BT LSR 1200 BT LSV 1600 BT LSV 1250 BT LST 1350 BT LSF 1250 Product family PS Master Service Manual

Description

BT LSR 1200 BT LSV 1600 BT LSV 1250 BT LST 1350 BT LSF 1250 Product family PS Master Service Manual – PDF DOWNLOAD

DESCRIPTION:

BT LSR 1200 BT LSV 1600 BT LSV 1250 BT LST 1350 BT LSF 1250 Product family PS Master Service Manual – PDF DOWNLOAD

Introduction, maintenance :

All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are only a guide and do not need to be followed to the letter.

• The operator may adapt them to local conditions, but it is important that the intervals comply with BT’s minimum requirements.
• The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened if the truck is used more frequently or in more demanding situations, e.g cold store, dusty or corrosive situations.

The following running times have been used when calculating the intervals:
– Day time: 08.00-17.00 (20 hr./week)
– 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
– 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)

• Ensure the truck is given a regular maintenance service after  every 500 driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.
• Only use BT approved spare parts when service and repair work are carried out

TABLE OF CONTENTS:

BT LSR 1200 BT LSV 1600 BT LSV 1250 BT LST 1350 BT LSF 1250 Product family PS Master Service Manual – PDF DOWNLOAD

Master Service Manual Product family PS 1
Contents Master Service Manual (MSM) 3
Valid from serial number: 3
T-code 3
Model 3
Serial No 3
Notes 3
1 Document list 3
Section 3
C-code 3
T-code 3
Document 3
Issued 3
Introduction to BT’s Service Manual 5
Contents, M 7
1 Truck information 7
Operator’s manual 9
Valid from serial number: 9
T-code 9
Model 9
Serial No 9
Notes 9
1 General 9
1 1 Issued operator’s manuals 9
T-code 9
Model 9
Serial number 9
Order number 9
Issued 9
Technical data 11
Valid from serial number: 11
T-code 11
Model 11
Serial number 11
Notes 11
MODEL 11
LSV 1600 11
LSV 1250 11
LST 1350 11
LSF 1250 11
Drive motor 11
Transmission/drive gear 11
Wheels 11
Hydraulic system 12
Fuses 14
Batteries 14
Driving speeds 14
Lifting/lowering times 14
Power consumption 14
Ordering Spare Parts 15
Quality Parts 17
Valid from serial number: 17
T-code 17
Model 17
Serial No 17
Notes 17
1 Issued Quality Parts 17
T-code 17
Model 17
Serial No 17
Order number 17
Issued 17
Recommended Spare Parts (RSP) 19
Valid from serial number: 19
T-code 19
Model 19
Serial No 19
Notes 19
1 Issued RSP 19
T-code 19
Model 19
Serial No 19
Issued 19
Contents, P 21
1 Preventive Maintenance 21
Introduction, maintenance 23
1 Safety regulations with maintenance work 23
WARNING! 23
WARNING! 24
WARNING! 24
NOTE! 24
CAUTION! 24
2 Cleaning and washing 25
NOTE! 25
2 1 External cleaning 25
NOTE! 25
2 2 Cleaning the motor compartment 25
NOTE! 25
2 3 Electrical components 26
NOTE! 26
3 Safe lifting 26
WARNING! 26
Preventive maintenance 27
Valid from serial number: 27
T-code 27
Model 27
Serial No 27
Notes 27
1 Maintenance schedule 27
Pos no 27
Work to carry out 27
Intervals in hours 27
5 27
20 27
80 27
250 27
500 27
1000 27
3000 27
Intervals in Days/Weeks/Months 27
1 D 27
1 W 27
1 M 27
3 M 27
6 M 27
12 M 27
36 M 27
0000 27
Chassis 27
1700 27
Motors 27
2550 27
Drive unit 27
3370 28
Brakes 28
3500 28
Wheels 28
4110 28
Tiller arm 28
4380 28
Steering bearings 28
5000 29
Electrical operations 29
5110 29
Battery 29
5400 29
Power system driving 29
5700 29
Electronic Card 29
6000 30
Hydraulic system 30
6600 30
Cylinders 30
7000 30
Mast 30
2 Lubrication chart 32
Pos no 32
Service point 32
Interval/Running hours 32
