BT FORKLIFT SPE125/160/135S/125L/160L SERVICE MANUAL 711956 – PDF DOWNLOAD

Description

BT FORKLIFT SPE125/160/135S/125L/160L SERVICE MANUAL 711956 – PDF DOWNLOAD

FILE DETAILS:

BT FORKLIFT SPE125/160/135S/125L/160L SERVICE MANUAL 711956 – PDF DOWNLOAD

Language : English
Pages : 222
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT FORKLIFT SPE125/160/135S/125L/160L SERVICE MANUAL 711956 – PDF DOWNLOAD

1- Contents..............................................................................  3
2- Presentation of the truck - M2........................................................ 13
	2.1 Intended application of the truck................................................ 14
	2.2 Forbidden application of the truck............................................... 14
	2.3 Truck data....................................................................... 15
	2.4 Truck dimensions................................................................. 16
		SPE125/125L/160/160L............................................................. 16
	2.5 Identification plate............................................................. 18
	2.6 Capacity plate................................................................... 18
	2.7 Addition and information plate................................................... 18
	2.8 Capacity plate for double pallet handling........................................ 19
	2.9 Main components.................................................................. 20
	2.10 Warning and information plates.................................................. 22
3- Technical data - M4................................................................... 25
	3.1 General tightening torques....................................................... 30
4- Installation and maintenance instructions - P1........................................ 31
	4.1 Truck installation............................................................... 31
		4.1.1 Lifting the truck.......................................................... 31
		4.1.2 Battery installation....................................................... 32
		4.1.3 Putting into service....................................................... 32
	4.2 Introduction, maintenance........................................................ 34
		4.2.1 Safety rules during maintenance work....................................... 34
	4.3 Cleaning and washing............................................................. 36
		4.3.1 External cleaning.......................................................... 36
		4.3.2 Cleaning the motor compartment............................................. 36
		4.3.3 Electric components........................................................ 36
	4.4 Safe lifting..................................................................... 37
5- Maintenance schedule - P2............................................................. 39
	5.1 Lubrication chart................................................................ 45
6- Oil and grease specification - P3..................................................... 47
7- Tools - P4............................................................................ 49
	7.1 Super Seal connectors............................................................ 49
	7.2 AMP connectors................................................................... 50
		7.2.1 AMP Connectors, 040 series................................................. 51
	7.3 Molex connectors................................................................. 51
	7.4 Grease guns...................................................................... 52
	7.5 Other tools...................................................................... 53
8- Support arms - 0350................................................................... 55
	8.1 General.......................................................................... 55
	8.2 Main components.................................................................. 56
	8.3 Maintenance...................................................................... 56
	8.4 Adjusting the support arm width.................................................. 57
	8.5 Support arm replacement.......................................................... 58
9- Electric drive motor - 1760........................................................... 59
	9.1 Included components.............................................................. 59
	9.2 Disassembly/assembly of the truck motor.......................................... 61
		9.2.1 Disassembly................................................................ 61
		9.2.2 Assembly................................................................... 61
	9.3 Service/repairs.................................................................. 62
		9.3.1 Disassembly of the motor................................................... 62
		9.3.2 Motor installation......................................................... 63
		9.3.3 Cleaning................................................................... 63
	9.4 Technical data................................................................... 64
10- Drive unit/gear - 2550............................................................... 65
	10.1 Included components............................................................. 66
		10.1.1 Technical data............................................................ 67
	10.2 Leakage from top cover.......................................................... 67
	10.3 Replacing the drive axle jointing ring.......................................... 67
		10.3.1 Disassembly............................................................... 68
		10.3.2 Assembly.................................................................. 68
11- Electromagnetic brake - 3370......................................................... 69
	11.1 Main components of the brake.................................................... 69
	11.2 Maintenance..................................................................... 70
		11.2.1 Basic adjustment of the play.............................................. 70
		11.2.2 Brake disc replacement.................................................... 71
12- Electrical steering system - 4300.................................................... 73
	12.1 Electrical steering servo....................................................... 73
		12.1.1 General................................................................... 73
	12.2 Steering servo components....................................................... 74
	12.3 Adjustment...................................................................... 75
		12.3.1 Reference sensor.......................................................... 75
		12.3.2 Calibration............................................................... 75
			Parameter 36................................................................. 75
			Parameter 37................................................................. 75
13- Electrical systems - 5000............................................................ 77
	13.1 Electrical equipment overview................................................... 77
	13.2 Equipment list and electrical diagram........................................... 79
		13.2.1 Electrical wiring diagram 1 of 15......................................... 83
		13.2.2 Electrical wiring diagram 2 of 15......................................... 84
		13.2.3 Electrical wiring diagram 3 of 15......................................... 85
		13.2.4 Electrical wiring diagram 4 of 15......................................... 86
		13.2.5 Electrical wiring diagram 5 of 15......................................... 87
		13.2.6 Electrical wiring diagram 6 of 15......................................... 88
		13.2.7 Electrical wiring diagram 7 of 15......................................... 89
		13.2.8 Electrical wiring diagram 8 of 15......................................... 90
		13.2.9 Electrical wiring diagram 9 of 15......................................... 91
		13.2.10 Electrical wiring diagram 10 of 15....................................... 92
		13.2.11 Electrical wiring diagram 11 of 15....................................... 93
		13.2.12 Electrical wiring diagram 12 of 15....................................... 94
		13.2.13 Electrical wiring diagram 13 of 15....................................... 95
		13.2.14 Electrical wiring diagram 14 of 15....................................... 96
		13.2.15 Electrical wiring diagram 15 of 15....................................... 97
		13.2.16 Electrical wiring diagram (SPE135S)...................................... 98
