BT IXION S10 12 12S S12F 16D Service Guide Manual 202179-040 - PDF DOWNLOAD

Service Guide IXION S10/12/12S, S12F/16D Valid from serial number: 425801AA-

Order number: 202179-040 Issued: 2002-01-22 ITS

© BT Industries AB

GB

C-code Version 001

2

© BT Europe AB

T-code 700-702 Date 2002-01-22

Valid from serial number 425801AAOrder number 202179-040

Service Manual IXION S10/12/12S, S12F/16D Approved by: L-G Andersson

Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code Version 001

Contents Electrical systems

.................................................. 5

1 Component identification ...................................... 15 2 List of symbols ......................................................... 17 3 Error codes and troubleshooting ......................... 19 4 Fault codes .............................................................. 20 5 Parameters .............................................................. 22 6 Part numbers ........................................................... 27

Hydraulic diagram and components

.... 29

1 Main components ................................................... 29

Tightening torque .................................................. 33 2 Basic Adjustment of gap ....................................... 34

Oil and grease specification Preventive maintenance

........................ 35

.................................. 37

1 Maintenance schedule .......................................... 37 2 Lubrication schedule .............................................. 42

Lifting points

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............................................................. 43

Service Manual IXION S10/12/12S, S12F/16DApproved by: L-G Andersson 3

C-code Version 001

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© BT Europe AB

T-code 700-702 Date 2002-01-22

Valid from serial number 425801AAOrder number 202179-040

Service Manual IXION S10/12/12S, S12F/16D Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 5000 Version 001

Electrical systems Electrical diagram S10/12, S12S 1(5)

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Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson

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S10/12, S12S 2(5)

6

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

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S10/12, S12S 3(5)

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S10/12, S12S 4(5)

8

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 5000 Version 001

S10/12, S12S 5(5)

© BT Europe AB

Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson

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Electrical diagram S12F, S16D 1(5)

10

© BT Europe AB

Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

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S12F, S16D 2(5)

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S12F, S16D 3(5)

12

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 5000 Version 001

S12F, S16D 4(5)

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Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson

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S12F, S16D 5(5)

14

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

1 S17 X41

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Component identification S10 S21

X5 Y1

X1 F50

M3

F51 F1

P2 Y34 Y52 P1 Y41

R1 K10 F3 K30 A1

M1

H1

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A17

16

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

2 Symbol

Description

A1

Transistor regulator

A2

Electronic card

A6

Display

A17

T-code 700-702 Date 2002-01-22

List of symbols Function

Notes

Keypad

PIN-number login

Option

F1

Fuse

Drive motor circuit

125 A

F3

Fuse

Pump motor circuit

125 A

F 50

Fuse

Operating circuit A5

7,5 A

F 51

Fuse

Operating circuit A1

7,5 A

F 52

Fuse

Optional equipment

Option

G1

Battery

H1

Horn

K10

Contactor

Main contactor

K30

Contactor

Pump motor

A2:S1-S9 A2:S10-S18

Speed control

Forwards/Reverse

M1

Motor

Drive motor

M3

Motor

Pump motor

P1

Pressure switch

Pressure switch support arm lift

70 bar

P2

Pressure switch

Pressure switch fork lift

120 bar

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Symbol

Description

Function

Notes

R1

PTC-resistor

Power supply

15 Ohm

S111

Switch

Option

S112

Switch

Option

S113

Switch

Turtle button

S114

Switch

Option

S115

Switch

Option

S116

Switch

Option

S10

Switch

Travel brake

S17

Switch

Key

S18

Switch

Horn button

A2:S17

Switch

Safety reversing

A2:S19

Switch

Fork lifting

A2:S20

Switch

Fork lowering

S21

Switch

Emergency switch off

A2:S21

Switch

Support arm, lifting

A2:S22

Switch

Support arm, lowering

S32

Switch

Lift height limiting, 1.6 m

S33

Switch

Lift height limiting

S90

Switch

Lift height limiting

Y1

Brake

Y34

Magnetic valve

Forks

Y41

Magnetic valve

Fork lowering

Y52

Magnetic valve

Support arm lifting

X1

Connector

Battery

X41

Connection point

CAN-communication

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Service Manual S10/12/12S, S12F/16D

Brake lever

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Error codes and troubleshooting

WARNING! Risk of short-circuiting.

