BT LT 2200-6 LT 2200-8 Product Family PT Master Service Manual – PDF DOWNLOAD
DESCRIPTION:
BT LT 2200-6 LT 2200-8 Product Family PT Master Service Manual – PDF DOWNLOAD
Part number:173666-040
Introduction to BT’s Service Manual :
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.
- 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 LT 2200-6 LT 2200-8 Product Family PT Master Service Manual – PDF DOWNLOAD
Master Service Manual Product family PT 1
LT 2200-6 LT 2200-8 1
C-code revision 2 1
Introduction to BT’s Service Manual 3
Contents Master Service Manual (MSM) 5
Valid from serial number: 5
1 Document list 5
1 Truck information 7
Operator’s manual 9
Valid from serial number: 9
1 General 9
1 1 Issued operator’s manuals 9
General product information 11
Valid from serial number: 11
T-code 11
Model 11
Serial No 11
Notes 11
1 Presentation of the truck 11
CAUTION! 12
1 1 Intended application of the truck 12
1 2 Forbidden application of the truck 13
2 Truck data 13
Truck type 13
LT 2200 13
LT 2200-8 13
3 Truck dimensions 14
LT 2200-8 14
LT 2200 15
Item 15
Measurement in mm 15
Item 15
Measurement in mm 15
LT 2200 15
LT 2200-8 15
LT 2200 15
LT 2200-8 15
4 Identification plate CE 16
Item 16
Text 16
Unit 16
5 Identification plate CE + ASME 16
Item 16
Text 16
Unit 16
6 Identification plate ASME 17
Item 17
Text 17
Unit 17
7 Modification plate 17
Item 17
Text 17
8 Main components 18
1 Tiller arm: The truck can be controlled by the operator standing on the rideon platform or wa 18
2 Identification plate: With model designation, serial number, year of manufacture, weight witho 18
3 Protective gates: A higher speed of 9,5 km/h is possible with the gates folded out, while the 18
4 Covers: Easily opened and removable which allows good access when servicing 18
5 Drive unit with brake: Suspended drive unit with two stage electromagnetic brake, drive motor, 18
6 Hydraulic unit: Pump motor, pump, valves and oil tank integrated in a compact unit 18
7 Platform: Folding rideon platform which automatically folds up when not loaded 18
8 Platform switch: Switch for control of the speed range and brake function 18
9 Support castor wheels: Two support castor wheels to ensure stability Fitted with rubber guard 18
10 Electric panel: Can be swung, which provides good access when servicing 24 volt electrical s 18
11 Lift cylinders: Located along the sides of the truck 18
12 Fork carriage: The forks are held horizontal by a link system The fork carriage requires no 18
13 Serial number: Serial number plate fitted to the chassis Partly hidden by the emergency disc 18
14 Emergency disconnector and battery connector: The battery is charged via the permanently fitt 19
15 Battery: 24 V with different Ah values Stands on rollers to facilitate replacement 19
9 Warning and information plates and symbols 20
1 Signal/Horn 20
2 Hydraulic control: Lower 20
3 Hydraulic control: Lift 20
4 Travel direction 20
5 Hydraulic oil filling 20
6 Lifting points 20
7 Serial number 20
8 Identification plate 20
9 Modification plate 20
Technical data 21
Valid from serial number: 21
T-code 21
Model 21
Serial No 21
Notes 21
Model 21
LT 2200 21
Drive motor 21
Transmission/drive gear 21
Wheels 21
Hydraulic system 22
Fuses 22
Batteries 22
Driving speed 22
Lifting-/lowering speed 23
Power consumption 23
Ordering Spare Parts 25
Quality Parts 27
Valid from serial number: 27
T-code 27
Model 27
Serial No 27
Notes 27
1 Issued Quality Parts 27
T-kod 27
Model 27
Serial No 27
Order number 27
Issued 27
Recommended Spare Parts (RSP) 29
Valid from serial number: 29
T-code 29
Model 29
Serial No 29
Notes 29
1 Issued RSP 29
T-code 29
Version 29
Model 29
Serial No 29