	13.3 Functional description.......................................................... 99
		13.3.1 Description of steering system............................................105
		13.3.2 Spider expansion unit (SEU)...............................................105
	13.4 Speed limitation................................................................107
	13.5 Hour meter and battery condition................................................108
	13.6 Diagnostic and troubleshooting..................................................110
		13.6.1 Fault codes...............................................................110
		13.6.2 Fault code history........................................................110
		13.6.3 List of fault codes.......................................................111
		13.6.4 Transistor regulator troubleshooting and error codes......................119
			General......................................................................119
			Transistor regulator errors..................................................119
			Resetting errors.............................................................121
			Safety.......................................................................121
		13.6.5 Built-in Test Function....................................................122
			Digital inputs/outputs test mode.............................................124
		13.6.6 Display test mode.........................................................127
	13.7 Part numbers....................................................................128
	13.8 Parameters......................................................................129
		13.8.1 General...................................................................129
		13.8.2 Viewing parameters -CAN key not connected.................................129
		13.8.3 Viewing parameters -CAN key connected.....................................130
		13.8.4 Setting Driver parameters.................................................131
		13.8.5 Setting Service parameters................................................131
		13.8.6 Summary of driver parameters..............................................132
		13.8.7 Description of driver parameters..........................................133
			# 2 - Maximum speed, high range..............................................133
			# 3 - Maximum acceleration...................................................133
			# 4 - Neutral braking effect.................................................133
			# 6 - Maximum speed, low range...............................................133
			# 7 - Maximum speed, “Turtle” mode...........................................133
		13.8.8 Summary of service parameters.............................................134
		13.8.9 Description of service parameters.........................................136
			# 10 - PIN code..............................................................136
			To enter a new PIN-code:.....................................................136
			To remove an existing PIN-code:..............................................137
			# 14 - Creep speed...........................................................137
			#15 - Non-configurable options...............................................137
			Setting Non-configurable options.............................................137
			#16 - Configurable option #1.................................................138
			#17 - Configurable option #2.................................................138
			#18 - Configurable option #3.................................................139
			#19 - Configurable option #4.................................................139
			# 20 - Hour meter selection..................................................139
			# 21 - Battery size..........................................................140
			# 22 - Maximum fork lowering speed...........................................140
			# 23 - Fork lower stop ramp..................................................140
			# 25 - Service interval......................................................140
			# 35 - Log off...............................................................141
			# 36 - Calibrate.............................................................141
			# 37 - Steering offset.......................................................144
			# 38 - Steer servo activated.................................................144
			# # 39 - Log-in method & operator parameter access...........................144
			Extended keypad - General....................................................145
			Extended keypad - Programming................................................145
		13.8.10 Configurable “Option” Parameters.........................................147
			General......................................................................147
			Parameter #16 to #19 Configurable options....................................148
	13.9 Technical specifications - Curtis 1243..........................................160
14- Hydraulic system - 6000..............................................................161
	14.1 Hydraulic diagram...............................................................161
		14.1.1 SPE125L/160L..............................................................161
		14.1.2 SPE125/160/135S...........................................................162
	14.2 Main components.................................................................163
	14.3 Description.....................................................................164
		14.3.1 Lifting system............................................................164
		14.3.2 The PowerTrak system......................................................164
		14.3.3 Working pressure..........................................................165
		14.3.4 Overflow valve............................................................165
		14.3.5 Pressure sensor...........................................................165
15- Main lift chain system - 7120........................................................167
	15.1 General.........................................................................167
	15.2 Checking the chain setting......................................................167
	15.3 Chain inspection................................................................167
		15.3.1 Noise.....................................................................167
		15.3.2 Surface rust..............................................................167
		15.3.3 Rusty links...............................................................167
		15.3.4 Stiff links...............................................................168
		15.3.5 Bolt rotation.............................................................168
		15.3.6 Loose bolts...............................................................168
		15.3.7 Outline wear..............................................................169
		15.3.8 Stretching................................................................170
		15.3.9 Damage....................................................................171
		15.3.10 Damaged discs............................................................171
		15.3.11 Damaged bolts............................................................171
		15.3.12 Dirty chain..............................................................172
	15.4 Cleaning........................................................................172
	15.5 Lubrication.....................................................................172
16- TruckCom.............................................................................175
	16.1 General.........................................................................175
	16.2 Connection......................................................................175
	16.3 Layout..........................................................................176
		16.3.1 Main program screen.......................................................176
		16.3.2 Nodes.....................................................................176
		16.3.3 Icons.....................................................................177
		16.3.4 Tool buttons and menu bar.................................................178
		16.3.5 Information window........................................................178
		16.3.6 Status bar................................................................178
	16.4 Connection function.............................................................178
	16.5 Disconnection function..........................................................179
