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Valid from serial number: 425801AA-
Order number: 202181-040

Issued: 2002-01-07 ITS
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7HFKQLFDOGDWD ............................................................ 7
,QWURGXFWLRQ0DLQWHQDQFH.............................. 11
1 Safety regulations with maintenance work .................. 11
2 Cleaning and washing ................................................. 13
3 Safe lifting .................................................................... 14
3UHYHQWLYHPDLQWHQDQFH.................................. 15
1 Maintenance schedule ................................................ 15
2 Lubrication schedule ................................................... 20
2LODQGJUHDVHVSHFLILFDWLRQ ........................ 21
7RROV ................................................................................. 23
1 Super Seal connectors ................................................ 23
(OHFWULFGULYHPRWRU ............................................. 27
1 Component parts ......................................................... 27
2. Service/Repairs ........................................................... 30
3 Technical data ............................................................. 32
'ULYHXQLWJHDU.......................................................... 33
1 Component parts ......................................................... 34
2 Leakage from top cover ............................................... 36
3 Changing of the drive shaft’s sealing ring .................... 36
© BT Europe AB Service Manual IXION S12F, S16D Approved by: L-G Andersson 3
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(OHFWURPDJQHWLFEUDNH..................................... 39
1 Main components of the brake .................................... 39
2 Maintenance ................................................................ 40
6WHHULQJ .......................................................................... 43
1 Component parts, tiller arm ......................................... 43
2 Adjustments ................................................................. 44
3 Tiller arm handle .......................................................... 45
(OHFWULFDOV\VWHPV................................................. 49
1 Component identification ............................................. 49
2 List of symbols and electrical
wiring diagram 51
3 Functional description .................................................. 58
4 Hour meter ................................................................... 60
5 Fault codes .................................................................. 60
6 Parameters .................................................................. 65
7 Part numbers ............................................................... 74
8 Transistor panel ........................................................... 75
9 Diagnostic and troubleshooting ................................... 76
10 Technical specifications – Curtis 1243 ........................ 78
+\GUDXOLFV\VWHP ................................................... 79
1 Hydraulic diagram and components ............................ 79
%DWWHU\FKDUJHU,QEXLOW................................... 81

1 General ........................................................................ 81
1 Charging ...................................................................... 81
2 Troubleshooting and service ....................................... 82
3 Technical data ............................................................. 82
4 Charging settings ......................................................... 83
4 © BT Europe AB Service Manual IXION S12F, S16D Approved by: L-G Andersson
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425801AA- 702
202181-040 2002-01-07 001
&RQWUROFRPSXWHUHTXLSPHQW ..................... 85
1 General ....................................................................... 85
2 Connection .................................................................. 85
3 Layout ......................................................................... 86
4 Function ...................................................................... 88
5 Specifications .............................................................. 97
© BT Europe AB Service Manual IXION S12F, S16D Approved by: L-G Andersson 5
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702 425801AA-
001 2002-01-07 202181-040
6 © BT Europe AB Service Manual IXION S12F, S16D Approved by: L-G Andersson
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Type TSL140S-DS30 TSL140S-DS30
Output, kW 1.2 1.2
Duty cycle S2, 60 min S2, 60 min
Minimum carbon brush length, mm 13 13
Nominal commutator diameter, mm 50 50
Minimum commutator diameter, mm 47 47
Resistance, shunt field winding, Ω at 25 C° 0.49 0.49
Resistance armature winding, Ω at 24 °C 0.0156 0.0156
Insulation resistance between the windings >=1 Mohm >=1 Mohm
and motor casing
Weight, kg 14 14
%URPV
Type BFK457-08 BFK457-08
Braking force, Nm 12 12
Output, W 25 25
Resistance coil, Ω 23 23
Nominal play in actuated position, mm 0.2-0.4 0.2-0.4
Minimum thickness brake disc, mm 5.5 5.5
Thickness of a new brake disc, mm 7.0 7.0
7UDQVPLVVLRQGULYHJHDU
Type 2-stage angle trans- 2-stage angle trans-
mission mission
Gear ratio 19,14:1 19,14:1
Oil volume, litre 1.0 1.0
Oil type Hypoid oil Hypoid oil
at normal temperature SAE 80W/90 SAE 80W/90
at temperature < -15oC SAE 75W SAE 75W
© BT Industries AB Service Manual S12F, S16D Approved by: L-G Andersson 7

7HFKQLFDOGDWD
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Drive wheel, mm Dia 215x70 Dia 215x70
Axle pressure without load, kg 345 345
Axle pressure at rated load, kg 345 345
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm
Support arm wheel, mm Dia 80x75 Dia 80x75
Axle pressure without load, kg (Ah) 2 x 270 (240) 2 x 220 (240)
Axle pressure at rated load, kg (Ah) 2 x 1310/1640 (240) 2 x 1195/1515 (240)
Support castor wheels, mm Dia 125 x 50 Dia 125 x 50
Axle pressure without load (Ah) 2 x 355 (240) 2 x 328 (240)
Axle pressure at rated load, kg 2 x 520/590 (240) 2 x 553/633 (240)
+\GUDXOLFV\VWHP
Output, kW 2.2 2.2
Duty cycle,% 5 5
Minimum carbon brush length, mm 12 12
Minimum commutator thickness/diameter, 4.75 4.75
mm
Pressure at rated load, bar 191 191
Overflow pressure, bar 220 190
Pump flow, litre/minute 5.0 5.0
Tank volume, litre 4.5 4.5
Oil type: Hydraulic oil Hydraulic oil
at normal temperature ISO-L-HM32 ISO-L-HM32
at temperature < -15oC ISO-L-HV32 ISO-L-HV32
)XVHV
Drive motor circuits, A 125 125
Pump motor circuits, A 125 125
Control circuits, A 7,5 7,5
8 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Andersson