Serious burns and damage to equipment can occur in the event of short-circuiting.

Remove all watches, jewellery and always use insulated tools only.

STATUS LED

Handheld terminal display

Explanation

Possible cause

LED off

-

No voltage or defective regulator

Burnt fuse, bad contact, not connected, defective regulator

LED on

-

Defective regulator

Defective regulator

1,1

¤¤

CURRENT SHUNT FAULT

Built-in current shunt defective

Armature current sensor fault in motor controller.

1,2

¤ ¤¤

HW FAILSAFE

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

1,3

¤ ¤¤¤

M- SHORTED

Internal M- short to B-

Problem with switch transistor in armature circuit inside motor controller.

3,1

¤¤¤ ¤

CONT COIL/FLD SHORT

Too high current for contactor feeding or shorted field winding

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault.

3,3

¤¤¤ ¤¤¤

FIELD OPEN

Open field winding

Shuntfield open, harness broken, motor controller defect.

4,1

¤¤¤¤ ¤

LOW BATTERY VOLTAGE

Low battery voltage

1. Battery voltage <17 volts 2. Corroded battery terminals 3. Loose battery or regulator connections

4,2

¤¤¤¤ ¤¤

OVERVOLTAGE

Overvoltage

1. Battery voltage > 33 volts

4,3

¤¤¤¤ ¤¤¤

THERMAL CUTBACK

Over-/under-temperature reduction

1. Temp. >85oC or < - 25oC 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions

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Fault codes

• Press S18 and turn S17 to “on” at the same time.

• Press S18 until you read E= fault codes.

• By choose E the symbol “E” will be highlighted to indicate what’s currently shown on display.

• The last 50 fault codes will be stored. The latest fault will be shown first. The display first show the error code and then wich hour the fault occured.

• The fault codes are devided into two groups C = caution and E = error.

• The C will not be stored. It’s only a caution and will be highlighted on display as long as the fault exists.

• If you for example only have one fault registerd in memory the second empty place will be shown like this: Fault : E - - - and time : ----.

Code

Description

Possible fault reason

C19

Default parameter warning

Parameter area is probably corrupt.

Default values have been down loaded, i.e special parameter settings must be restored.

C20

Butterfly warning

Problem with butterfly sensor.

Butterfly may have been activated during start up or faulty sensor.

C28

Emergency switch warning

Emergency switch activated No voltage supply to motor controller.

Harness problem.

C29

Service time warning

Time to make service Service counter not reset after latest service

C41

Battery undervoltage warning

Battery voltage < 17 volts Battery parameter not correct adjusted Time to charge battery

C42

Battery overvoltage warning

Battery voltage > 33 volts Fully charged battery and regenerative braking

C43

Power amplifier thermal cutback

Too intensive driving Defect motor controller

E101

Motor controller does not correspond with the type of truck

Check that the right type of motor controller is fittedk

E104

Brake switch transistor shorted

Defect motor controller Check the cables and magnetic coil to the brake

20

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 5000 Version 001

Code

Description

Possible fault reason

E106

Digital output or field over current

Attempt to drive more current than specified from outputs.

Problem to regulate field currrent.

Internal controller fault

E107

Contactor off

Problem with main contactor tips or cabling (open circuit).

Contactor control wire not connected.

Contactor drive output in controller faulty (off)

E108

Contactor welded

Main contactor tips welded.

Contactor drive output in controller faulty (on)

E110

System error

Possible fault in the motor controller. Restart the machine

E140

Checksum error

Internal microcontroller fault (tiller head), faulty software or pcb.