	16.6 Downloading program function....................................................180
		16.6.1 Normal downloading (truck with key).......................................180
		16.6.2 Normal downloading (truck with keypad)....................................180
		16.6.3 Emergency downloading (truck with keypad).................................181
		16.6.4 Emergency downloading (truck with keypad).................................181
		16.6.5 Downloading in old versions of logic card.................................181
	16.7 Truck report function...........................................................182
	16.8 Parameters function.............................................................183
	16.9 Diagnostics function............................................................184
		16.9.1 Representation of signal colours..........................................185
		16.9.2 “Tiller arm” tab..........................................................185
		16.9.3 “Drive Controller” tab (transistor regulator driving).....................186
		16.9.4 “Pump controller” tab (transistor regulator pump).........................187
		16.9.5 “EPS” (steering servo tab)................................................188
	16.10 Other menu functions...........................................................189
		16.10.1 Save to file.............................................................189
		16.10.2 Download from file.......................................................189
		16.10.3 Reset CAN adapter........................................................189
		16.10.4 Delete error code log....................................................189
		16.10.5 Reset hour meter.........................................................189
		16.10.6 Read error code log......................................................189
		16.10.7 Adjust date and time.....................................................189
		16.10.8 Adjusting the hour meter on older cards..................................190
		16.10.9 Help.....................................................................190
			About the TruckCom application...............................................190
		16.10.10 Exit....................................................................190
	16.11 Specifications.................................................................190
	16.12 Installation...................................................................190
		16.12.1 Installation on a PC with Windows® 95/ 98................................191
		16.12.2 Installation on a PC with Windows XP/ 2000...............................192
			Changes in Windows® Control Panel............................................194
		16.12.3 Installation on a PC with Windows NT.....................................197
		16.12.4 In case of communication problems with CAN...............................197
		16.12.5 To uninstall.............................................................197
17- Destruction instructions - M6........................................................199
	17.1 General.........................................................................199
	17.2 Procedure.......................................................................199
	17.3 Abbreviations...................................................................200
	17.4 Sorting.........................................................................200
	17.5 Chassis (0300)..................................................................201
		17.5.1 Dismantling...............................................................201
		17.5.2 Material handling.........................................................201
	17.6 Hoods, covers (0340)............................................................202
		17.6.1 Dismantling...............................................................202
		17.6.2 Material handling.........................................................202
	17.7 Fork structure (low-lifter) (0380)..............................................203
		17.7.1 Dismantling...............................................................203
		17.7.2 Material handling.........................................................203
	17.8 Travel platform including mount (0560)..........................................204
		17.8.1 Dismantling...............................................................204
		17.8.2 Material handling.........................................................204
	17.9 Overhead guard (option) (0810)..................................................205
		17.9.1 Dismantling...............................................................205
		17.9.2 Material handling.........................................................205
	17.10 Operator protective device (0840)..............................................206
		17.10.1 Dismantling..............................................................206
		17.10.2 Material handling........................................................206
	17.11 Electric pump motor (1710).....................................................207
		17.11.1 Dismantling..............................................................207
		17.11.2 Material handling........................................................207
	17.12 Electric travel drive motor (1760).............................................208
		17.12.1 Dismantling..............................................................208
		17.12.2 Material handling........................................................208
	17.13 Drive unit/gear (2550).........................................................209
		17.13.1 Dismantling..............................................................209
		17.13.2 Material handling........................................................209
	17.14 Wheels (3500)..................................................................210
		17.14.1 Dismantling..............................................................210
		17.14.2 Material handling........................................................210
	17.15 Steering arm (4110)............................................................211
		17.15.1 Dismantling..............................................................211
		17.15.2 Material handling........................................................211
	17.16 Steering arm (4110)............................................................212
		17.16.1 Dismantling..............................................................212
		17.16.2 Material handling........................................................212
	17.17 General electric equipment (5100)..............................................213
		17.17.1 Dismantling..............................................................213
		17.17.2 Material handling........................................................213
	17.18 Cabling (5590).................................................................214
		17.18.1 Dismantling..............................................................214
		17.18.2 Material handling........................................................214
	17.19 Steering and protective electronics (5700).....................................215
		17.19.1 Dismantling..............................................................215
		17.19.2 Material handling........................................................215
	17.20 Lift/lowering sensor (5820) and safety sensor (5830)...........................216
		17.20.1 Dismantling..............................................................216
		17.20.2 Material handling........................................................216
	17.21 Hydraulic unit (6100)..........................................................217
		17.21.1 Dismantling..............................................................217
		17.21.2 Material handling........................................................217
	17.22 Main mast (7100)...............................................................218
		17.22.1 Dismantling..............................................................218
		17.22.2 Material handling........................................................218
	17.23 Chassis-mounted hydraulic oil lines (6230) (and main lift cylinder (6610) )....219
		17.23.1 Dismantling..............................................................219
		17.23.2 Material handling........................................................219
	17.24 Battery charger connector (9380)...............................................220
		17.24.1 Dismantling..............................................................220
		17.24.2 Material handling........................................................220