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202181-040 2002-01-07 001
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Dimensions LxWxH, mm 180 Ah 196 x 643 x 452 196 x 643 x 452
240 Ah 196 x 643 x 572 196 x 643 x 572
Capacity, Ah 180 -320 180 -320
Weigh, kg 150 -250 150 -250
'ULYLQJVSHHG
Without load, 0 - 750 kg, km/h 6,0 6,0
With rated load, 750 - 1200 kg, km/h 5.3 5.3
With rated load, 1200 - 1600 kg, km/h 4.4 4.4
support arms
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Lift without load, m/s 0.19 0.19

Lift with rated load, m/s 0.10 0.11
Lowering without load, m/s 0.15 0.15
Lowering with rated load, m/s 0.19 0.19
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Driving without load, A 23 23
Driving with rated load, A 36 36
Lift without load, A 54 54
Lift with rated load, A 148 148
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With rated load 10 % 10 %
0HDVXUHPHQW/
Medium 796 813
Long 848 865
Turning radius WA 1685 1786
:HLJKW
Truck without battery, Medium 735 655
© BT Industries AB Service Manual S12F, S16D Approved by: L-G Andersson 9

7HFKQLFDOGDWD
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10 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Andersson

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202181-040 2002-01-07 001
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 require-
ments.
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 situa-
tions. The following running times have been used when calcu-
lating 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 serv-
ice 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.
6DIHW\UHJXODWLRQVZLWK
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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
• Never wear loose objects or jewellery when working on the
truck
:$51,1*
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© BT Industries AB Service Manual S12F, S16D Approved by: 11

702 425801AA-
001 2002-01-07 202181-040
• Always disconnect the battery by pulling out the battery isola-

tor when carrying out maintenance work on the truck unless
otherwise stated in this Service Manual
• Always switch off the truck’s power supply before opening the
covers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on
the truck’s hydraulic system
• Use paper or a rigid sheet of cardboard when checking for oil
leakage. 1HYHU use your hand
• Bear in mind that the oil in the transmission or the hydraulic
system can be hot
:$51,1*
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• Only fill the hydraulic system with new and clean oil
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• Store and dispose of changed oil in accordance with local
directives
• Do not release solvents and the like, which are used for
cleaning/washing, into drains that are not intended for this
purpose. Follow the local directives that apply for disposal
• Disconnect the battery when welding on the truck
127(
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• Remove at least 100 mm of paint around the welding/grinding
area through sand-blasting or the use of a paint stripper when
welding or grinding on painted surfaces
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12 © BT Industries AB Service Manual S12F, S16D Approved by:

425801AA- 702
202181-040 2002-01-07 001
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Cleaning and washing of the truck is important to ensure the
truck’s reliability.
• Carry out general cleaning and washing weekly
127(
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• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable con-
centration
• Rinse off loose grime using tepid water
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• Cover the electric motors, connections and valves before
washing
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• Clean the motor compartment using a well-known degreasing
agent, diluted to a suitable concentration
• Rinse off loose grime using tepid water
© BT Industries AB Service Manual S12F, S16D Approved by: 13

702 425801AA-
001 2002-01-07 202181-040
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• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors,
connections, solenoid valves, etc. using a damp cloth and a
cleaning agent
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All lifting must be carried out on a flat, non-slip and firm surface.
Avoid new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving
during the lift. If the lift applies to the brake wheel, chock the
other wheels so that the truck stands still
• Select a lifting point so that the lift is as easy as possible (one
corner at a time). If the truck has marked lifting points on the
under side of the chassis these can be used to obtain a well
balanced lift
• Ensure that the surface under the jack is clean and free from
oil and grease
• Ensure that your hands and the jack’s lever are free from oil
and grease
• Use the lever that belongs to the jack. A lever that is too short
requires more force than is necessary. If the lever is too long
there is a risk of the jack being overloaded
• Support the truck:
- as close as possible to the part of the chassis that is to be
lifted. This reduces the risk of the truck tipping over
- so that the truck cannot roll
• 1HYHU lift up the jack in order to lift higher
• 1HYHU work under a lifted truck unless it is well supported
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14 © BT Industries AB Service Manual S12F, S16D Approved by:

3UHYHQWLYHPDLQWHQDQFH
425801AA- 702
202181-040 2002-01-07 001
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I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary
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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 T
chassis
0000.5 Check finger guard I
0000.6 Check signs and stickers I
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0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
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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
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2550.1 Check for leakage I3 I
2550.2 Check the oil level. Measured using the I
screwed in 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 S12F, S16D Approved by: L-G Anddersson 15

