BT SL 2.0 Product family SL Master Service Manual 170422-040 – PDF DOWNLOAD

BT SL 2.0 Product family SL Master Service Manual 170422-040 – PDF DOWNLOAD

DESCRIPTION:

BT SL 2.0 Product family SL Master Service Manual 170422-040 – PDF DOWNLOAD

Part number: 170422-040

This Service manual contains product information regarding the current trucks including the technical data and instructions for maintenance and service. It includes the operator’s Instruction Manual, Spare Part Handbook and oil and grease
specifications:
M Machine information
P Preventive maintenance
S Service instructions
O Options

• It is our ambition to send modification notifications concerning improvements to you as soon as possible. It’s stated on the notifications which section/s in the binder should be replaced; note that the HQWLUHsection should be replaced! Notifications should be inserted immediately so that the binder always contains current service information.
• When contacting BT’s technical support always have the actual Service Manual close at hand. If you have any views regarding the Service Manual, please contact your training officer at BT who will forward your views to the technical documentation department.

TABLE OF CONTENTS:

BT SL 2.0 Product family SL Master Service Manual 170422-040 – PDF DOWNLOAD

Master Service Manual Product family SL 1
Introduction to BT’s Service Manual 2
Contents Master Service Manual (MSM) 4
Valid from serial number: 4
T-code 4
Model 4
Serial No 4
Notes 4
1 Document list 4
Section 4
C-code 4
Document 4
Issued 4
Contents, M 6
1 Truck information 6
Operator’s manual 8
Valid from serial number: 8
T-code 8
Model 8
Serial No 8
Notes 8
1 General 8
1 1 Issued operator’s manuals 8
T-code 8
Model 8
Serial number 8
Order number 8
Issued 8
General product information 10
Valid from serial number: 10
T-code 10
Model 10
Serial No 10
Notes 10
1 Presentation of the truck 10
1 1 Intended application of the truck 10
1 2 Forbidden application of the truck 10
2 Truck data 11
Truck type 11
SL 2 0 11
3 Truck dimensions 12
Dimensions (mm) 13
SL 2 0 13
4 Main components 13
1 Control console: Steering, raise/lower, signal, travel direction, accelerator/ brake, and all 13
2 Identification plate: With model designation, serial number, year of manufacture, weight witho 13
3 Serial number: The serial number plate fitted to the chassis 13
4 Cover: Easily swivelled to provide good access for servicing 13
5 Pedal: Safety pedal with automatic parking brake 13
6 Left foot pedal: Safety pedal for the left foot 14
7 Drive motor fuse: 160A, BT part no 29223 14
8 Pump motor fuse: 200A, BT part no 29673 14
9 Control circuit fuse: 10A, BT part no 122308-100 14
10 Fuse for electrical steering wheel: 20A BT part no 122308-200 14
11 Electronics: All the electronics are located together in a protected area of the motor 14
12 Electrical steering motor: Mounted with the drive gear to provide a compact design 14
13 Battery: 24V with different Ah values 14
14 Recharging connector: The battery is recharged via this permanently attached recharging conne 14
15 Hydraulic unit: Pump motor, pump, valve and oil tank 14
16 Drive unit with brake: Drive motor, gears and drive wheel integrated in a compact unit Steer 14
5 Warning and information plates and symbols 16
1 Identification plate 16
2 Modification plate 16
3 Serial number 16
4 Hydraulic oil filling 16
5 Lifting points 16
6 Travel control 16
7 Brake control 16
8 Horn 16
9 Hydraulic control: Lifting/Lowering 16
Technical Service Data 18
Valid from serial number: 18
T-code 18
Model 18
Serial No 18
Notes 18
Model 18
SL 2 0 18
Drive motor 18
Transmission/gear 18
Wheel 18
Hydraulic system 19
Steering motor 19
Fuses 19
Battery 19
Lifting/lowering speed 20
Power consumption 20
Ordering Spare Parts 22
Quality Parts 24
Valid from serial number: 24
T-code 24
Model 24
Serial No 24
Notes 24
1 Issued Quality Parts 24
T-code 24
Model 24
Serial No 24
Order number 24
Issued 24
Content, P 26
1 Preventive Maintenance 26
Introduction, maintenance 28
1 Safety regulations with maintenance work 28
WARNING! 28
WARNING! 29
WARNING! 29
NOTE! 29
CAUTION! 29
2 Cleaning and washing 30
NOTE! 30
2 1 External cleaning 30
NOTE! 30
2 2 Cleaning the motor compartment 30
NOTE! 30
2 3 Electrical components 31
NOTE! 31
3 Safe lifting of the truck 31
WARNING! 31
Service schedule 32
Valid from serial number: 32
T-code 32
Model 32
Serial No 32
Notes 32
1 Maintenance chart 32
Pos no 32
Work to carry out 32
Intervals in hours 32
5 32
20 32
80 32
160 32
250 32
500 32
1000 32
Intervals in Days/Weeks/Months 32
1 D 32
1 W 32
