repair manual 7605990 – PDF DOWNLOAD

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

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TABLE OF CONTENTS:

BT FORKLIFT SPE120XR SPE120XRD Repair manual 7605990 – PDF DOWNLOAD

1 General introduction..........................................................................................................  9
	1.1 Warning levels and symbols..............................................................................................  9
	1.2 Pictograms..............................................................................................................  9
	1.3 Abbreviations........................................................................................................... 10
2 General safety rules.......................................................................................................... 13
	2.1 Authorised personnel.................................................................................................... 13
	2.2 Work safety............................................................................................................. 13
	2.3 Electrical system....................................................................................................... 14
		2.3.1 Electrostatic risks............................................................................................... 14
		2.3.2 Battery handling.................................................................................................. 14
	2.4 Safe lifting............................................................................................................ 15
	2.5 Product modification.................................................................................................... 16
	2.6 Software................................................................................................................ 16
	2.7 Hydraulic system........................................................................................................ 16
3 Operating principle........................................................................................................... 19
	3.1 Description............................................................................................................. 19
		3.1.1 Battery is connected.............................................................................................. 19
		3.1.2 Login via keypad.................................................................................................. 19
		3.1.3 Login via “ID key” option......................................................................................... 19
		3.1.4 Tiller arm lowered for driving.................................................................................... 20
		3.1.5 Driving in fork direction......................................................................................... 20
		3.1.6 Driving in the drive wheel direction.............................................................................. 20
		3.1.7 Braking in neutral................................................................................................ 20
		3.1.8 Reverse braking................................................................................................... 21
		3.1.9 Mechanical braking................................................................................................ 21
		3.1.10 Emergency reversal............................................................................................... 21
	3.2 Description............................................................................................................. 22
4 Parameters.................................................................................................................... 25
	4.1 Display/change parameters............................................................................................... 25
	4.2 Parameters in general................................................................................................... 25
	4.3 Parameter list.......................................................................................................... 25
5 Installation.................................................................................................................. 61
	5.1 Transport............................................................................................................... 61
		5.1.1 Transporting the mast............................................................................................. 61
	5.2 Lifting the truck....................................................................................................... 61
		5.2.1 Lifting the truck................................................................................................. 61
		5.2.2 Lift using a jack................................................................................................. 63
	5.3 Commissioning........................................................................................................... 63
		5.3.1 Parameters on commissioning....................................................................................... 63
			5.3.1.1 Setting parameters.......................................................................................... 63
			5.3.1.2 Setting collision sensor parameters (option)................................................................ 63
			5.3.1.3 Setting battery parameters.................................................................................. 63
		5.3.2 Battery........................................................................................................... 64
			5.3.2.1 Battery installation........................................................................................ 64
6 Maintenance................................................................................................................... 69
	6.1 Introduction............................................................................................................ 69
	6.2 Maintenance instructions................................................................................................ 69
		6.2.1 Cleaning.......................................................................................................... 69
		6.2.2 High-pressure washers............................................................................................. 69
		6.2.3 Degreasing agents................................................................................................. 70
		6.2.4 Cleaning the exterior............................................................................................. 70
		6.2.5 Cleaning the chain................................................................................................ 70
		6.2.6 Cleaning the motor compartment.................................................................................... 70
		6.2.7 Electric components............................................................................................... 70
		6.2.8 Hydraulic system.................................................................................................. 71
		6.2.9 Signs, warnings and adhesive labels............................................................................... 71
			6.2.9.1 Placement of signs.......................................................................................... 71
			6.2.9.2 Placement of signs.......................................................................................... 72
	6.3 Lubricants specification................................................................................................ 74
	6.4 Periodic maintenance.................................................................................................... 74
7 Troubleshooting............................................................................................................... 89
	7.1 Initial troubleshooting................................................................................................. 89
	7.2 Concluding troubleshooting.............................................................................................. 90
	7.3 Auxiliary functions..................................................................................................... 91
		7.3.1 Towing a defective truck.......................................................................................... 91
			7.3.1.1 Towing and transporting a defective truck................................................................... 91
		7.3.2 Emergency driving mode............................................................................................ 91
			7.3.2.1 Emergency driving mode...................................................................................... 91
		7.3.3 Error code history................................................................................................ 91
			7.3.3.1 Error code history.......................................................................................... 91
		7.3.4 Extended error log................................................................................................ 92
			7.3.4.1 Extended error log.......................................................................................... 92
		7.3.5 Built-in test function for the tiller arm......................................................................... 92
			7.3.5.1 General..................................................................................................... 92
			7.3.5.2 Display test................................................................................................ 93
			7.3.5.3 Speed control............................................................................................... 93
			7.3.5.4 Safety reversing............................................................................................ 93
			7.3.5.5 Controls for lifting/lowering............................................................................... 94
			7.3.5.6 Sensilift................................................................................................... 94
			7.3.5.7 Keypad...................................................................................................... 95
		7.3.6 Digital input/output status....................................................................................... 95
			7.3.6.1 Test mode "9"............................................................................................... 95
		7.3.7 Service information............................................................................................... 96
			7.3.7.1 Service information......................................................................................... 96
	7.4 Troubleshooting using error codes....................................................................................... 97
		7.4.1 List of error codes............................................................................................... 97
8 Chassis C0000.................................................................................................................167
	8.1 Overview................................................................................................................167