E141

Software problem

Internal microcontroller fault (tiller head), faulty software or pcb.

E150

Drive communication error

Broken CAN-cable.

Motor controller broken

E151

Drive communication Tx error

Motor controller does not answer, bad connections or faulty motor controller

E157

Bus off error

CAN-bus problem, harness or hardware problem

E159

Over flow error

CAN-bus problem, harness or hardware problem

E160

Error in safety reversing

Critical sensor element faulty

E200

Field open

Shuntfield open, harness broken, motor controller defect

E201

M minus error

Problem with switch transistor in armature circuit inside motor controller

E202

Power amplifier sensor error

Armature current sensor fault in motor controller

E214

Power amplifier CAN-timeout

Motor controller reports unexpected loss of data flow from tiller head

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Parameters

• Press S18 and turn S17 to on at the same time.

• Press S18 until you read P= parameters.

A

• You have now choosen P=parameters the symbol “C” on display will be highlighted to indicate what’s currently shown on display.

• Scroll to the parameter you want to change or look at by pressing the speed control up or down.

E

D

C

B

• Press S18 ones to get access to the parameter.

• Set parameter value by pressing the speed control up or down.

• Press S18 ones to confirm change.

• Turn S17 to off.

You have now completed a parameter change and the next time you start the truck the new parameter setting will be valid.

NOTE !

Truck handling.

Modifying specific truck parameters will change the driving characteristics of the truck.

Do not change any parameters without the necesarry know-how.

22

© BT Europe AB

Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 5000 Version 001

5.1 Driver parameters Parameter

Name

Unit

Min

Max

Step

Std

Description

1

Speed, turtle button

%

40

100

5

90

Speed, turtle button 40: low speed 100: full speed

02

Max speed

%

40

100

5

100

Max speed 10:low Speed 100:full Speed

03

Acceleration

10

100

5

70

10:low acceleration 100:full acceleration

04

Neutral speed reduction

5

100

5

50

Defines motor speed reduction force when lever goes to neutral position.

5: low reduction force 100: full reduction force

05

Logg off

0

20

1

0

The time until the truck will be switched off when a key pad is used. Time is counted from when the latest power consumer is used

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5.2 Service parameters • Connect CAN-key in X41 • Choose parameter

Parameter

Name

10

Unit

Min

Max

Step

Std

Description

PIN code

0

9999

1

0

Possibility to state up to 10 PIN codes (10 different drivers)

14

Creep speed

-10

10

1

0

This defines how much output the controller gives when you reach the first speed sensor.

-10 : low speed when reaching first speed sensor 10: high speed when reaching first speed sensor

20

Hour meter selection

1

5

1

2

Select wich hour meter

21

Battery size

1

20

1

8

Battery size selection

25

Service interval

0

2000

50

100

Possible to set servicetimer

28

Button option

1

3

1

1

State what button button should be used for lifting/ lowering

39

Access code

1

4

1

1

Defines what access level service personnel will have to parameters.

1h

Parameter 21 You must give data about with wich battery the truck is equipped.

To adjust the disconnection point of the battery discharge indicator meassure according to : • Acid concentration when fully charged battery. To check quality of battery. Shall be between 1,27-1,29.

When you get lift cut out (80 % discharged of battery capacity) you shall have close to 1,14 not less.

24

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Electrical systems Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 5000 Version 001

Service display • Connect the CAN key in X41 and start the machine.

A

• The battery status is displayed and the symbol “D” is lit continually.

• Press S18 to choose display mode.

E

D

C

B

See table below.

Flashing symbol

Displayed data

B

Speed reference value sent to Curtis.

C

Digital inputs to Curtis and hallelements. * See explanation below

BC

Battery voltage (V)

D

Armature current (A)

BD

Field current (A)

CD

PWM Armature in %

BCD

Status Curtis

*They are displayed by high lighting segments of three of the figures (A).

• The most significant figure active (marked with arrow).

• Power amplifier inputs.

