BT W18 W20 Service Manual 178825-040 – PDF DOWNLOAD
DESCRIPTION:
BT W18 W20 Service Manual 178825-040 – 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.
SAFETY REGULATION WITH MAINTENANCE WORKS :
Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work.
• Do not carry out any maintenance work on the truck unless you have the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water makes the floor slippery
TABLE OF CONTENTS:
BT W18 W20 Service Manual 178825-040 – PDF DOWNLOAD
Contents 1 3
Technical data 2 – 1 3
Introduction Maintenance 3 – 1 3
Safety regulations with maintenance work 1 3
Cleaning and washing 3 3
Safe lifting 4 3
Maintenance, Lubrication schedule 4 – 1 3
Maintenance schedule 1 3
Lubrication schedule 7 3
Oil and grease specification 5 – 1 3
Tools 6 – 1 3
Super Seal connectors 1 3
Electric drive motor 7 – 1 3
Component parts 1 3
Service/Repairs 4 3
Technical data 6 3
Drive unit/gear 8 – 1 3
Component parts 2 3
Leakage from top cover 4 3
Changing of the drive shaft’s sealing ring 4 3
Electro magnetic brake 9 – 1 4
Main components of the brake 1 4
Maintenance 2 4
Steering 10 – 1 4
Component parts, tiller arm 1 4
Adjustments 4 4
Tiller arm handle 5 4
Electrical systems 11 – 1 4
Electrical parts 1 4
List of symbols and electrical wiring diagram 3 4
Functional description 11 4
Hour meter 13 4
Fault codes 13 4
Parameters 18 4
Part numbers 27 4
Transistor panel 27 4
Diagnostic and troubleshooting 28 4
Technical specifications – Curtis 1243 30 4
Hydraulic system 12 – 1 4
Hydraulic chart and list of symbols 1 4
Adjustments W18 2 4
Adjustments W20 4 4
Battery charger (Inbuilt) 13 – 1 5
General 1 5
Charging 1 5
Troubleshooting and service 1 5
Technical data 2 5
Charging settings 3 5
Control/computer equipment 14 – 1 5
General 1 5
Connection 1 5
Layout 2 5
Function 4 5
Specifications 12 5
Technical data 2 7
Model 7
W18 7
W20 7
Introduction Maintenance 3 11
Safety regulations with maintenance work 11
WARNING! 11
WARNING! 12
WARNING! 12
NOTE! 12
CAUTION! 12
Cleaning and washing 13
NOTE! 13
External cleaning 13
NOTE! 13
Cleaning the motor compartment 13
NOTE! 13
Electrical components 14
NOTE! 14
Safe lifting 14
WARNING! 14
Maintenance, Lubrication schedule 4 15
Maintenance schedule 15
Pos No 15
Work to carry out 15
Lubrication schedule 21
Pos No 21
Service point 21
Interval/Operating hours 21
Type of lubricant 21
Oil and grease specification 5 23
Pos 23
Type of lubricant 23
Specification 23
Application 23
Tools 6 25
Super Seal connectors 25
Figure 25
Number 25
Application 25
AMP connectors 26
Figure 26
Number 26
Application 26
Other tools 27
Figure 27
Number 27
Application 27
Electric drive motor 7 29
Component parts 29
Pos 29
Description 29
Note 29
Dismantling of motor from truck 30
Assembling 31
Service/Repairs 32
Dismantling of motor 32
Assembling of motor 33
Cleaning 33
Technical data 34
Type of machine 34
W18 34
W18/20 34
Drive unit/gear 8 35
Component parts 36
Pos 36
Description 36
Note 36
Technical data 37
Type of truck 37
W18/20 P20 37
Leakage from top cover 38
Changing of the drive shaft’s sealing ring 38
Dismantling 38
Assembling 39
Electro magnetic brake 9 41
Main components of the brake 41
Maintenance 42
Basic Adjustment of gap 42
Exchange of brake disc 42
Steering 10 45
Component parts, tiller arm 45
Serial number 364690AA-W18- 432799AA/ W20- 432864AA 45
Serial number 364690AA-W18- 432799AA/ W20- 432864AA 46
Pos 46
Description 46
Note 46
Serial number W18- 432800AA-/ W20- 432865AA- 47
Serial number W18- 432800AA-/ W20- 432685AA- 47
Pos 47
Description 47
Note 47
Adjustments 48
Adjusting of brake microswitch 48
Tiller arm handle 49
Pos 49
Description 49
Note 49
Dismantling/Assembling 51
NOTE! 51
Change from ignition key to keyboard (2) 51
Remove the keyboard (2) on the tiller arm 51
Changing of signal button/switch (9, 10) 52
Changing of lift/lowering button (13) 53
Changing of pushbutton (16) 53
Electrical systems 11 55
Electrical parts 55
List of symbols and electrical wiring diagram 57
Symbol 57
Description 57
Function 57
Notes 57
Electrical diagram – Serial number 59
364690AA- W18- 4322799AA/ W20- 432865AA 59
Electrical diagram 1(5)- 60
Serial number W18- 432800AA-/ W20- 432865AA- 60
Electrical diagram 2(5)- 61
Serial number W18- 432800AA-/ W20- 432865AA- 61