	8.2 Inspection of the rear chassis..........................................................................................168
	8.3 Frame, chassis C0300....................................................................................................169
		8.3.1 Inspection covers C0340...........................................................................................169
			8.3.1.1 Motor compartment covers....................................................................................169
				8.3.1.1.1 Overview..............................................................................................169
				8.3.1.1.2 Replacing a service cover.............................................................................170
					8.3.1.1.2.1 Removing a service cover........................................................................170
					8.3.1.1.2.2 Installing a service cover......................................................................170
				8.3.1.1.3 Replacing a side cover................................................................................170
					8.3.1.1.3.1 Removing a side cover...........................................................................170
					8.3.1.1.3.2 Installing a side cover.........................................................................171
				8.3.1.1.4 Replacing an emblem cover.............................................................................171
					8.3.1.1.4.1 Removing an emblem cover........................................................................171
					8.3.1.1.4.2 Installing an emblem cover......................................................................172
				8.3.1.1.5 Replacing an upper cover..............................................................................172
					8.3.1.1.5.1 Removing an upper cover.........................................................................172
					8.3.1.1.5.2 Installing an upper cover.......................................................................173
				8.3.1.1.6 Replacing a cover.....................................................................................174
					8.3.1.1.6.1 Removing a cover................................................................................174
					8.3.1.1.6.2 Installing a cover..............................................................................174
		8.3.2 Support arms, stabilizers C0350...................................................................................175
			8.3.2.1 Checking the support arms...................................................................................175
			8.3.2.2 Lubrication of the support arms.............................................................................175
		8.3.3 Battery compartment parts C0390...................................................................................176
			8.3.3.1 Overview....................................................................................................176
			8.3.3.2 Description.................................................................................................176
				8.3.3.2.1 Battery lock, fixed...................................................................................176
			8.3.3.3 Checking the battery lock...................................................................................177
	8.4 Frame/chassis components C0400..........................................................................................177
		8.4.1 Motor mount/brackets C0450........................................................................................177
			8.4.1.1 Checking the motor mounts...................................................................................177
			8.4.1.2 Drive unit mountings........................................................................................178
				8.4.1.2.1 Drive unit mountings 6/8 km/h.........................................................................178
					8.4.1.2.1.1 Overview........................................................................................178
	8.5 Operator compartment, cab C0500.........................................................................................179
		8.5.1 Platform including fixing points C0560............................................................................179
			8.5.1.1 Overview....................................................................................................179
			8.5.1.2 Checking the function of the platform switches..............................................................180
			8.5.1.3 Adjusting the position sensor [B120]........................................................................180
			8.5.1.4 Checking the platform.......................................................................................181
			8.5.1.5 Gas strut...................................................................................................181
				8.5.1.5.1 Checking the gas strut................................................................................181
				8.5.1.5.2 Replacing a gas strut.................................................................................181
					8.5.1.5.2.1 Removing a gas strut............................................................................181
					8.5.1.5.2.2 Installing a gas strut..........................................................................184
			8.5.1.6 Platform suspension.........................................................................................185
				8.5.1.6.1 Adjusting platform suspension.........................................................................185
				8.5.1.6.2 Replacing the platform suspension.....................................................................186
					8.5.1.6.2.1 Removing the platform suspension................................................................186
					8.5.1.6.2.2 Fitting the platform suspension.................................................................187
			8.5.1.7 Safety switch, platform [B119]..............................................................................188
				8.5.1.7.1 Adjusting the position sensor play [B119].............................................................188
				8.5.1.7.2 Checking the position sensor [B119]...................................................................189
			8.5.1.8 Safety switch, platform [B119]/[B120].......................................................................189
				8.5.1.8.1 Measuring the detection distance [B120]...............................................................189
				8.5.1.8.2 Replacing sensor [B119]...............................................................................190
					8.5.1.8.2.1 Removing the platform position sensor [B119]....................................................190
					8.5.1.8.2.2 Fitting the platform position sensor [B119].....................................................191
				8.5.1.8.3 Replacing sensor [B120]...............................................................................191
					8.5.1.8.3.1 Removing the platform position sensor [B120]....................................................191
					8.5.1.8.3.2 Fitting the platform position sensor [B120].....................................................192
			8.5.1.9 Replacing the platform......................................................................................192
				8.5.1.9.1 Removing the platform.................................................................................192
				8.5.1.9.2 Installing the platform...............................................................................195
	8.6 Safety equipment C0800..................................................................................................198
		8.6.1 Operator protection C0840.........................................................................................198
			8.6.1.1 Gate........................................................................................................198
				8.6.1.1.1 ......................................................................................................198
				8.6.1.1.2 Checking the gate bar.................................................................................198
				8.6.1.1.3 Replacing a gas strut.................................................................................199
					8.6.1.1.3.1 Removing the gate damper........................................................................199
					8.6.1.1.3.2 Fitting the gate damper.........................................................................200
				8.6.1.1.4 Replacing the pad.....................................................................................200
					8.6.1.1.4.1 ................................................................................................200
					8.6.1.1.4.2 ................................................................................................201
				8.6.1.1.5 Replacing the gate....................................................................................202
					8.6.1.1.5.1 ................................................................................................202
					8.6.1.1.5.2 ................................................................................................203
				8.6.1.1.6 Replacing the gate bar................................................................................204
					8.6.1.1.6.1 ................................................................................................204
					8.6.1.1.6.2 ................................................................................................205
		8.6.2 Signs, warnings, labels C0850.....................................................................................205
			8.6.2.1 Checking signs and labels...................................................................................205
			8.6.2.2 Placement of signs..........................................................................................205
			8.6.2.3 Placement of signs..........................................................................................207
9 Motors C1000..................................................................................................................211
	9.1 Electric motors C1700...................................................................................................211
		9.1.1 Electric pump motor C1710.........................................................................................211
			9.1.1.1 Overview....................................................................................................211
			9.1.1.2 Replacing the pump motor....................................................................................211
				9.1.1.2.1 Removing a pump motor.................................................................................211
				9.1.1.2.2 Installing a pump motor...............................................................................212
		9.1.2 Electric steering motor C1730.....................................................................................213
			9.1.2.1 Overview....................................................................................................213