Lubricant 32
500h 32
1000h 32
3000h 32
Oil and grease specification 33
Valid from serial number: 33
T-code 33
Model 33
Serial No 33
Notes 33
1 Approved oil’s and grease 33
Lubticant 33
Specification 33
Application area 33
> – 15C 33
< – 15C 33
Contents, S 35
1 Service instructions 35
Support arms, stabilizators 37
Valid from serial number: 37
1 Welding of support arms on LST1000/1350 37
2 Adjustment of rated lift capacity 39
Electric pump motor 41
Valid from serial number: 41
T-code 41
Model 41
Serial number 41
Notes 41
1 General 41
1 1 Mechanical construction 42
1 2 Special tools 43
Tool 43
2 Removal/Refitting 43
2 1 Removing the motor from the truck 43
2 2 Refitting 43
3 Service/Repairs 44
3 1 Cleaning 44
3 2 Dismantling 45
3 3 Re-assembling 46
3 4 Armature bearings 46
3 4 1 Changing bearings 47
3 5 Carbon brushes and brush holder 47
3 5 1 Changing carbon brushes 47
3 6 Commutator 48
3 6 1 Machining the commutator 48
4 Storage/Transport 49
4 1 Storage 49
5 Data 50
Torque 50
Nm 50
Component 50
Item 50
Min 50
Max 50
Unit 50
Electric drive motor 51
Valid from serial number: 51
T-code 51
Model 51
Serial number 51
Notes 51
1 General 51
1 1 Mechanical contruction 52
1 2 Special tools 53
Tool 53
2 Removal/Refitting 53
2 1 Removing the motor from the truck 53
2 2 Reassembly 54
3 Service/Repairs 55
3 1 Cleaning 55
3 2 Removal of motor 56
3 3 Refitting of motor 57
3 4 Armature bearings 58
3 4 1 Changing the drive end bearing 58
3 4 2 Changing the commutator end bearing 58
3 5 Carbon brushes and brush holder 59
3 5 1 Changing carbon brushes 59
3 6 Commutator 60
3 6 1 Turning the commutator 60
4 Storage/Transport 61
4 1 Storage 61
5 Data 62
Torque 62
Nm 62
Grease specification 62
Component 62
Item 62
Min 62
Max 62
Unit 62
Mechanical drive gear unit 63
Valid from serial number: 63
T-code 63
Model 63
Serial No 63
Notes 63
1 General technical description 63
1 1 Technical data 64
Data 64
Description 64
1 2 Gear components 65
Pos No 65
Component 65
1 3 Special tools 66
Pos No 66
Tool 66
2 Removing the gear from the truck 67
3 Change of seal on the drive shaft 68
4 Reconditioning of the gear 70
Electromagnetic parking brake 75
Gäller maskinnummer: 75
T-code 75
Model 75
Serial No 75
Notes 75
1 General 75
2 Function 76
2 1 Releasing the brake 76
2 2 Braking 76
3 Maintenance 77
3 1 Adjustment of gap 78
3 1 1 Adjustment procedure 78
3 2 Exchange of brake disc/magnetic coil 79
3 2 1 Exchange procedure 79
3 2 2 Transport securing screws 80
3 3 Check/adjustment of the braking force 81
Warning! 81
Electric parking brake, magnetic brake 83
Valid from serial number: 83
T-code 83
Model 83
Serial no 83
Note 83
1 General 83
2 Function 84
2 1 Releasing the brake 84
2 2 Braking 85
3 Maintenance 86
3 1 Adjustment of gap 86
3 1 1 Adjustment procedure 86
3 2 Exchange of brake disc/magnetic coil 87
3 2 1 Exchange procedure 87
3 3 Check/adjustment of the braking force 88
WARNING! 88
Tiller arm with servo 89
Valid from serial number: 89
T code 89
Model 89
Machine no 89
Note 89
1 General 89
2 Electrical diagram 90
3 Adjustment 91
NB! 91
Electrical system 93
Valid from serial number: 93
T-code 93
Model 93
Serial No 93
Notes 93
1 Electrical panel, components 93
2 List of symbols and electrical diagrams 94
2 1 List of symbols 94
Symbol 94
Description 94
Function 94
Notes 94
2 2 Electrical diagram 1(5) 96
2 3 Electrical diagram 2(5) 97
2 4 Electrical diagram 3(5) 98
2 5 Electrical diagram 4(5) 99
2 6 Electrical diagram 5(5) 100
3 Description of function 101
3 1 General 101
3 2 Adjustable settings 101
Setting 101
Std value 101
Min value 101
Max value 101
3 3 Description 101
