Service Guide GB

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

Valid from serial number: 425801AA-

Order number: 202179-040

Issued: 2002-01-22 ITS

© BT Industries AB
 C-code T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

2 © BT Europe AB Service Manual IXION S10/12/12S, S12F/16D Approved by: L-G Andersson
 Valid from serial number T-code C-code
425801AA- 700-702
Order number Date Version
202179-040 2002-01-22 001

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

Preventive maintenance .................................. 37

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

Lifting points ............................................................. 43

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

 C-code T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

4 © BT Europe AB Service Manual IXION S10/12/12S, S12F/16D Approved by: L-G Andersson
 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

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

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 5

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

S10/12, S12S 2(5)

6 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

S10/12, S12S 3(5)

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 7

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

S10/12, S12S 4(5)

8 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

S10/12, S12S 5(5)

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 9

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

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 T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

S12F, S16D 2(5)

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 11

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

S12F, S16D 3(5)

12 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

S12F, S16D 4(5)

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 13

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

S12F, S16D 5(5)

14 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

1 Component identification

S17 S10

X41
S21
X5

Y1
X1
F50
M3
F51
F1
R1 P2
Y34
K10
Y52
F3 P1
Y41
K30
A1

H1 M1

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 15

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

A17

16 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

2 List of symbols
Symbol Description Function Notes
A1 Transistor regulator
A2 Electronic card
A6 Display
A17 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 24 V

H1 Horn

K10 Contactor Main contactor

K30 Contactor Pump motor

A2:S1-S9 Speed control Forwards/Reverse

A2:S10-S18

M1 Motor Drive motor

M3 Motor Pump motor

P1 Pressure switch Pressure switch support arm 70 bar

lift
P2 Pressure switch Pressure switch fork lift 120 bar

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 17

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

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 Brake lever
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

18 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

3 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 ter- Explanation Possible cause

minal display
LED off - No voltage or defec- Burnt fuse, bad contact, not con-
tive regulator nected, defective regulator
LED on - Defective regulator Defective regulator
1,1 ¤¤ CURRENT Built-in current shunt Armature current sensor fault in
SHUNT FAULT defective motor controller.
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in
B- armature circuit inside motor control-
ler.
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current for Attempt to drive more current than
SHORT contactor feeding or specified from outputs.
shorted field winding 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 Low battery voltage 1. Battery voltage <17 volts
VOLTAGE 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-temper- 1. Temp. >85oC or < - 25oC
CUTBACK ature reduction 2. Truck overloaded
3. Wrong installation of transistor reg-
ulator
4. Operation under extreme condi-
tions

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 19

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

4 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
C101 Motor controller does not corre- Check that the right type of motor controller is fittedk
spond with the type of truck
C104 Brake switch transistor shorted Defect motor controller
Check the cables and magnetic coil to the brake

20 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

Code Description Possible fault reason

C106 Digital output or field over cur- Attempt to drive more current than specified from out-
rent puts.
Problem to regulate field currrent.
Internal controller fault
C107 Contactor off Problem with main contactor tips or cabling (open cir-
cuit).
Contactor control wire not connected.
Contactor drive output in controller faulty (off)
C108 Contactor welded Main contactor tips welded.
Contactor drive output in controller faulty (on)
C110 System error Possible fault in the motor controller. Restart the
machine
C140 Checksum error Internal microcontroller fault (tiller head), faulty soft-
ware or pcb.
C141 Software problem Internal microcontroller fault (tiller head), faulty soft-
ware or pcb.
C150 Drive communication error Broken CAN-cable.
Motor controller broken
C151 Drive communication Tx error Motor controller does not answer, bad connections or
faulty motor controller
C157 Bus off error CAN-bus problem, harness or hardware problem
C159 Over flow error CAN-bus problem, harness or hardware problem
C160 Error in safety reversing Critical sensor element faulty
C200 Field open Shuntfield open, harness broken, motor controller
defect
C201 M minus error Problem with switch transistor in armature circuit
inside motor controller
C202 Power amplifier sensor error Armature current sensor fault in motor controller
C214 Power amplifier CAN-timeout Motor controller reports unexpected loss of data flow
from tiller head