			9.1.2.2 Description.................................................................................................213
				9.1.2.2.1 Design................................................................................................213
			9.1.2.3 Cleaning the ring gear......................................................................................214
			9.1.2.4 Checking the electrical connections.........................................................................214
			9.1.2.5 Checking the steering motor gears...........................................................................214
			9.1.2.6 Checking the steering motor.................................................................................214
			9.1.2.7 Lubricating the ring gear...................................................................................214
			9.1.2.8 Check the drive gear's attachment...........................................................................214
			9.1.2.9 Replacing the steering motor................................................................................214
				9.1.2.9.1 Removing the steering motor [M6]......................................................................214
				9.1.2.9.2 Installing the steering motor [M6]....................................................................216
		9.1.3 Electric fan motor/fan C1740......................................................................................217
			9.1.3.1 Overview....................................................................................................217
			9.1.3.2 Description.................................................................................................217
				9.1.3.2.1 Design................................................................................................217
			9.1.3.3 Replacing the motor control fan.............................................................................217
				9.1.3.3.1 Removing a motor control fan..........................................................................217
				9.1.3.3.2 Installing a motor control fan........................................................................219
		9.1.4 Electric drive motor C1760........................................................................................220
			9.1.4.1 Overview 1.8 kW.............................................................................................220
			9.1.4.2 Description.................................................................................................220
				9.1.4.2.1 Design................................................................................................220
			9.1.4.3 Checking the electrical connections.........................................................................221
			9.1.4.4 Checking the drive motor....................................................................................221
			9.1.4.5 Listen for any abnormal noise in the drive motor bearings...................................................221
			9.1.4.6 Check the drive motor mountings.............................................................................222
			9.1.4.7 Checking the rotational speed sensor........................................................................222
			9.1.4.8 Check the rotational speed sensor fitting...................................................................223
			9.1.4.9 Replacing the drive motor...................................................................................223
				9.1.4.9.1 Removing the drive motor [M1].........................................................................223
				9.1.4.9.2 Removing the drive motor [M1].........................................................................226
				9.1.4.9.3 Removing the drive motor [M1].........................................................................228
				9.1.4.9.4 Installing the drive motor [M1].......................................................................231
				9.1.4.9.5 Installing the drive motor [M1].......................................................................234
				9.1.4.9.6 Installing the drive motor [M1].......................................................................236
			9.1.4.10 Replacing the temperature sensor...........................................................................239
				9.1.4.10.1 Installing the temperature sensor....................................................................239
			9.1.4.11 Replacing the rotational speed sensor......................................................................240
				9.1.4.11.1 Removing a rotational speed sensor...................................................................240
				9.1.4.11.2 Installing a rotational speed sensor.................................................................242
			9.1.4.12 Replacing the toothed wheel................................................................................243
				9.1.4.12.1 Removing a toothed wheel.............................................................................243
				9.1.4.12.2 Installing a toothed wheel...........................................................................244
10 Transmission/Drive gear C2000................................................................................................247
	10.1 Drive unit, final gear C2500...........................................................................................247
		10.1.1 Drive unit/gear C2550 ...........................................................................................247
			10.1.1.1 Overview...................................................................................................247
			10.1.1.2 Description ...............................................................................................247
				10.1.1.2.1 Design...............................................................................................247
				10.1.1.2.2 Technical data.......................................................................................248
			10.1.1.3 Check the drive gear's attachment .........................................................................248
			10.1.1.4 Checking for leaks in the drive gear.......................................................................248
			10.1.1.5 Checking for noise in the drive gear.......................................................................248
			10.1.1.6 Replacing the drive gear ..................................................................................249
				10.1.1.6.1 Removing the drive gear..............................................................................249
				10.1.1.6.2 Installing the drive gear............................................................................251
			10.1.1.7 Replacing the wheel hub seal ..............................................................................253
				10.1.1.7.1 Removing the wheel hub seal..........................................................................253
				10.1.1.7.2 Installing the wheel hub seal........................................................................254
			10.1.1.8 Drive gear oil change......................................................................................255
				10.1.1.8.1 Empty the drive gear oil.............................................................................256
				10.1.1.8.2 Filling oil in the drive gear........................................................................257
			10.1.1.9 Drive gear oil change......................................................................................258
				10.1.1.9.1 Empty the drive gear oil.............................................................................258
				10.1.1.9.2 Filling oil in the drive gear........................................................................259
			10.1.1.10 Replacing the drive gear steering bearing ................................................................260
				10.1.1.10.1 Removing the drive gear steering bearing............................................................260
				10.1.1.10.2 Installing the drive gear steering bearing..........................................................261
			10.1.1.11 Stud replacement .........................................................................................262
				10.1.1.11.1 Removing a stud.....................................................................................262
				10.1.1.11.2 Installing a stud...................................................................................262
11 Brake/wheel/track system C3000...............................................................................................265
	11.1 Travel brake system C3100..............................................................................................265
		11.1.1 Description......................................................................................................265
			11.1.1.1 Brake types................................................................................................265
				11.1.1.1.1 Travel brake.........................................................................................265
				11.1.1.1.2 Emergency brake......................................................................................265
				11.1.1.1.3 Parking brake........................................................................................265
	11.2 Parking brake details C3300............................................................................................266
		11.2.1 Electrical parking brake, magnet brake C3370.....................................................................266
			11.2.1.1 Overview...................................................................................................266
			11.2.1.2 Description................................................................................................267
				11.2.1.2.1 Technical data.......................................................................................267
			11.2.1.3 Cleaning the parking brake.................................................................................267
			11.2.1.4 Adjusting the parking brake gap............................................................................268
			11.2.1.5 Tighten the parking brake mounting bolts...................................................................268
			11.2.1.6 Checking the parking brake.................................................................................269
			11.2.1.7 Replacing the brake hub....................................................................................269
				11.2.1.7.1 Disassembling the brake hub..........................................................................269
				11.2.1.7.2 Installing a brake hub...............................................................................270
			11.2.1.8 Replacing the friction disc................................................................................270
				11.2.1.8.1 Removing the friction disc...........................................................................270
				11.2.1.8.2 Fitting the friction disc............................................................................271