Issued 29
Contents, P 31
1 Preventive Maintenance 31
Introduction, maintenance 33
1 Safety regulations with maintenance work 33
WARNING! 33
WARNING! 34
WARNING! 34
NOTE! 34
CAUTION! 34
2 Cleaning and washing 35
NOTE! 35
2 1 External cleaning 35
NOTE! 35
2 2 Cleaning the motor compartment 35
NOTE! 35
2 3 Electrical components 36
NOTE! 36
3 Safe lifting 36
WARNING! 36
Preventive maintenance 37
Valid from serial number: 37
T-code 37
Model 37
Serial No 37
Notes 37
1 Service schedule 37
Pos nr 37
Work to carry out 37
Interval in hours 37
5 37
20 37
80 37
160 37
250 37
500 37
1000 37
Interval in days/weeks/months 37
1d 37
1w 37
1m 37
2m 37
3m 37
6m 37
12m 37
0000 37
Chassis 37
0380 37
Fork carriage 37
1700 37
Motors 37
2550 38
Drive unit 38
3100 38
Brake 38
3500 38
Wheels 38
5110 38
Battery 38
4110 39
Tillerarm 39
4380 39
Steering bearing 39
5000 39
Electrical operations 39
5400 39
Power system driving 39
5700 39
Electronic card 39
6100 39
Hydraulic system 39
6600 40
Lift cylinders 40
2 Lubrication chart 42
Pos no 42
Service point 42
Interval/Running hours 42
Lubricant 42
250h 42
1000h 42
3000h 42
Oil and grease specification 43
Valid from serial number: 43
T-code 43
Model 43
Serial No 43
Notes 43
Lubricant 43
Specification 43
Application area 43
> – 15C 43
< – 15C 43
Contents, S 45
1 Service instructions 45
Electric drive motor 47
Valid from serial number: 47
T-code 47
Model 47
Serial number 47
Notes 47
1 General 47
å 47
1 1 Mechanical construction 48
1 2 Special tools 49
Tool 49
2 Removal/Refitting 49
2 1 Removing the motor from the truck 49
2 2 Re-assembly 51
3 Service/Repairs 52
3 1 Cleaning 52
3 2 Removal of motor 53
3 3 Refitting of motor 54
3 4 Armature bearings 55
3 4 1 Changing the drive end bearing 55
3 4 2 Changing the commutator end bearing 55
3 5 Carbon brushes and brush holder 56
3 5 1 Changing carbon brushes 56
3 6 Commutator 57
3 6 1 Turning the commutator 57
4 Storage/Transport 58
4 1 Storage 58
5 Data 59
Torque 59
Nm 59
Grease specification 59
Component 59
Item 59
Min 59
Max 59
Unit 59
Mechanical drive gear unit 61
Valid from serial number: 61
T-code 61
Model 61
Serial No 61
Notes 61
1 General technical description 61
1 1 Technical data 62
Data 62
Description 62
1 2 Gear components 63
Pos No 63
Component 63
1 3 Special tools 64
Pos No 64
Tool 64
2 Removing the gear from the truck 65
3 Change of seal on the drive shaft 66
4 Reconditioning of the gear 68
Electromagnetic parkingbrake 73
Valid from serial number: 73
T-code 73
Model 73
Serial No 73
Notes 73
1 General 73
2 Function 74
2 1 Releasing the brake 74
2 2 Braking 75
3 Maintenance 76
3 1 Adjustment of gap 76
3 1 1 Adjustment procedure: 76
3 2 Exchange of brake disc/magnetic coil 77
3 2 1 Exchange procedure: 77
3 2 2 Transport securing screws 78
3 3 Check/adjustment of the braking force 79
WARNING! 79
Electrical system 81
Valid from serial numbers: 81
Model 81
Serial number 81
Notes 81
1 Electrical panel 81
2 List of symbols 82
Symbol 82
Description 82
Function 82
Notes 82
2 1 List of symbols for logic card 83
Symbol 83
Description 83
Function 83
Notes 83
3 Electrical diagram 83
3 1 Electrical diagram, standard 1/3 84
3 2 Electrical diagram, EU gates 2/3 85
3 3 Electrical diagram, safety gates 3/3 86
4 Operating description 87
4 1 General 87
4 2 Description 88
4 2 1 Tiller arm in parking position, S17 in OFF position 88
4 2 2 Tiller arm in parking position, S17 in ON position 88
4 2 3 Driving forwards, S15 in ON position 88
4 2 4 Free wheeling 90
4 2 5 Reversing, S16 in ON position 90
4 2 6 Maximum speed 91
4 2 7 Motor braking 92
4 2 8 Safety reversing, S20 in the ON position 92
4 2 9 Load dependent current limiting 93