3 4 Ignition lock S17 in the ON position 102
3 5 The tiller arm in drive position, S10 103
3 6 Driving, fork direction 104
3 7 Driving, steer wheel direction 105
3 8 Reversing/motor brake, fork direction to steer wheel direction 106
3 9 Reversing/motor brake, steer wheel direction to fork direction 106
3 10 Safety reverse function 107
3 11 Hydraulic functions: lifting, protruding and tilting 108
3 12 Horn 108
Electrical system 109
Valid from serial number: 109
T-code 109
Model 109
Serial No 109
Notes 109
1 Electrical panel, components 109
2 List of symbols and electrical diagrams 110
2 1 List of symbols 110
Symbol 110
Description 110
Function 110
Remark 110
2 2 Electrical diagram 1(3) 112
2 3 Electrical diagram 2(3) 113
2 4 Electrical diagram 3(3) 114
3 Description of function 115
3 1 General 115
3 2 Adjustable settings 115
Setting 115
Std value 115
Min value 115
Max value 115
3 3 Description 115
3 4 Ignition lock S17 in the ON position 116
3 5 The tiller arm in drive position, S10 117
N B ! 117
3 6 Driving, fork direction 118
3 7 Driving, steer wheel direction 119
3 8 Load dependent current limit 120
3 8 1 S59 Activation ranger 120
S59 120
Min (kg) 120
Max (kg) 120
3 9 Reversing/motor brake, fork direction to steer wheel direction 121
3 10 Reversing/motor brake, steer wheel direction to fork direction 121
3 11 Safety reverse function 122
3 12 Lifting the support arms 123
3 13 Lowering the support arms 123
3 14 Lifting the forks 124
3 15 Horn 124
3 16 Platform switch function (option) 125
N B ! Function without platform switch 125
3 16 1 Driving with platform folded up 125
3 16 2 Driving with platform folded down 125
3 16 3 Stepping off the platform whilst driving 126
Electrical system 127
Valid from serial number: 127
T-code 127
Model 127
Serial number 127
Notes 127
1 Electrical panel, components 127
2 List of symbols and electrical diagrams 128
2 1 List of symbols 128
Symbol 128
Description 128
Function 128
Notes 128
2 2 Electrical diagram 1(4) 130
2 3 Electrical diagram 2(4) 131
2 4 Electrical diagram 3(4) 132
2 5 Electrical diagram 4(4) 133
3 Operating description 134
3 1 General 134
3 2 Adjustable settings 134
Setting 134
Std value 134
Min value 134
Max value 134
3 3 Description 134
3 4 Ignition switch S17 in the ON position 135
3 5 Tiller arm in driving position, S10 136
3 6 Driving, direction of the forks 137
Driving permitted Speed 137
Yes 6km/h 137
No 137
No 137
Yes 8km/h 137
No 137
NOTE! 138
3 7 Driving, direction of the steer wheel 139
Driving permitted Speed 139
Yes 6km/h 139
No 139
No 139
Yes 8km/h 139
No 139
NOTE! 140
3 8 Load dependent current limit 141
3 8 1 S59 Activation range 141
S59 141
Min (kg) 141
Max (kg) 141
3 9 Reversing/motor brake, direction of forks to direction of steer wheel 142
3 10 Reversing/motor brake, direction of steer wheel to direction of forks 142
3 11 Safety reversing 143
3 12 Lifting the support arms 144
3 13 Lowering the support arms 144
3 14 Lifting the forks 145
3 15 Horn 145
3 16 Switch operation for the platform and gates 146
1 Driving with the platform raised and without using the gates 146
2 Driving with the platform lowered and using the gates; 8km/h 146
3 Alighting from the platform while driving 147
4 Driving with the platform lowered and without using the gates, or driving with the platform ra 147
3 17 Limited lifting and driving 148
1 Lifting the forks with the platform lowered and using the gates 148
2 When the forks are already over 1 8m and an attempt is made to drive the truck with the platf 148
Electrical system 149
Valid from serial number: 149
T-code 149
Model 149