	11.3 Wheels C3500...........................................................................................................273
		11.3.1 Drive wheel C3530................................................................................................273
			11.3.1.1 Overview...................................................................................................273
			11.3.1.2 Description................................................................................................274
				11.3.1.2.1 Wheel wear...........................................................................................274
			11.3.1.3 Measuring the drive wheel tread............................................................................274
			11.3.1.4 Check the drive wheel mountings............................................................................274
			11.3.1.5 Replacing the drive wheel..................................................................................275
				11.3.1.5.1 Disassembling the drive wheel........................................................................275
				11.3.1.5.2 Installing a drive wheel.............................................................................277
		11.3.2 Support arm wheels/castor wheels C3540...........................................................................278
			11.3.2.1 Replacing the castor wheel.................................................................................278
				11.3.2.1.1 Removing the castor..................................................................................278
				11.3.2.1.2 Removing the castor..................................................................................279
				11.3.2.1.3 Installing a castor wheel............................................................................280
				11.3.2.1.4 Installing a castor wheel............................................................................281
			11.3.2.2 Replacing the castor wheel assembly........................................................................282
				11.3.2.2.1 Removing the castor wheel assembly...................................................................282
				11.3.2.2.2 Installing the castor wheel assembly.................................................................283
		11.3.3 Fork wheels/support arm wheels C3550.............................................................................283
			11.3.3.1 Replacing the support arm wheels...........................................................................283
				11.3.3.1.1 Removing the support arm wheels......................................................................283
				11.3.3.1.2 Fitting the support arm wheel........................................................................285
12 Steering system C4000........................................................................................................291
	12.1 Description............................................................................................................291
		12.1.1 Power steering...................................................................................................291
	12.2 Mechanical steering system C4100.......................................................................................291
		12.2.1 Steering arm/wheel/lever C4110...................................................................................291
			12.2.1.1 Overview tiller arm........................................................................................291
			12.2.1.2 Operating panel............................................................................................293
				12.2.1.2.1 Overview operating panel.............................................................................293
				12.2.1.2.2 Controls.............................................................................................294
					12.2.1.2.2.1 Replacing the signal button/switch.............................................................294
						12.2.1.2.2.1.1 Removing the signal button/switch........................................................294
						12.2.1.2.2.1.2 Fitting the signal button/switch.........................................................295
					12.2.1.2.2.2 Replacing the lift/lower button................................................................297
						12.2.1.2.2.2.1 Removing the lift/lower button...........................................................297
						12.2.1.2.2.2.2 Fitting the lift/lower button............................................................298
						12.2.1.2.2.2.3 Checking the hydraulic functions.........................................................299
					12.2.1.2.2.3 Replacing the stomach button...................................................................299
						12.2.1.2.2.3.1 Removing the stomach button..............................................................299
						12.2.1.2.2.3.2 Installing a stomach button..............................................................300
						12.2.1.2.2.3.3 Checking the stomach button..............................................................301
					12.2.1.2.2.4 Replacing the sensilift........................................................................301
						12.2.1.2.2.4.1 Removing the sensilift...................................................................301
						12.2.1.2.2.4.2 Installing sensilift.....................................................................302
					12.2.1.2.2.5 Changing the position of the controls - support arm lift/fork lift.............................302
					12.2.1.2.2.6 Replacing the keypad...........................................................................303
						12.2.1.2.2.6.1 Removing the keypad......................................................................303
						12.2.1.2.2.6.2 Installing a keypad......................................................................303
				12.2.1.2.3 Replacing the operating panel........................................................................303
					12.2.1.2.3.1 Removing the operating panel...................................................................303
					12.2.1.2.3.2 Installing an operating panel..................................................................304
					12.2.1.2.3.3 Checking the speed control.....................................................................306
				12.2.1.2.4 Replacing the logic card.............................................................................306
					12.2.1.2.4.1 Removing the logic card........................................................................306
					12.2.1.2.4.2 Installing a logic card........................................................................307
					12.2.1.2.4.3 Logic card [A5]................................................................................309
			12.2.1.3 Tiller arm handle..........................................................................................309
				12.2.1.3.1 Replacing the handle to the tiller arm...............................................................309
					12.2.1.3.1.1 Removing the tiller arm handle.................................................................309
					12.2.1.3.1.2 Fitting the handle to the tiller arm...........................................................310
			12.2.1.4 Tiller arm.................................................................................................311
				12.2.1.4.1 Replacing the tiller arm.............................................................................311
					12.2.1.4.1.1 Removing the tiller arm........................................................................311
					12.2.1.4.1.2 Fitting tiller arm.............................................................................313
				12.2.1.4.2 Checking the brake microswitches.....................................................................315
				12.2.1.4.3 Checking the play and the return travel..............................................................316
				12.2.1.4.4 Replacing the tiller arm cover.......................................................................316
					12.2.1.4.4.1 Removing the tiller arm cover..................................................................316
					12.2.1.4.4.2 Installing the tiller arm cover................................................................317
			12.2.1.5 Steering yoke..............................................................................................318
				12.2.1.5.1 Overview steering servo..............................................................................318
				12.2.1.5.2 Replacing the steering yoke..........................................................................319
					12.2.1.5.2.1 Removing the steering yoke.....................................................................319
					12.2.1.5.2.2 Installing a steering yoke.....................................................................320
				12.2.1.5.3 Changing the tiller arm spring.......................................................................320
					12.2.1.5.3.1 Removing the tiller arm spring.................................................................320
					12.2.1.5.3.2 Installing the tiller arm spring...............................................................321
				12.2.1.5.4 Replacing the safety switch..........................................................................321
					12.2.1.5.4.1 Removing the safety switch [B60]...............................................................321
					12.2.1.5.4.2 Installing the safety switch [B60].............................................................323
			12.2.1.6 Steering adapter...........................................................................................324
				12.2.1.6.1 Overview steering servo..............................................................................324
				12.2.1.6.2 Replacing the steering adapter.......................................................................325
					12.2.1.6.2.1 Removing the steering adapter..................................................................325
					12.2.1.6.2.2 Installing a steering adapter..................................................................326
				12.2.1.6.3 Replacing the steering adapter cover.................................................................328
					12.2.1.6.3.1 Removing the steering adapter cover............................................................328
					12.2.1.6.3.2 Installing the steering adapter cover..........................................................329
				12.2.1.6.4 Replacing a gas strut - height adjuster..............................................................329
					12.2.1.6.4.1 Removing a gas strut - height adjuster.........................................................329
					12.2.1.6.4.2 Installing a gas strut - height adjuster.......................................................330
				12.2.1.6.5 Replacing the height adjustment lock.................................................................330
					12.2.1.6.5.1 Removing the height adjustment lock............................................................330
					12.2.1.6.5.2 Installing the height adjustment lock..........................................................331