Electrical diagram 3(5)- 62
Serial number W18- 432800AA-/ W20- 432865AA- 62
Electrical diagram 4(5)- 63
Serial number W18- 432800AA-/ W20- 432865AA- 63
Electrical diagram 5(5)- 64
Serial number W18- 432800AA-/ W20- 432865AA- 64
Functional description 65
Starting the truck 65
Driving speed £ 6 km/h 65
Neutral speed reduction 65
Picture 3 65
Neutral speed reduction on slopes 66
Braking 66
Lifting the forks 66
Lowering the forks 66
Horn 66
Hour meter 67
Fault codes 67
Code 67
C19 67
Code 67
C20 67
Code 68
C29 68
Code 68
C31 68
Code 68
C41 68
Code 68
C42 68
Code 68
C43 68
Code 69
E101 69
Code 69
E104 69
Code 69
E106 69
Code 69
E107 69
Code 69
E108 69
Code 69
E110 69
Code 70
E140 70
Code 70
E141 70
Code 70
E150 70
Code 70
E151 70
Code 70
E157 70
Code 70
E159 70
Code 71
E160 71
Code 71
E200 71
Code 71
E201 71
Code 71
E202 71
Code 71
E214 71
Parameters 72
NOTE ! 72
Driver parameters 73
Serial number 364690AA- W18- 432799AA/ W20- 432864AA 73
Parameter 73
Name 73
Unit 73
Min 73
Max 73
Step 73
Std 73
Description 73
Parameter description 73
Parameter 2 73
Parameter 3 73
Parameter 4 73
Parameter 5 73
Driver parameters 74
Serial number W18- 432799AA-/ W20- 432864AA- 74
Parameter 74
Name 74
Unit 74
Min 74
Max 74
Step 74
Std 74
Description 74
Parameter description 74
Parameter 1 74
Parameter 2 74
Parameter 3 74
Parameter 4 74
Parameter 5 75
Service parameters 75
Parameter 75
Name 75
Unit 75
Min 75
Max 75
Step 75
Std 75
Description 75
Parameter description 76
Parameter 10 76
Parameter 14 76
Parameter 20 76
Parameter 21 76
Value 77
Function 77
Battery (Ah) 77
WARNING ! 77
Parameter 25 77
Parameter 28 — Serial number W18- 432800AA- / W20- 432865AA- 78
Parameter 39 78
Parameter 40 — Serial number 364690AA- W18- 432799AA / W20- 432864AA 78
Service indication — Serial number W18- 432800AA- / W20- 432865AA- 78
Flashing symbol 78
Displayed data 78
Segment 79
Function 79
Segment 79
Function 79
Segment 80
Function 80
Segment 80
Function 80
Part numbers 81
Transistor panel 81
General 81
Diagnostic and troubleshooting 82
Error codes and troubleshooting 82
STATUS LED 82
Handheld terminal display 82
Explanation 82
Possible cause 82
Resetting errors 83
Error 83
Reset when 83
Safety 83
WARNING! 83
Technical specifications – Curtis 1243 84
Value 84
Unit 84
Explanation 84
Hydraulic system 12 85
Hydraulic chart and list of symbols 85
List of Symbols 85
Pos No 85
Description 85
Function 85
Remarks 85
Adjustments W18 86
Adjusting the pressure limit valve 86
1 Locking nut Use special tool, see drawing in chapter “Tools” 86
2 Adjuster screw, pressure limit Adjusting clockwise results in increased pressure Adjusting a 86
3 Pressure limit valve Use special tool, see drawing in chapter “Tools” 86
Tools 87
Adjustments W20 88
Adjusting the pressure limit valve 88
1 Locking nut 88
2 Adjuster screw, pressure limit Adjusting clockwise results in increased pressure Adjusting a 88
Battery charger (Inbuilt) 13 89
General 89
Charging 89
Troubleshooting and service 89
Technical data 90
Charging settings 91
Freely ventilated batteries 91
Switch 91
Batterysize 91
Output current 91
I2 current 91
Max current maintenance 91
Valve regulated batteries 91
Switch 91
Batterysize 91
Output current 91
I2 current 91
Max current maintenance 91
Control/computer equipment 14 93
General 93
Connection 93
Layout 94
Main window 94
Nodes 94
14 0 1 Icons 95
Icon 95
Description 95
Tool buttons 95
Information window 96
Status bar 96
Function 96
Connection 96
Disconnection 97
Downloading program 97
14 0 1 Normal downloading 98
14 0 2 Downloading in old versions of logic card 98
14 0 3 Emergency downloading 98
NOTE! 98
Truck report 99
Parameters 100
NOTE! 100
Diagnostics 101
NOTE! 101
14 0 1 Analogue 101
14 0 2 Temperature 102
NOTE! 102
14 0 3 Digital 102
Other functions 103
14 0 1 Save to file 103
14 0 2 Download from file 103
14 0 3 Reset CAN adapter 103
14 0 4 Delete error code log 103
14 0 5 Reset hour meter 103
14 0 6 Read error code log 103
14 0 7 Adjust date and time 103
NOTE! 103
14 0 8 Adjusting the hour meter on older cards 104
Help 104
14 0 1 About TruckCom 104
Exit 104
Specifications 104
CAN interface 104
Installation 105
To uninstall 105
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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