Serial number 149
Notes 149
1 Electrical panel, components 149
2 List of symbols and electrical diagrams 150
2 1 List of symbols 150
Symbol 150
Description 150
Function 150
Notes 150
2 2 Electrical diagram 1(5) 152
2 3 Electrical diagram 2(5) 153
2 4 Electrical diagram 3(5) 154
2 5 Electrical diagram 4(5) 155
2 6 Electrical diagram 5(5) 156
3 Functional description 157
3 1 General 157
3 2 Description 157
3 3 Ignition key switch S17 in ON position 158
3 4 Tiller arm in drive position, S10 159
3 5 Driving in direction of forks 160
Driving permitted Speed 160
Yes 6km/h 160
No 160
Yes 6 km/h 160
Yes 8km/h 160
No 160
Yes 6 km/h 160
NOTE 161
3 6 Driving in steer wheel direction 162
Driving permitted Speed 162
Yes 6km/h 162
No 162
Yes 6 km/h 162
Yes 8km/h 162
No 162
Yes 6 km/h 162
NOTE 163
3 7 Load dependent current limits 164
3 7 1 S59 Activation area 164
S59 164
Min (kg) 164
Max (kg) 164
3 8 Reversing/motor brakes, fork direction to steer wheel direction 165
3 9 Reversing/motor brakes, steer wheel direction to fork direction 165
3 10 Safety reversing 166
3 11 Support arm lifting 167
3 12 Support arm lower 167
3 13 Fork lift 168
3 14 Horn 168
3 15 Breaker function for platform and gates 169
1 Driving with platform up and without gates being used 169
2 Driving with the platform down and without using the gates 169
3 Driving with platform up and without gates being used 170
4 Brake function when leaving platform 170
3 16 Lifting and driving limits 171
1 Lifting forks with platform down and with gates being used 171
2 When the forks are over 1 8m and an attempt is made to drive the truck with the platform down 171
Voltage/battery indicator/control 173
Valid from serial number: 173
T-code 173
Model 173
Serial No 173
Notes 173
1 General 173
2 Electrical 174
2 1 Voltage 174
2 1 1 The contact voltage and current ratings for switching resistive loads 174
2 1 2 Memory retention 174
3 Battery controller 174
3 1 General 174
3 1 1 Discharge Adjustment 174
SETTING 175
VPC 175
PIN NO: 176
FUNCTION 176
NOTE: 176
NOTE: 176
3 2 Reset 176
3 3 Keyswitch 177
3 4 Hourmeter 177
4 Trouble shooting 177
4 1 Battery Discharge Indicator 177
4 1 1 No reset 177
4 1 2 Always resets after break in power 178
NOTE: 178
4 1 3 No discharge, gauge does not run down 178
4 1 4 No lockout 178
4 1 5 No lift 179
4 1 6 Early lockout 179
4 1 7 LEDs don’t light 179
4 2 Hour meter 180
4 2 1 No display 180
4 2 2 Hour glass icon does not flash 180
4 2 3 Hour meter glass icon always flashes 180
Transistor panel 181
Valid from serial number: 181
T-code 181
Model 181
Serial No 181
Notes 181
1 Transistor panel 181
2 Motor circuit 182
Terminal 182
Connecting 182
3 Control circuit 182
Pin No 182
Connecting 182
Contactor drivers 182
Throttle connections 182
Basic control signals 182
4 Technical specification 183
Parameter 183
Range 183
STD setting 183
Units 183
Description 183
5 Adjustment panel 185
5 1 Adjustable potentiometers 185
5 2 Connection of handheld terminal 185
5 3 Status LED 185
6 Maintenance 186
Note! 186
6 1 Safety 186
WARNING! 186
6 2 Cleaning 186
6 3 Diagnostics and troubleshooting 187
LED code 187
Terminal LCD display 187
Explanation 187
Possible cause 187
Transistor panel 189
Valid from serial number: 189
1 General 189
2 Connections 189
Connection pin 189
Connection 189
3 Control circuit 190
Pin No 190
Connection 190
Contactor driving 190
Connections for throttle 190
Control signals 190
4 Technical specification 191
NOTE! 191
Parameter (Programmer’s display) 191
Ran- ge 191
Std value 191
Unit 191
P/M 191
Description 191
5 Adjustment panel 193
5 1 Adjustable potentiometers 193