1 M 32
2 M 32
3 M 32
6 M 32
12 M 32
2 Lubrication chart 36
Pos no 36
Service point 36
Interval/Running hours 36
Lubricant 36
Volume 36
250h 36
1000h 36
3000h 36
Oil and grease specification 38
Valid from serial number: 38
T-code 38
Model 38
Serial No 38
Notes 38
Lubricant 38
Specification 38
Application area 38
> – 15C 38
< – 15C 38
Content, S 40
1 Service instructions 40
Electro magnetic brake 42
Valid from machine number: 42
T-code 42
Model 42
Serial No 42
Notes 42
1 General description 42
2 Main components of the brake 43
Pos no 43
Description 43
3 Maintenance 43
4 Adjustment of gap 44
1 Loosen the tension of the three mounting bolts (1) 44
2 Turn the lock nuts (2) anti-clockwise and tighten the bolts slightly while checking the gap in 44
3 Tighten the mounting bolts 25 Nm and recheck the gap with the feeler gauge 44
5 Optimising the brake system 45
5 1 Adjusting the change between the brake stages 45
5 2 Adjusting of the first brake stage 46
5 3 Adjusting of the second brake stage 46
6 Exchange of brake disc 47
6 1 Exchange procedure: 47
1 Disconnect the electrical wires of the brake 47
2 Loosen and remove the three mounting bolts and remove the brake coil 47
3 Replace the brake disc on the hub and make a visual inspection of the wear of the friction pla 47
4 Unwind the lock nuts on the coil at least 6 mm to make sure there is a gap between the coil an 47
5 Mount the coil on the motor end and carry out adjustment of the gap according to section 4 47
6 Reconnect the electrical wiring 47
Electrical systems 48
: 48
T code 48
Model 48
Serial No 48
Notes 48
1 Electrical parts 48
2 List of symbols and electrical wir- ing diagram 49
Symbol 49
Description 49
Function 49
Notes 49
2 1 Electrical wiring diagram (1/5) 51
2 2 Electrical wiring diagram (2/5) 52
2 3 Electrical wiring diagram (3/5) 53
2 4 Electrical wiring diagram (4/5) 54
2 5 Electrical wiring diagram (5/5) 55
3 Functional description 56
3 1 General 56
56
Designation 56
LED number 56
3 2 Key in position 0 57
Designation 57
LED number 57
3 3 Key in position I 57
Designation 58
LED number 58
3 4 Driving in the drive wheel direction 58
Designation 59
LED number 59
3 4 1 Picture 1 59
3 5 Driving in the fork direction 59
Designation 60
LED number 60
3 5 1 Picture 2 60
3 6 Motor braking and reversing 61
3 6 1 Picture 3 61
3 6 2 Picture 4 62
3 7 Braking 62
3 8 Lifting the forks 63
Designation 63
LED number 63
3 9 Lowering the forks 63
Designation 63
LED number 63
3 10 Horn 63
Transistor panel 64
Valid from serial number: 64
T code 64
Model 64
Serial No 64
Notes 64
1 General 64
2 Connectors 65
Connector 65
Function 65
2 1 Logic connector 66
Pin No 66
Connection 66
Contactor, drivers 66
Speed signals 66
Control signals 66
3 Parameters 67
Parameter 67
Area 67
Standard value 67
Unit 67
Explanation 67
3 1 Mode 1 and 2 69
4 Diagnosing and troubleshooting 69
4 1 Display of error codes and error logging 69
4 2 Error codes and troubleshooting 70
STATUS LED 70
Handheld terminal display 70
Explanation 70
Possible cause 70
4 3 Resetting errors 72
Error 72
Reset when 72
5 Maintenance 72
5 1 Safety 72
WARNING! 72
5 2 Cleaning 73
1 Disconnect the regulator from the battery 73
2 Prior to performing any work on the transistor regulator, discharge the capacitors inside the 73
3 Remove all dirt and traces of corrosion from the power terminals Wipe the regulator clean usi 73
6 Technical specifications – Curtis 1243 74
Value 74
Unit 74
Explanation 74
7 1307 Handheld terminal 75
Function 76
Explanation 76
8 Using the handheld terminal 77
8 1 Checking and adjusting parameters 78
NOTE! 78
8 1 1 Using MORE INFO in the PROGRAM MODE 78
8 2 SPECIAL PROGRAM MODE 79
8 3 Using the TEST mode 79
Test value 80
Explanation 80
8 4 Using the DIAGNOSTICS MODE 80
8 5 SPECIAL DIAGNOSTICS MODE 81
Electronic card 82
Valid from machine number: 82
T-code 82
Model 82
Truck No 82
Note 82
1 General description 82
2 Parameter settings 83
Parameter 83
Name 83
Unit 83
Min 83
Max 83
Step 83
Std 83
Description 83
2 1 Setting the battery size/type 84
Parameter value 84
Battery size 84
WARNING! 84
3 Card pin connections and led’s 85
Terminal no 85
LED no 85
Signal name 85
Function 85
4 Error codes 88
Code No 88
Error type 88
Display 88
Effect on the truck 88
Hydraulic/pneumatic system 90
Valid from serial number: 90
T code 90
Model 90
Serial No 90
Notes 90
1 General 90
2 Hydraulic diagram 91
2 1 List of symbols 91
Symbol 91
Designation 91
Function 91
3 Functional description 92
3 1 Lifting the forks 92
3 2 Lowering the forks 92
3 3 Pressure guard S61 92

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