					12.2.1.6.5.3 Checking the height adjustment lock............................................................331
				12.2.1.6.6 Replacing the mechanical stop of the steering shaft..................................................332
					12.2.1.6.6.1 Removing the mechanical stop of the steering shaft (power steering)............................332
					12.2.1.6.6.2 Fitting the mechanical stop of the steering shaft (power steering).............................333
			12.2.1.7 Tiller arm wiring harness..................................................................................335
				12.2.1.7.1 Replacing the tiller arm wiring harness..............................................................335
					12.2.1.7.1.1 Removing the tiller arm wiring harness.........................................................335
					12.2.1.7.1.2 Fitting the tiller arm wiring harness..........................................................339
			12.2.1.8 Replacing the steering bearing.............................................................................344
				12.2.1.8.1 Removing the steering bearing........................................................................344
				12.2.1.8.2 Fitting the steering bearing.........................................................................346
			12.2.1.9 Replacing the rubber seals.................................................................................347
				12.2.1.9.1 Removing rubber seals................................................................................347
				12.2.1.9.2 Installing rubber seals..............................................................................348
	12.3 Electric steering system C4300.........................................................................................350
		12.3.1 Overview.........................................................................................................350
		12.3.2 Steering angle sensor C4350......................................................................................350
			12.3.2.1 Description................................................................................................350
				12.3.2.1.1 Design...............................................................................................350
			12.3.2.2 Replacing the steering angle sensor servo unit.............................................................351
				12.3.2.2.1 Removing the steering angle sensor...................................................................351
				12.3.2.2.2 Installing steering angle sensor.....................................................................352
			12.3.2.3 Checking the reference sensor..............................................................................353
13 Electrical system C5000......................................................................................................359
	13.1 Description............................................................................................................359
		13.1.1 Using the anti-static carpet.....................................................................................359
	13.2 Programming tools......................................................................................................359
		13.2.1 TruckCom.........................................................................................................359
			13.2.1.1 Connect the CAN interface to the truck.....................................................................359
	13.3 General electric equipment C5100.......................................................................................360
		13.3.1 Battery C5110....................................................................................................360
			13.3.1.1 Description................................................................................................360
				13.3.1.1.1 Mast dimensions......................................................................................360
			13.3.1.2 Cleaning the battery.......................................................................................360
			13.3.1.3 Checking the connections...................................................................................360
			13.3.1.4 Checking the battery cables................................................................................360
			13.3.1.5 Checking the battery.......................................................................................361
			13.3.1.6 Checking cell and terminal protectors......................................................................361
			13.3.1.7 Checking the level of the electrolyte......................................................................361
			13.3.1.8 Checking the electrolyte density...........................................................................362
			13.3.1.9 Checking the battery parameters............................................................................362
			13.3.1.10 Checking the battery voltage..............................................................................362
			13.3.1.11 Resetting/restarting the battery..........................................................................362
			13.3.1.12 Charging the battery......................................................................................363
			13.3.1.13 Replacing a battery using a lifting device................................................................364
				13.3.1.13.1 Removing a battery using a lifting device...........................................................364
			13.3.1.14 Replacing a battery using a battery changing table........................................................364
				13.3.1.14.1 Removing a battery using a battery changing table...................................................364
		13.3.2 General alarm signals (audible/visual) C5160.....................................................................365
			13.3.2.1 Horn.......................................................................................................365
				13.3.2.1.1 Overview.............................................................................................365
				13.3.2.1.2 Checking the horn function...........................................................................365
		13.3.3 Battery charger (built-in) C5170.................................................................................365
			13.3.3.1 Checking the battery charger cables........................................................................365
			13.3.3.2 Checking the battery charger parameters....................................................................365
		13.3.4 Battery cut out switch, main contactor C5190.....................................................................366
			13.3.4.1 Main contactor.............................................................................................366
				13.3.4.1.1 Replacing the main contactor.........................................................................366
					13.3.4.1.1.1 Removing the main contactor....................................................................366
					13.3.4.1.1.2 Fitting the main contactor.....................................................................369
	13.4 Instrument panel, display C5200........................................................................................371
		13.4.1 Menu.............................................................................................................371
			13.4.1.1 Menus......................................................................................................371
			13.4.1.2 Menu navigation............................................................................................371
			13.4.1.3 Menu overview..............................................................................................372
			13.4.1.4 Menu list..................................................................................................373
			13.4.1.5 Menu information...........................................................................................373
			13.4.1.6 Show hour meter values.....................................................................................373
			13.4.1.7 Show error codes...........................................................................................374
			13.4.1.8 Show part numbers for software/hardware....................................................................374
			13.4.1.9 Built-in test ICH..........................................................................................374
			13.4.1.10 Show collisions...........................................................................................374
			13.4.1.11 Show/change parameters....................................................................................375
			13.4.1.12 Emergency driving mode....................................................................................375
			13.4.1.13 Calibration...............................................................................................375
			13.4.1.14 Show/change PIN code......................................................................................375
			13.4.1.15 PIN codes.................................................................................................376
				13.4.1.15.1 General.............................................................................................376
				13.4.1.15.2 PIN code for resetting the truck....................................................................376
				13.4.1.15.3 Programming PIN codes...............................................................................376
				13.4.1.15.4 PIN code defaults...................................................................................378
		13.4.2 Hour counter, tachograph C5290...................................................................................378
			13.4.2.1 Checking error log and operating hours.....................................................................378
	13.5 Control system travel function C5300...................................................................................379
		13.5.1 Direction selector/speed regulator...............................................................................379
		13.5.2 Pressure equalization............................................................................................379
		13.5.3 Weighing system..................................................................................................379
		13.5.4 Display..........................................................................................................379
		13.5.5 Symbols on keypad and display....................................................................................379
		13.5.6 Option buttons...................................................................................................379
		13.5.7 Signal buttons...................................................................................................380
		13.5.8 Lifting and lowering control.....................................................................................380
		13.5.9 Hour meter.......................................................................................................380