NOTE! 193
5 2 Connection for the hand terminal 193
5 3 Status LEDs 193
6 Maintenance 194
NOTE! 194
6 1 Safety 194
WARNING 194
6 2 Cleaning 194
7 Diagnostics and troubleshooting 195
LED code 195
Programmer’s LCD-display 195
Explanation 195
Probable cause 195
8 Curtis 1307 hand terminal 197
Pos 198
Function 198
Notes 198
9 Using the hand terminal 199
9 1 Checking and adjusting parameters 199
NOTE! 200
9 2 Using TEST mode 200
Test value 201
Description 201
9 3 Using DIAGNOSTICS mode 201
NOTE 201
Transistor panel 203
Valid from serial number: 203
T-code 203
Model 203
Serial number 203
Notes 203
1 General 203
1 1 Characteristics and functions 203
2 Connections 204
Connection pin 204
Connection 204
2 1 Connection to the control circuits 205
Pin No 205
Connection 205
Contactor driving 205
Connections for throttle 205
Basic control signals 205
3 Technical specification 206
Range 206
Unit 206
Description 206
4 Parameters 207
Parameter (1307-display) 207
Range 207
Std value 207
Unit 207
Description 207
4 1 Mode 1 and 2 208
5 Diagnostics and trouble shooting 208
5 1 Trouble shooting 208
5 2 Error codes 209
5 2 1 LED indications 209
LED code 209
Programmer’s LCD- display 209
Explanation 209
Probable cause 209
5 3 Testing circuits for error detection 211
6 Maintenance 211
WARNING! 211
6 1 Safety 211
WARNING 211
6 2 Cleaning 212
7 Curtis 1307 hand terminal 212
Connection to Curtis 1207 212
Connection to Curtis 1207A 213
Pos 214
Function 214
Notes 214
8 Using the hand terminal 214
8 1 Using the PROGRAM mode, checking and adjusting parameters 215
NOTE! 216
8 1 1 Using the key MORE INFO in PROGRAM mode 216
8 2 Using SPECIAL PROGRAM mode 216
8 3 Using TEST mode 217
Example 217
Test value 218
Description 218
8 4 Using DIAGNOSTICS mode 219
NOTE 219
8 5 Using SPECIAL DIAGNOSTICS mode 219
Electronic card 221
Valid from serial number: 221
T-code 221
Model 221
Serial number 221
Notes 221
1 General 221
2 Connections and adjustments 222
Position 222
Connections/adjustments 222
3 Connections for inputs and outputs 222
Pin No 222
LED No 222
I/O 222
LSV, LST, LSF Signal name 222
LSR Signal name 222
Function 222
Electronic card 225
Valid from serial number: 225
1 General 225
1 1 Connections and adjustments 226
Position 226
Connections/Adjustments 226
1 2 Connections for inputs and outputs 226
Pin No 226
LED No 226
I/O 226
LSV, LST, LSF 226
Function 226
Signal name 226
Electronic card 229
Valid from serial number: 229
T-code 229
Model 229
Serial number 229
Notes 229
1 General 229
1 1 Components 229
1 2 Connectors and adjustments 230
Position 230
Connectors/adjustments 230
1 3 Connections for inputs/outputs 231
Pin No 231
LED No 231
I/O 231
LS, Signal Name 231
Function 231
1 4 Adjustment of max speed 233
NOTE 233
2 Cleaning/maintenance 234
3 Changing the card 234
Hydraulic/pneumatic system 235
Valid from serial number: 235
T-code 235
Model 235
Serial number 235
Notes 235
1 General 235
2 Hydraulic diagram 237
3 List of symbols 238
Symbol 238
Description 238
Function 238
Notes 238
4 Functional description 239
4 1 Lifting the forks 239
4 2 Lowering the forks 239
4 3 Switch, S59 239
5 Adjustments 240
5 1 Adjustment procedure 240
WARNING 240
Main valve unit lift/reach/tilt 241
Valid from serial number: 241
T-code 241
Model 241
Serial No 241
Notes 241
1 General description 241
Solenoid 241
Function 241
Location 241

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BT LSR 1200 BT LSV 1600 BT LSV 1250 BT LST 1350 BT LSF 1250 PRODUCT FAMILY PS MASTER SERVICE MANUAL:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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