A

T

E

D

C

B

Segment

Function

A

S32, input A1:13. No lifting limit

B C

P2, input A1:15. Pressure switch fork lift

D

S10, input A1:12

E

P1, input A1:10. Pressure switch support arm liftt Note! S12F, S16D only

F

S42, input A1:11. Manual lowering of the forks

G

S10, input A1:5

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$ )

A *

( '

% & '3

• The second most significant figure active (marked with arrow).

• Power amplifier outputs.

Segment

Function

A

Y41, output A1:9 Sänkventil

B C

Y34, output A1:2. Lifting/lowering-valve forks

D

Y52, output A1:3. Lifting/lowering-valve support arm lift Note! S12F, S16D only

E

K10, output A1:4

F

H1, output A1:7

G

Y1 , output A1:5

DP

K30, output A1:6

• The third most significant figure active (marked with arrow) • Digital input from control sensors.

Segment

Function

A B C

26

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D

Forks up

E

Forks down

F

Support arms up

G

Support arms down

DP

Horn

Service Manual S10/12/12S, S12F/16D

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Electrical systems Valid from serial number 425801AAOrder number 202179-040

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• The fourth most significant figure active (marked with arrow).

A

E

D

C

B

Segment

Function

A

Extra function 6

B

Extra function 5

C

Extra function 4

D

S113 Turtle button

E

Extra function 2

F

Extra function 1

G DP

6

Part numbers

• Press S18 and turn S17 to “on” at the same time.

A

• Press S18 until you Pn= partnumbers.

• You have now choosen Pn= part numbers the symbol “D” on display will be highlighted to indicate what’s currently shown on display. In the start the Pn = part number complete unit will be shown.

E

D

C

B

• By scrolling with the speed control you can get the following information: • SPn= Software part number.

• HPn= Hardware part number.

• HSn= Hardware serial number.

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Electrical systems C-code 5000 Version 001

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© BT Europe AB

T-code 700-702 Date 2002-01-22

Service Manual S10/12/12S, S12F/16D

Valid from serial number 425801AAOrder number 202179-040

Approved by: L-G Andersson

Hydraulic diagram and components Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 6000 Version 001

Hydraulic diagram and components S10/12, S12S

1

3

C

2

B A

D

E

P

F

F

1

© BT Industries AB

Main components

Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Hydraulic Unit

A = Non return valve B = Lowering valve, manual C = Lowering valve, el D = Overflow valve E = Flow control valve F = Filter M = Pump motor P = Pump

3

Tryckvakt

Load >750 kg Speed = 5,3 km/h

Service Manual S10/12/12S, S12F/16D

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Hydraulic diagram and components C-code 6000 Version 001

T-code 700-702 Date 2002-01-22

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S12F, S16D n

2

4

1

G J

3

H

K

C

B A E D P

F

F

1.1 Main components

30

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Pos No

Description

Remark

1

Lift Cylinders

Fork lift

2

Lift Cylinders

Support arm lift

3

Hydraulic Unit

A = Non return valve B = Lowering valve, manual C = Lowering valve, el D = Overflow valve E = Flow control valve F = Filter M = Pump motor P = Valve

Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Hydraulic diagram and components Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code 6000 Version 001

Pos No

Description

Remark

4

Pressure switch

G = Support arm lift Load >750 kg Speed = 5,3 km/h H = Fork lift Load = 750 kg Speed = 5,3 km/h J = Valve, support arm lift K = Valve, fork lift

1.2 Description 1.2.1 Lift When the pump motor starts, the oil flows through the non return valve to the lift cylinders.

1.2.2 Lowering When the lowering valve is actuated by the lowering lever on the chassis, or the lowering button on the tiller arm, the valve opens to allow the oil in the pressure lines to return to the oil tank. The lowering speed can be regulated by the movement of the lowering lever on the chassis. Lowering using the button on the tiller arm gives a constant lower speed.

1.2.3 Operating pressure The operating pressures at rated load are: • S 10: 150 bar.

• S12: 180 bar.