		13.5.10 Battery indicator...............................................................................................380
		13.5.11 Safety reversing................................................................................................380
	13.6 Power system travel function C5400.....................................................................................381
		13.6.1 Overview.........................................................................................................381
		13.6.2 Transistor panel C5460...........................................................................................381
			13.6.2.1 Description................................................................................................381
				13.6.2.1.1 General..............................................................................................381
			13.6.2.2 Checking the contactors....................................................................................382
			13.6.2.3 Checking the cable connections.............................................................................382
			13.6.2.4 Checking the electric panel mounting.......................................................................382
			13.6.2.5 Cleaning the electric panel heatsink.......................................................................383
			13.6.2.6 Replacing the motor control panel..........................................................................383
				13.6.2.6.1 Removing the motor control panel.....................................................................383
				13.6.2.6.2 Installing the motor control panel...................................................................384
	13.7 Control system, working function C5500.................................................................................385
		13.7.1 Work function harnesses/fuse C5590...............................................................................385
			13.7.1.1 Checking the wiring harnesses..............................................................................385
	13.8 Protective sensors, position sensors C5800.............................................................................385
		13.8.1 Description......................................................................................................385
			13.8.1.1 Inductive sensors..........................................................................................385
				13.8.1.1.1 Position sensors.....................................................................................385
				13.8.1.1.2 Steering reference sensor............................................................................386
			13.8.1.2 Pressure sensor............................................................................................386
			13.8.1.3 Pulse transducer...........................................................................................387
		13.8.2 Safety probes/sensors C5830......................................................................................387
			13.8.2.1 Emergency switch off.......................................................................................387
				13.8.2.1.1 Description..........................................................................................387
					13.8.2.1.1.1 Task and function..............................................................................387
				13.8.2.1.2 Checking the emergency switch function...............................................................388
			13.8.2.2 Gate switches [B121]/[B122]................................................................................388
				13.8.2.2.1 Replacing the gate switch [B120].....................................................................388
					13.8.2.2.1.1 ...............................................................................................388
					13.8.2.2.1.2 ...............................................................................................389
				13.8.2.2.2 Replacing the gate switch [B122].....................................................................390
					13.8.2.2.2.1 ...............................................................................................390
					13.8.2.2.2.2 ...............................................................................................391
	13.9 Calibrations...........................................................................................................391
		13.9.1 Steering angle calibration.......................................................................................391
		13.9.2 Hydraulic valve calibration......................................................................................392
			13.9.2.1 Proportional valve calibration.............................................................................392
			13.9.2.2 Calibrating the tilt sensor................................................................................393
		13.9.3 Pressure sensor calibration......................................................................................393
			13.9.3.1 Weight measuring calibration...............................................................................393
			13.9.3.2 Weight measuring calibration...............................................................................394
			13.9.3.3 Calibrating the reach sensor...............................................................................394
			13.9.3.4 Overload calibration.......................................................................................395
			13.9.3.5 Overload calibration.......................................................................................396
14 Hydraulics/Pneumatics C6000..................................................................................................399
	14.1 Overview...............................................................................................................399
	14.2 Description............................................................................................................399
		14.2.1 Hydraulic hygiene................................................................................................399
			14.2.1.1 Inside cleaning............................................................................................399
			14.2.1.2 Packaging..................................................................................................399
			14.2.1.3 Handling...................................................................................................400
			14.2.1.4 Storage....................................................................................................400
			14.2.1.5 Work procedures............................................................................................400
			14.2.1.6 Definitions – hydraulic parts..............................................................................400
		14.2.2 Erroneous hydraulic system pressure..............................................................................400
	14.3 Quick change connectors................................................................................................401
		14.3.1 Overview quick change connectors.................................................................................401
		14.3.2 Removing female quick change connectors..........................................................................401
		14.3.3 Installing female quick change connectors........................................................................402
		14.3.4 Removing a quick change connector (male).........................................................................403
		14.3.5 Installing a quick change connector (male).......................................................................403
	14.4 Hydraulic unit C6100...................................................................................................404
		14.4.1 Description......................................................................................................404
			14.4.1.1 Pressure limiting valve....................................................................................404
		14.4.2 Hydraulic oil tank C6110.........................................................................................405
			14.4.2.1 Tank.......................................................................................................405
			14.4.2.2 Description................................................................................................405
				14.4.2.2.1 Design...............................................................................................405
			14.4.2.3 Cleaning the tank..........................................................................................406
			14.4.2.4 Cleaning the tank..........................................................................................406
			14.4.2.5 Checking the tank..........................................................................................406
			14.4.2.6 Oil change.................................................................................................407
				14.4.2.6.1 Topping up with oil..................................................................................407
			14.4.2.7 Replacing the tank.........................................................................................408
				14.4.2.7.1 Removing the tank....................................................................................408
				14.4.2.7.2 Fitting the tank.....................................................................................409
		14.4.3 Filter, filter housing C6130.....................................................................................409
			14.4.3.1 Air filter.................................................................................................409
				14.4.3.1.1 Cleaning the air filter..............................................................................409
			14.4.3.2 ...........................................................................................................409
				14.4.3.2.1 Replacing the suction filter.........................................................................409
					14.4.3.2.1.1 Removing suction filter........................................................................409
					14.4.3.2.1.2 Installing the suction filter..................................................................410
			14.4.3.3 Oil filter replacement.....................................................................................411
				14.4.3.3.1 Removing oil filter..................................................................................411
				14.4.3.3.2 Installing the oil filter............................................................................411
				14.4.3.3.3 Oil filter replacement...............................................................................412
				14.4.3.3.4 Oil filter replacement...............................................................................412
		14.4.4 .................................................................................................................412