4 2 10 Forks lifting/lowering 93
4 2 11 Horn 93
Electrical system 95
Valid from serial number: 95
T-code 95
Model 95
Serial number 95
Note 95
1 Electrical panel 95
2 List of symbols 96
Symbol 96
Description 96
Function 96
Notes 96
2 1 Electrical diagram 1/5 98
2 2 Electrical diagram 2/5 99
2 3 Electrical diagram 3/5 100
2 4 Electrical diagram 4/5 101
2 5 Electrical diagram 5/5 102
3 Description of function 103
3 1 General 103
4 Description 103
4 1 Ignition switch S17 in the ON position 103
4 2 Tiller arm in driving position, S10 in the On position 104
4 3 Driving in the fork direction 105
Driving permitted Speed 105
YES 6 km/h 105
NO 105
YES 6 km/h 105
YES 9 5km/h 105
4 4 Driving in the steer wheel direction 106
Driving permitted Speed 106
YES 6 km/h 106
NO 106
YES 6 km/h 106
YES 9 5 km/h 106
4 5 Load dependent current limit 107
4 6 S59 Activation range 108
S59 108
Min (kg) load 108
Max (kg) load 108
4 7 Reverse/motor brake, fork direction to steer wheel direction 108
4 8 Reverse/motor brake, steer wheel direction to fork direction 109
4 9 Safety reversing function 109
4 10 Lifting the forks 110
4 11 Lowering the forks 111
4 12 Horn 111
4 13 Switch operation for the platform and gates 112
4 13 1 Driving with the platform raised and without using the gates 112
4 13 2 Driving with the platform lowered and without using the gates 113
4 13 3 Driving with the platform lowered and using the gates 113
4 13 4 Brake function when alighting from the platform 114
Electrical system 115
Valid from serial number: 115
T-code 115
Model 115
Serial number 115
Notes 115
1 Electrical panel 115
2 List of symbols 116
Symbol 116
Description 116
Function 116
Notes 116
2 1 List of symbols for the logic card A1 117
Symbol 117
Description 117
Function 117
Notes 117
3 Electrical diagrams 118
3 1 Electrical diagram, standard 119
3 2 Electrical diagram, EEC-gates 120
3 3 Electrical diagram, safety gates 121
4 Description of function 122
4 1 General 122
4 2 Ignition switch, S17 ON 122
4 3 Driving 123
4 4 Driving forwards, direction of the forks, first speed stage 123
4 5 Reversing, direction of the drive wheel, first speed stage 124
4 6 Driving forwards or reversing, second speed stage 124
4 7 Driving forwards or reversing, third speed range 125
4 8 Reversing/ motor brake 125
4 9 Safety reversing 126
4 10 Lifting the forks 126
4 11 Lowering the forks 126
Electrical system 127
Valid from serial number: 127
T-code 127
Model 127
Serial number 127
Notes 127
1 Electrical panel 127
2 List of symbols 128
Symbol 128
Description 128
Function 128
Notes 128
2 1 Electrical diagram 1/5 130
2 2 Electrical diagram 2/5 131
2 3 Electrical diagram 3/5 132
2 4 Electrical diagram 4/5 133
2 5 Electrical diagram 5/5 134
3 Description of function 135
3 1 General 135
3 2 Description 135
3 3 Ignition switch S17 in ON position 135
3 4 Tiller arm in driving position, S10 136
3 5 Driving, direction of the forks 137
3 6 Driving, steer wheel direction 138
3 7 Switch function for platform (option) 139
3 7 1 Driving with the platform raised 139
3 7 2 Driving with the platform lowered 139
3 7 3 Alighting from the platform while driving 139
3 8 Load dependent current limit 140
3 9 S59 Activation range 140
S59 140
Min (kg) load 140
Max (kg) load 140
3 10 Reversing/motor brake, fork direction to steer wheel direction 141
3 11 Reversing/motor brake, steer wheel direction to fork direction 141
3 12 Safety reversing function 142
3 13 Lifting the forks 143
3 14 Lowering the forks 143
3 15 Horn 144
Volt-/battery indicator 145
Valid from serial number: 145
T-code 145
Model 145
Serial No 145
Notes 145
1 General 145
2 Electrical 146
2 1 Voltage 146