• S12S: 190 bar.

• S 12F: 191 bar • S 16D: 191 bar

1.2.4 Relief valve The relief valve opens at the following pressures: • S10: 170 bar.

• S12: 200 bar • S12S: 210 bar.

• S 12F: 220 bar • S 16D: 190 bar

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Hydraulic diagram and components C-code 6000 Version 001

T-code 700-702 Date 2002-01-22

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1.2.5. Pressure switch The pressure switch is used to regulate the speed and is influenced by the load. It only has an off/on operation.

Load > 750 kg. Speed = 5,3 km/h Load < 750 kg. Speed = 6,0 km/h.

32

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Service Manual S10/12/12S, S12F/16D

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Tightening torque Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code Version 001

Tightening torque

2 3 4 5

6

01

7 8

24

9 27

25 26

10 11

28

13 12 14 32 29

15

18

16

30

31

19

17 20

23 21

22

Pos

Description

Amount Dimension Tightening Procedure torque

7

Nut

1

12 16

70 Nm

Lock with punch mark

Screw

26,6 Nm

Lock with LOCTITE 242

Nut

300 Nm

Lock with punch mark

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Tightening torque C-code Version 001

T-code 700-702 Date 2002-01-22

Valid from serial number 425801AAOrder number 202179-040

Pos

Description

Amount Dimension Tightening Procedure torque

20

Screw

26,6 Nm

Lock with LOCTITE 242

21

Screw

26,6 Nm

Lock with LOCTITE 242

26

Nut

30 Nm

Lock with LOCTITE 603

28

Nut

4

26,6 Nm

Lock with LOCTITE 242

Screw, drive wheel

5

65 Nm

2

Basic Adjustment of gap 5,5 Nm

0,2

34

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Service Manual S10/12/12S, S12F/16D

Approved by: L-G Andersson

Oil and grease specification Gäller från maskinnr 425801AABeställningsnr 202179-040

T-kod 700-702 Datum 2002-01-22

C-kod Version 001

Oil and grease specification Lubticant

Specification

Application area

> - 15°C

< - 15°C

A

Grease

BT 26777 (Spray)

BT 26777 (Spray)

Bearings and bushings

B

Hydraulic oil

ISO-L-HM32

ISO-VG32

Hydraulic system

C

Transmission oil

Hypoidolja SAE 80W/90

Hypoidolja SAE 75W

Gears

D

Grease

BT 26778 (Spray)

BT 26778 (Spray)

Chains and wires

F

Grease

BT 055-70111

BT 055-74320

Side shift forks

G

Grease

Staburags NBU 8EP

Staburags NBU 8EP

Steering bearings

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Servicemanual S10/12/12S,S12F/16DGodkänd av: L-G Andersson

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Oil and grease specification C-kod Version 001

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T-kod 700-702 Datum 2002-01-22

Servicemanual S10/12/12S,S12F/16D

Gäller från maskinnr 425801AABeställningsnr 202179-040

Godkänd av: L-G Andersson

Preventive maintenance Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code Version 001

Preventive maintenance 1

Maintenance schedule

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

0000.

Chassis

0000.1

Check all links and locking pins

I

0000.2

Check wear on cover/battery locking

I

0000.3

Check of cracking and damage

I

0000.4

Check the drive housing’s mounting on the chassis

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0380.

Fork carriage

0380.1

Check for crack formation and damage

I

0380.2

Check clearance in bushes and links

I

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

2550

Drive gear

2550.1

Check for leakage

2550.2

Check the oil level. Measured using the screwed in dipstick

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in steering bearing

I

2550.5

Change the oil in the drive gear

© BT Industries AB

T

I/T1

I/T

T2 I I3

L4

I

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Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson

37

Preventive maintenance C-code Version 001

T-code 700-702 Date 2002-01-22

Valid from serial number 425801AAOrder number 202179-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

3100.