			14.4.4.1 Description................................................................................................412
				14.4.4.1.1 Checking the pressure limiting valve.................................................................412
			14.4.4.2 Replacing the flow control valve...........................................................................413
				14.4.4.2.1 Removing the flow control valve......................................................................413
				14.4.4.2.2 Fitting the flow control valve.......................................................................414
			14.4.4.3 Replacing the pressure limiting valve......................................................................415
				14.4.4.3.1 Removing the pressure limiting valve.................................................................415
				14.4.4.3.2 Fitting the pressure limiting valve..................................................................415
		14.4.5 Replacing the valve coil.........................................................................................415
			14.4.5.1 Removing the valve coil....................................................................................415
			14.4.5.2 Fitting the valve coil.....................................................................................416
		14.4.6 Replacing the pressure sensor....................................................................................417
			14.4.6.1 Removing the pressure sensor...............................................................................417
			14.4.6.2 Fitting the pressure sensor................................................................................418
	14.5 Hydraulic system, fitted on the mast C6300.............................................................................418
		14.5.1 Mast hydraulic conduits C6320....................................................................................418
			14.5.1.1 Replacing the hose rupture valve...........................................................................418
				14.5.1.1.1 Disassembly of the hose rupture valve................................................................418
				14.5.1.1.2 Assembling the hose rupture valve....................................................................418
			14.5.1.2 Checks for leaks from hydraulic conduits and connections, hydraulic unit...................................418
	14.6 Hydraulic cylinder C6600...............................................................................................419
		14.6.1 Main lift cylinders C6610........................................................................................419
			14.6.1.1 Checking for leaks in the lift cylinder....................................................................419
			14.6.1.2 Replacing the main lift cylinders..........................................................................419
				14.6.1.2.1 Removing the lift cylinder...........................................................................419
				14.6.1.2.2 Fitting the lift cylinder............................................................................421
		14.6.2 Reach/telescoping cylinder C6650.................................................................................423
			14.6.2.1 Lubricate the reach cylinder attachment points.............................................................423
			14.6.2.2 Replacing the reach cylinder...............................................................................423
				14.6.2.2.1 Removing the reach cylinder..........................................................................423
				14.6.2.2.2 Installing the reach cylinder........................................................................426
15 Work function - lifting masts C7000..........................................................................................431
	15.1 Description............................................................................................................431
		15.1.1 Ordering a replacement mast......................................................................................431
	15.2 Chain system, general..................................................................................................431
		15.2.1 General..........................................................................................................431
		15.2.2 Adjusting the chain..............................................................................................431
		15.2.3 Lubrication......................................................................................................432
		15.2.4 Checking the chains..............................................................................................432
			15.2.4.1 Noise......................................................................................................432
			15.2.4.2 Surface rust...............................................................................................432
			15.2.4.3 Rusty links................................................................................................432
			15.2.4.4 Stiff links................................................................................................432
			15.2.4.5 Bolt rotation..............................................................................................433
			15.2.4.6 Loose bolts................................................................................................433
			15.2.4.7 Outline wear...............................................................................................433
			15.2.4.8 Chain gauge................................................................................................434
			15.2.4.9 Stretching.................................................................................................434
			15.2.4.10 Damaged plates............................................................................................435
			15.2.4.11 Damaged bolts.............................................................................................435
			15.2.4.12 Other damage..............................................................................................435
			15.2.4.13 Dirty chain...............................................................................................435
	15.3 Checking the chains....................................................................................................436
	15.4 Lubricating the chains.................................................................................................436
	15.5 Checking the split pins................................................................................................437
	15.6 Check-tighten the locking nuts.........................................................................................437
	15.7 Main mast C7100........................................................................................................438
		15.7.1 Check for cracks/damages to the mast.............................................................................438
		15.7.2 Checking the 1.8 meter sensor....................................................................................438
		15.7.3 Lubrication of the mast roller guides ...........................................................................438
		15.7.4 Adjusting the slide pad..........................................................................................439
		15.7.5 Adjusting the slide pad..........................................................................................440
		15.7.6 Replacement of the mast..........................................................................................442
			15.7.6.1 Disassembling the mast.....................................................................................442
			15.7.6.2 Mounting the mast..........................................................................................447
		15.7.7 Main mast suspension C7190.......................................................................................448
			15.7.7.1 Reach carriage.............................................................................................448
				15.7.7.1.1 Checking the reach movement sensor...................................................................448
				15.7.7.1.2 Check the reach carriage rollers.....................................................................448
				15.7.7.1.3 Checking the reach/tilt cylinder bracket.............................................................448
				15.7.7.1.4 Replacing the idler roller...........................................................................448
					15.7.7.1.4.1 Removing the reach carriage rollers............................................................448
					15.7.7.1.4.2 Installing the reach carriage rollers..........................................................449
			15.7.7.2 Mast strut.................................................................................................449
				15.7.7.2.1 Check the bolts to the scissor cross strut...........................................................449
			15.7.7.3 Scissors...................................................................................................450
				15.7.7.3.1 Overview.............................................................................................450
				15.7.7.3.2 Checking the play between bushings and shafts........................................................450
				15.7.7.3.3 Checking the mast pivot bushing......................................................................451
				15.7.7.3.4 Checking the wiring harnesses, scissors..............................................................451
				15.7.7.3.5 Checking the valve unit, scissors....................................................................451
				15.7.7.3.6 Replacing the mast pivot bushing.....................................................................452
					15.7.7.3.6.1 Removing the mast pivot bushing................................................................452
	15.8 Auxiliary mast/mast C7200..............................................................................................454
		15.8.1 Replacing the auxiliary mast.....................................................................................454
			15.8.1.1 Removing the auxiliary mast................................................................................454
			15.8.1.2 Installing the auxiliary mast..............................................................................456
		15.8.2 Auxiliary mast struts C7210......................................................................................458
			15.8.2.1 Adjusting the angle of the auxiliary mast..................................................................458
		15.8.3 Auxiliary mast yoke carriage C7230...............................................................................458
			15.8.3.1 Fork yoke..................................................................................................458
				15.8.3.1.1 Replacing forks......................................................................................458
					15.8.3.1.1.1 Removing the forks.............................................................................458