DESCRIPTION:

BT FORKLIFT SPE125/160/135S/125L/160L SERVICE MANUAL 711956 – PDF DOWNLOAD

• The truck is a battery driven support arm truck. The truck is equipped with a tiller arm for optional control: standing on the ride-on platform or walking. Best advantage can be taken of the truck’s properties by the operator standing on the ergonomically designed platform as this provides the operator with a clear view over the truck and load, allowing work to be carried out with ease and safety.
• The truck is also equipped with protective gates to protect the operator when driving standing on the platform. When the gates are retracted the truck’s maximum speed is always 6 km/h. When the gates are raised and the operator is standing on the platform the truck’s maximum speed is 8 km/h.
• The tiller arm is specially designed to provide the best possible operator ergonomy, having all the controls and buttons within easy reach without the operator needing to release the handle. The tiller arm is also equipped with a display showing running time and battery status among other things. The display is also used when the operator wishes to change any of the operator parameters with which the truck can be programmed.
• The truck is equipped with BT’s patented PowerTrak system, which means that the drive wheel pressure is adjusted according to the weight of the load and the wear on the drive wheel. This reduces the wear and tear on the drive wheel and ensures safer load handling.
• The truck has a 24V electrical system and the speed is regulated by means of a transistor controller to provide gentle control of acceleration and speed while driving.
• The forks are lifted using a compact, yet powerful hydraulic unit. Lifting is controlled by a transistorised variable speed controller. The truck’s proportional valve is used to adjust the lowering speed and fork positioning during stacking.
• The battery compartment is designed to allow the battery to be changed from either side as well as from above, which means the truck is well suited to most types of battery changing situations.

S.S 05/01/2025