BT PS Series Forklift (LSR, LSV, LST, LSF) Master Service Manual – PDF
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This is the complete Master Service Manual for the BT PS Family of warehouse trucks, covering models LSR 1200, LSV 1600/1250, LST 1350, and LSF 1250. Issued in 1999, this 240+ page guide is the definitive resource for professional technicians. It covers everything from preventive maintenance schedules and oil specifications to deep component repair. Key features include detailed troubleshooting for Curtis 1207/1207A transistor controllers (including LED error codes), electromagnetic brake adjustments, and complete hydraulic system diagrams
Description
BT PS Series Forklift (LSR, LSV, LST, LSF) Master Service Manual – PDF DOWNLOAD
Description
This BT Industries Master Service Manual (MSM) provides comprehensive technical data, service instructions, and maintenance protocols for the PS range of pedestrian and rider-seated stackers. It is essential for diagnosing complex electrical faults in the Curtis 1207/1207A control systems and performing mechanical overhauls on drive units and lift masts.
The manual is logically divided into three primary sections: M (Machine Info), P (Preventive Maintenance), and S (Service Instructions), ensuring quick access to critical data like torque settings, lubricant types, and wiring schematics.
๐ Table of Contents & Key Sections
1. General Information (Section M)
M1: Operator’s Manual & Serial Number Guides.
M4: Technical Data:
Drive Motor: Type TTL 140B-D11, Output 1.4 kW, Brush length min 11mm.
Transmission: Hypoid oil SAE 80W/90 (1.0 Liter).
Wheel Torques: 65 Nm.
M6-M8: Spare Parts Ordering & Recommended Parts Lists.
2. Preventive Maintenance (Section P)
P2: Maintenance Schedule:
Daily, Weekly, Monthly checks (5h, 20h, 80h, 500h, 1000h intervals).
Lubrication Chart: Grease points (Hinges, Bearings) and Oil changes.
P3: Oil and Grease Specifications (Hydraulic Oil ISO-L-HM32, Grease BT 26777).
3. Service Instructions (Section S)
S0: Chassis & Support Arms: Welding instructions for LST 1000/1350 support arms.
S1: Electric Motors:
Pump Motor: Disassembly, brush replacement (min 11mm), and cleaning.
Drive Motor: Armature bearing replacement (HT24 grease), commutator machining.
S2: Drive Gear: Mechanical drive gear unit (Ratio 19.29:1), shim adjustment for pinion height.
S3: Electromagnetic Brake:
Adjustment Procedure: Setting brake force using Allen screws on the magnetic coil (e.g., LS 8km/h: Stage 1 – 5 turns down).
S4: Steering System: Tiller arm servo adjustment and logic card diagnostics.
S5: Electrical System:
Curtis 1207/1207A Controller: Wiring diagrams, parameter setup (Acceleration, Current Limits).
Troubleshooting: Complete list of LED Fault Codes (see below).
S6: Hydraulic System: Functional descriptions, cylinder repair, and hose breakage valve checks.
โ ๏ธ Curtis 1207 Controller Error Codes
The manual provides a detailed diagnostic table for the Status LED flashes:
1,2: HW Failsafe (Panel defective).
1,3: M- Fault (Motor output shorted, or direction contactor not closing).
1,4: SRO Fault (Static Return to Off – Improper sequence of KSI/Brake/Direction).
2,1: Throttle Fault 1 (Wiper fault or 5kฮฉ-0 pot error).
2,3: HPD Fault (High Pedal Disable – Throttle applied before interlock).
3,1: Contactor Driver Overcurrent (Coil or shunt shorted).
3,2: Welded Direction Contactor.
4,1: Low Battery Voltage (<16V).
4,3: Thermal Cutback (>85ยฐC or <-25ยฐC).
๐๏ธ File Details
Manual Name: BT PS Series Master Service Manual
Models Covered: BT LSR 1200, BT LSV 1600, BT LSV 1250, BT LST 1350, BT LSF 1250
Year: 1999-2000 (Revisions included)
Manual PDF Quality: High Quality, Text-Searchable
No. of Pages: 242