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 21

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

5 Parameters
• Press S18 and turn S17 to on at the same time.
A • Press S18 until you read P= parameters.
• 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 charac-
teristics 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 T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

5.1 Driver parameters

Parameter Name Unit Min Max Step Std Description

1 Speed, % 40 100 5 90 Speed, turtle button
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 5 100 5 50 Defines motor speed
reduction reduction force when
lever goes to neutral
position.
5: low reduction force
100: full reduction
force
05 Logg off 1min 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 con-
sumer is used

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 23

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

5.2 Service parameters

• Connect CAN-key in X41
• Choose parameter

Parameter Name Unit Min Max Step Std Description

10 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 1 5 1 2 Select wich hour meter
selection
21 Battery size 1 20 1 8 Battery size selection
25 Service inter- 1h 0 2000 50 100 Possible to set service-
val timer
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.

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 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

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

A • Power amplifier inputs.

T

Segment Function
A S32, input A1:13. No lifting limit
B
E D C 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
DP

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 25

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

$
• The second most significant figure active (marked with arrow).
) A %
* • Power amplifier outputs.

( &
'3 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
D Forks up
E Forks down
F Support arms up
G Support arms down
DP Horn

26 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
425801AA- 700-702 5000
Order number Date Version
202179-040 2002-01-22 001

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

A Segment Function
A Extra function 6
B Extra function 5
C Extra function 4
E D C B
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 dis-
play will be highlighted to indicate what’s currently shown on dis-
play. In the start the Pn = part number complete unit will be shown.
• By scrolling with the speed control you can get the following infor-
E D C B
mation:
• SPn= Software part number.
• HPn= Hardware part number.
• HSn= Hardware serial number.

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 27

 Electrical systems
C-code T-code Valid from serial number
5000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

28 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Hydraulic diagram and components
Valid from serial number T-code C-code
425801AA- 700-702 6000
Order number Date Version
202179-040 2002-01-22 001

Hydraulic diagram and components

S10/12, S12S

C
2
B
A

D E

P F
F

1 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

© BT Industries AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson 29

 Hydraulic diagram and components
C-code T-code Valid from serial number
6000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

S12F, S16D
n

2 1

4 G H
J K

3 B C
A

E
D

P
F
F

1.1 Main components

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

30 © BT Industries AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Hydraulic diagram and components
Valid from serial number T-code C-code
425801AA- 700-702 6000
Order number Date Version
202179-040 2002-01-22 001

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 chas-
sis, 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

© BT Industries AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson 31

 Hydraulic diagram and components
C-code T-code Valid from serial number
6000 700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

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 © BT Industries AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Tightening torque
Valid from serial number T-code C-code
425801AA- 700-702
Order number Date Version
202179-040 2002-01-22 001

Tightening torque

3
4
5

6
01

7
8
24
9

25 27
10 26
11
28

13
12 14
32
31
30
15 29

19
18

17
16

20
23
21 22

Pos Description Amount Dimension Tightening Procedure

torque
7 Nut 1 70 Nm Lock with punch mark
12 Screw 26,6 Nm Lock with LOCTITE 242
16 Nut 300 Nm Lock with punch mark

© BT Europe AB Service Manual S10/12/12S, S12F/16DApproved by: L-G Andersson 33

 Tightening torque
C-code T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 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 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson

 Oil and grease specification
Gäller från maskinnr T-kod C-kod
425801AA- 700-702
Beställningsnr Datum Version
202179-040 2002-01-22 001

Oil and grease specification

Lubticant Specification Application area
> - 15°C < - 15°C
A Grease BT 26777 BT 26777 Bearings and bushings
(Spray) (Spray)
B Hydraulic oil ISO-L-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoidolja Hypoidolja Gears
SAE 80W/90 SAE 75W
D Grease BT 26778 BT 26778 Chains and wires
(Spray) (Spray)
F Grease BT 055-70111 BT 055-74320 Side shift forks
G Grease Staburags Staburags Steering bearings
NBU 8EP NBU 8EP