					15.8.3.1.1.2 Fitting the forks..............................................................................460
				15.8.3.1.2 Replacing the fork yoke..............................................................................461
					15.8.3.1.2.1 Removing the fork yoke.........................................................................461
					15.8.3.1.2.2 Fitting the fork yoke..........................................................................462
				15.8.3.1.3 Adjusting the fork yoke..............................................................................464
	15.9 Lifting/carrying/clamping devices C7400................................................................................465
		15.9.1 Fork carriage unit/with integrated sideshift/fork spread C7420...................................................465
			15.9.1.1 Measuring the fork-to-floor distance.......................................................................465
16 Auxiliary equipment, installation equipment C8000............................................................................469
17 Optional equipment/Extra equipment C9000.....................................................................................473
	17.1 Overview...............................................................................................................473
	17.2 Extra electrical equipment C9400.......................................................................................474
		17.2.1 Extra power socket...............................................................................................474
			17.2.1.1 Overview...................................................................................................474
			17.2.1.2 Description................................................................................................474
				17.2.1.2.1 DC/DC converter......................................................................................474
		17.2.2 Truck log equipment, code lock C9420.............................................................................475
			17.2.2.1 Overview...................................................................................................475
			17.2.2.2 I_Site.....................................................................................................475
				17.2.2.2.1 Description..........................................................................................475
					17.2.2.2.1.1 I_Site.........................................................................................475
			17.2.2.3 Impact Manager.............................................................................................476
				17.2.2.3.1 Impact sensor........................................................................................476
				17.2.2.3.2 Description..........................................................................................476
					17.2.2.3.2.1 Impact sensor..................................................................................476
				17.2.2.3.3 Checking the impact sensor parameters................................................................476
				17.2.2.3.4 Checking DHU/I-site [K110]...........................................................................476
	17.3 Other extra equipment C9500............................................................................................476
		17.3.1 Ground strap.....................................................................................................476
			17.3.1.1 Replacing the ground strap.................................................................................476
				17.3.1.1.1 Removing the ground strap............................................................................476
				17.3.1.1.2 Installing a ground strap............................................................................477
		17.3.2 Fire extinguisher................................................................................................478
			17.3.2.1 Description................................................................................................478
				17.3.2.1.1 Fire extinguisher....................................................................................478
		17.3.3 Horizontal E-bar.................................................................................................479
			17.3.3.1 Description................................................................................................479
				17.3.3.1.1 E-bar................................................................................................479
		17.3.4 Spider expansion unit............................................................................................480
			17.3.4.1 Description................................................................................................480
				17.3.4.1.1 Spider expansion unit................................................................................480
18 Instructions for disposal....................................................................................................485
	18.1 General................................................................................................................485
	18.2 Marking of plastics....................................................................................................485
		18.2.1 General marking of products and packaging........................................................................485
		18.2.2 Marking according to the manufacturer’s standards................................................................485
			18.2.2.1 Abbreviations..............................................................................................485
			18.2.2.2 Marking examples...........................................................................................486
	18.3 Pressure vessels.......................................................................................................486
		18.3.1 Gas struts.......................................................................................................486
	18.4 Sorting categories.....................................................................................................487
19 Wiring diagram...............................................................................................................491
	19.1 Colour code table......................................................................................................491
	19.2 Diagram................................................................................................................491
		19.2.1 Component list...................................................................................................491
		19.2.2 Explanation S112-115, the functions controlled by the switch depend on what options the truck is fitted with.....497
		19.2.3 Component placement..............................................................................................498
		19.2.4 General diagram..................................................................................................517
		19.2.5 Detailed diagrams................................................................................................518
20 Hydraulics schematics........................................................................................................547
	20.1 List of symbols........................................................................................................547
	20.2 Diagram................................................................................................................549
		20.2.1 Component list...................................................................................................549
		20.2.2 Component placement..............................................................................................550
		20.2.3 Detailed diagrams................................................................................................553
	20.3 Diagram................................................................................................................554
		20.3.1 Component list...................................................................................................554
		20.3.2 Component placement..............................................................................................555
		20.3.3 Detailed diagrams................................................................................................557
21 Tools........................................................................................................................561
	21.1 Tools for electric connectors..........................................................................................561
		21.1.1 AMP connectors...................................................................................................561
		21.1.2 MQS connectors...................................................................................................561
		21.1.3 CPC connectors...................................................................................................562
		21.1.4 AMP Seal connectors..............................................................................................563
	21.2 Special tools..........................................................................................................563
22 Service data and grease specifications.......................................................................................569
	22.1 General tightening torques.............................................................................................569
		22.1.1 Galvanised, non-oiled screws.....................................................................................569
		22.1.2 Untreated, oiled screws..........................................................................................569
	22.2 Lubricants specification...............................................................................................570
23 Technical data...............................................................................................................573
	23.1 Truck Dimensions.......................................................................................................573
	23.2 Truck Dimensions.......................................................................................................574
	23.3 Truck data.............................................................................................................575
24 Index........................................................................................................................577

DESCRIPTION:

BT FORKLIFT SPE120XR SPE120XRD Repair manual 7605990 – PDF DOWNLOAD

The Operating principle section provides a general description on how the AutoShuttle functions work and how they are interdependent.
Because the control structure of the product is so complex, it is not possible to describe all combinations. Similarly, it is not possible to describe all influencing factors. Only a selection of such factors are indicated. A good aid is found in the descriptive sections of the repair manual and in the parameter descriptions in particular.

S.S 05/01/2025