Brake

3100.1

Clean and check functionality

3100.2

Check the brake disc

M

3100.3

Check the clearance in disengaged position 0,2-0,5 mm

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts (New wheel: Drive tread thickness = 30mm) (Tightening torque = 65Nm)

I/T

3500.3

Check that the castor wheel turns and rotates freely

I

3500.4

Check for wear on the castor wheel (New wheel:Drive tread thickness = 10mm)

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

5000

Electrical functions

5000.1

Check the function of the brake microswitch

I

5000.2

Check the function of the collision safety switch

I

5000.3

Check the function of the horn

I

5000.4

Check for wear to cables in the tiller arm

5000.5

Check the function of the driver’s control

I

I

5000.6

Check the error code log and operating times

I

I

38

© BT Industries AB

C

I

I I

I

I I

Service Manual S10/12/12S,S12F/16D

Approved by: L-G Anddersson

Preventive maintenance Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code Version 001

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

5110

Battery

5110.1

Check the electrolyte level, 10-15 mm over the cell plates

M

5110.2

Check connections to battery, truck and charger

I

5110.3

Check that the cell and pole guards are undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on display

6000

Hydraulic system

6000.1

Check hoses and connections for leakage

I

6000.2

Check hoses for wear and damage

I

6000.3

Check the oil tank for cracks, leakage and damaged mountings

I

6000.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

© BT Industries AB

I

C/T

TI I

I

I L5

L

Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson

39

Preventive maintenance C-code Version 001

T-code 700-702 Date 2002-01-22

Valid from serial number 425801AAOrder number 202179-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos. No.

Work to carry out Interval in hours - may vary due to application

5

20

80

500

1000

3000

Interval in days/weeks/months - may vary due to application

1d

1w

1m

6m

12m

36m

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

7100

Lifting Mast

7100.1

Check for damage and crack formation

I

7100.2

Re-tighten tha mast mounting bolts (Tightening torque =197N m)

T

7100.3

Check the play of the inner section rollers

I

7100.4

Check the lateral play of the inner section

I

7100.5

Check for wear on the lifting chains and chain rollers

I

7100.6

Check the adjustment of the lifting chains

I

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm. 3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months 5 = The oil is changed and the filter cleaned for the first time after 80 h/ 1 month, and then every 1000 h/12 months When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

40

© BT Industries AB

Service Manual S10/12/12S,S12F/16D

Approved by: L-G Anddersson

Preventive maintenance Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code Version 001

© BT Industries AB

Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson

41

Preventive maintenance C-code Version 001

2 Pos no

T-code 700-702 Date 2002-01-22

Valid from serial number 425801AAOrder number 202179-040

Lubrication schedule

Service point

Interval/Running hours 500h

1000h

Lubricant

3000h

1

Wheel bearings

L

2

Mast beam

L

F

3

Lifting chains

L

D

4

Hydraulic system

C

5

Steering Bearings

6

Drive gear

O

B

L

G

C

L = Lubrication

A

O C = Check

C O = Oil change

42

© BT Industries AB

Service Manual S10/12/12S,S12F/16D

Approved by: L-G Anddersson

Lifting points Valid from serial number 425801AAOrder number 202179-040

T-code 700-702 Date 2002-01-22

C-code Version 001

Lifting points • Lift the truck from the marked lifting points when using a lifting device.

WARNING! Risk of overturning.

The truck can overturn if it is lifted from the wrong lifting points.

Always lift the truck from the marked lifting points.

• Lift from the truck’s centre of gravity when using another fork lift truck.

WARNING! Risk of overturning.

The truck can overturn if it is lifted incorrectly.

Always lift the truck secured to, and with the centre of gravity between, the lifting truck’s forks.

© BT Europe AB

Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson

43

Lifting points C-code Version 001

44

© BT Europe AB

T-code 700-702 Date 2002-01-22

Service Manual S10/12/12S, S12F/16D

Valid from serial number 425801AAOrder number 202179-040

Approved by: L-G Andersson