 

© BT Europe AB Servicemanual S10/12/12S,S12F/16DGodkänd av: L-G Andersson 35

 Oil and grease specification
C-kod T-kod Gäller från maskinnr
700-702 425801AA-
Version Datum Beställningsnr
001 2002-01-22 202179-040

36 © BT Europe AB Servicemanual S10/12/12S,S12F/16D Godkänd av: L-G Andersson

 Preventive maintenance
Valid from serial number T-code C-code
425801AA- 700-702
Order number Date Version
202179-040 2002-01-22 001

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. Work to carry out
No. Interval in hours - may vary due to application 5 20 80 500 1000 3000
Interval in days/weeks/months - may vary due 1d 1w 1m 6m 12m 36m
to application
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 T
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 I/T1 I/T
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 T2
1700.5 Check for abnormal noise in bearing I
2550 Drive gear
2550.1 Check for leakage I3 I
2550.2 Check the oil level. Measured using the screwed in I
dipstick
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steering I
bearing
2550.5 Change the oil in the drive gear L4 L

© BT Industries AB Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson 37

 Preventive maintenance
C-code T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to application 5 20 80 500 1000 3000
Interval in days/weeks/months - may vary due 1d 1w 1m 6m 12m 36m
to application
3100. Brake
3100.1 Clean and check functionality C
3100.2 Check the brake disc M
3100.3 Check the clearance in disengaged position M
0,2-0,5 mm
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tightening I/T
torque on bolts
(New wheel: Drive tread thickness = 30mm)
(Tightening torque = 65Nm)
3500.3 Check that the castor wheel turns and rotates I
freely
3500.4 Check for wear on the castor wheel I
(New wheel:Drive tread thickness = 10mm)
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I
5000 Electrical functions
5000.1 Check the function of the brake microswitch I I
5000.2 Check the function of the collision safety switch I
5000.3 Check the function of the horn I I
5000.4 Check for wear to cables in the tiller arm I
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 Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson

 Preventive maintenance
Valid from serial number T-code C-code
425801AA- 700-702
Order number Date Version
202179-040 2002-01-22 001

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to application 5 20 80 500 1000 3000
Interval in days/weeks/months - may vary due 1d 1w 1m 6m 12m 36m
to application
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over the cell M
plates
5110.2 Check connections to battery, truck and charger I
5110.3 Check that the cell and pole guards are undam- I
aged
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 I
5400 Power system
5400.1 Cleaning and checking of mounting in chassis C/T1 C/T
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 TI
5700.2 Check all segments on display I
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 dam- I
aged mountings
6000.4 Check that the oil level is correct I I
6100.5 Change the oil and clean the filter L5 L

© BT Industries AB Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson 39

 Preventive maintenance
C-code T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours - may vary due to application 5 20 80 500 1000 3000
Interval in days/weeks/months - may vary due 1d 1w 1m 6m 12m 36m
to application
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 T
(Tightening torque =197N m)
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 roll- I
ers
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 eve-
ry 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 speci-
fied above.

40 © BT Industries AB Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson

 Preventive maintenance
Valid from serial number T-code C-code
425801AA- 700-702
Order number Date Version
202179-040 2002-01-22 001



 







 





 

© BT Industries AB Service Manual S10/12/12S,S12F/16D Approved by: L-G Anddersson 41

 Preventive maintenance
C-code T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

2 Lubrication schedule
Pos no Service point Interval/Running hours Lubricant
500h 1000h 3000h
1 Wheel bearings L A
2 Mast beam L F
3 Lifting chains L D
4 Hydraulic system C O B
5 Steering Bearings L G
6 Drive gear C O C

L = Lubrication C = Check 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 T-code C-code
425801AA- 700-702
Order number Date Version
202179-040 2002-01-22 001

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 T-code Valid from serial number
700-702 425801AA-
Version Date Order number
001 2002-01-22 202179-040

44 © BT Europe AB Service Manual S10/12/12S, S12F/16D Approved by: L-G Andersson