2 1 1 The contact voltage and current ratings for switching resistive loads 146
2 1 2 Memory Retention 146
3 Battery Controller 146
3 1 General 146
3 1 1 Discharge Adjustment 147
147
SETTING 147
VPC 147
Pin No 148
Function 148
NOTE: 148
NOTE: 148
3 2 Reset 149
3 3 Keyswitch 149
3 4 Hourmeter 149
4 Trouble shooting 150
4 1 Battery Discharge Indicator 150
4 1 1 No reset 150
4 1 2 Always resets after break in power 150
NOTE: 150
4 1 3 No discharge, gauge does not run down 151
4 1 4 No lockout 151
4 1 5 No lift 151
4 1 6 Early lockout 151
4 1 7 LEDs don’t light 152
4 2 Hour meter 152
4 2 1 No display 152
4 2 2 Hour glass icon does not flash 152
4 2 3 Hour meter glass icon always flashes 152
Transistor panel 153
Valid from serial number: 153
T-code 153
Model 153
Serial number 153
Notes 153
1 General 153
1 1 Construction 153
1 2 Operation 154
2 Technical specification 155
Characteristics 155
Value 155
Unit 155
3 Settings and indications 156
Speed 156
S3* 156
S4** 156
Connection pin 23 156
Rotor current 156
Shunt field current 156
S2:s position 156
Ramp time 156
LED No : 156
Colour 156
Normal status 156
Explanation 156
4 Maintenance 157
4 1 Watchdog 157
4 2 Adjusting the current limit 157
4 3 Trouble shooting 158
Possible cause 158
4 4 Main transistor check 158
4 5 Check the transistor regulator’s safety circuit 159
Transistor panel 161
Valid from serial number: 161
T-code 161
Model 161
Serial number 161
Notes 161
1 General 161
1 1 Characteristics and functions 161
2 Connections 162
Connection pin 162
Connection 162
2 1 Connection to the control circuits 163
Pin No 163
Connection 163
Contactor driving 163
Connections for throttle 163
Basic control signals 163
3 Technical specification 164
Range 164
Unit 164
Description 164
4 Parameters 165
Parameter (1307-display) 165
Range 165
Std value 165
Unit 165
Description 165
4 1 Mode 1 and 2 166
5 Diagnostics and trouble shooting 166
5 1 Trouble shooting 166
5 2 Error codes 167
5 2 1 LED indications 167
LED code 167
Programmer’s LCD- display 167
Explanation 167
Probable cause 167
5 3 Testing circuits for error detection 169
6 Maintenance 169
NOTE! 169
6 1 Safety 169
WARNING 169
6 2 Cleaning 170
7 Curtis 1307 hand terminal 171
Pos 172
Function 172
Notes 172
8 Using the hand terminal 173
8 1 Using the PROGRAM mode, checking and adjusting parameters 174
NOTE! 174
8 1 1 Using the key MORE INFO in PROGRAM mode 175
8 2 Using SPECIAL PROGRAM mode 175
8 3 Using TEST mode 176
Test value 177
Description 177
8 4 Using DIAGNOSTICS mode 178
NOTE 178
8 5 Using SPECIAL DIAGNOSTICS mode 178
Electronic card, drive/multi function 179
Valid from serial number: 179
T-code 179
Model 179
Serial number 179
Notes 179
1 General 179
2 Components 179
2 1 Connection/adjustments 180
Position 180
Connection/ adjustment 180
2 2 Connections for inputs and outputs 180
Pin No 180
LED No 180
I/O 180
LT 180
Function 180
Signal name 180
Electronic card drive/multi function 183
Valid from serial number: 183
T-code 183
Model 183
Serial number 183
Notes 183
1 General 183
2 Components 183
2 1 Connections/adjustments 184
Position 184
Connections/adjustments 184
2 2 Connections for inputs/outputs 184
Pin No 184
LED No 184
I/O 184
LT 184
Function 184
Signal name 184
Hydraulic/pneumatic system 187
Valid from serial number: 187
T-code 187
Model 187
Serial number 187
Notes 187
1 General 187
2 Hydraulic chart and list of symbols 188
2 1 List of Symbols 188
Symbol 188
Description 188
Function 188
Notes 188
3 Operating description 189
3 1 Lifting the forks 189
3 2 Lowering the forks 189
3 3 Switch, S59 189
4 Adjustments 190
4 1 Adjusting the pressure limit valve 190
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