702 425801AA-
001 2002-01-07 202181-040

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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
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3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tighten- I/T
ing 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)
7LOOHUDUP
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I
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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
16 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson

425801AA- 702
202181-040 2002-01-07 001

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5110.1 Check the electrolyte level, 10-15 mm over the M
cell 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
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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
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5700.1 Check connectors and cables TI
5700.2 Check all segments on display I
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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
5
6100.5 Change the oil and clean the filter L L

702 425801AA-
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6600.1 Check for leakage I
6600.2 Check the mountings I
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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 I
rollers
7100.6 Check the adjustment of the lifting chains I
= The connections are re-tightened for the first time after 80 h, and
then every 1000 h/12 months.
= The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm.
= Check for leakage in conjunction with the first oil change.
= The oil is changed for the first time after 80 h/1 month, and then eve-
ry 3000 h/36 months
= 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.

425801AA- 702
202181-040 2002-01-07 001


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K K K
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


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!& &
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 S12F, S16D Godkänd av: L-G Andersson 21

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159232 Tool for application of pins/
sleeves
159229 Tool for release of lock (1)
159230 Tool for application of secondary

locking 2-pole (2)
159231 Tool for application of secondary

locking 4-pole (2)
159228 Tool for removal of pins/sleeves

(3)
© BT Industries AB Service Manual Ixion S12F, S16D Approved by: L-G Andersson 23
7RROV
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31-151080 Tool for removal of pins/sleeves
1=163787 Tool for application of sleeves

2=163788
1
2
1=163789 Tool for application of pins
2=163790 1: For 0.2-0.5 mm2
3=163791 2: For 0.5-1.0 mm2
3: For 1.5-2.5 mm2
24 © BT Industries AB Service Manual Ixion S12F, S16D Approved by: L-G Andersson
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202181-040 2002-01-07 001
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156263 Service instrument (CAN)
1=163793 Service instrument for

2=163792 program modification
1=155619-001 1= Service instrument for Curtis

2=166161 transistor panel
3=166473 2= Cable for Curtis 1243 and
1207A
When ordering 3= Cable for Curtis 1207
155619-001 both
cables are
received
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702 425801AA-
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08-13022 Puller, drive gear
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202181-040 2002-01-07 001
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1 Screw M6x25
2 Bearing shield
3 Locking ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20
8 Carbon brush
9 Rotor
10 Key
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1760 702 425801AA-
001 2002-01-07 202181-040

11 Plug
12 Stator
13 Cable
14 Cable
15 Bearing shield
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Locking ring
21 Locking ring
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• Switch off the truck and pull out the battery plug.
• Remove the covers for the motor compartment.
• Release the cables for the motor and tiller arm.
• Unscrew the four nuts for the attachment of the motor to the
drive gear.
• Loosen the cables for the key switch and emergency switch.
Pull out all the cables from the cover’s cable duct.
• Loosen the cover over the motor compartment and the tiller
arm’s mounting from the motor. Remove the cover over the
motor compartment together with the tiller arm.
• Carefully lift the motor straight up, without damaging the seal-
ing surfaces to the drive gear and place the motor on a clean
surface.
• Protect the drive gear from impurities by covering over its
opening in an appropriate manner, e.g. with a piece of plastic.
The requisite service and repair of the motor can now be carried
out.
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425801AA- 702 1760
202181-040 2002-01-07 001
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• Assembling is carried out in the reverse order.
• Carefully lift down the motor in the drive gear to avoid damag-
ing the seals and gear wheels.
• Tighten the nuts on the studs to the prescribed torque,
26.6 Nm.
• Fit and adjust the brakes as per the instructions. Screw tight
the cover and tiller arm, and connect the cables that were pre-
viously removed. Check that the polarity is correct.
• The function of the brakes should be checked before the truck
is moved.
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001 2002-01-07 202181-040
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21
20
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15 10
12
11 8
7
6
5
4
3
1
2
• Release the brake disc’s companion flange by first removing

the locking ring together with the washer in the end of the rotor
shaft. The companion flange can now be lifted off. It may be
necessary to unclamp it with an appropriate tool.
• Remove the four plugs that cover the carbon brushes, move
the springs on the carbon brushes to one side and pull out the
carbon brushes.
• Dismantle the commutator end’s bearing shield (2) together
with the carbon brush bridge (5) and carbon brushes (8) by un-
screwing the eight screws (1). Now put down the motor with a
firm resting point against the edge of the bearing shield, and
carefully tap on the rotor shaft’s end with a rubber mallet.
• Dismantle the drive end’s bearing shield (15) together with the
rotor (9). Make sure not to damage the motor windings when
the rotor is removed from the motor housing.
(OHFWULFGULYHPRWRU
425801AA- 702 1760
202181-040 2002-01-07 001
• After dismantling the motor’s bearing shields and removing the

rotor from the motor housing, the gear wheel in the rotor’s
drive end is removed. This is done by unscrewing the nuts on
the gear wheel and then pulling the gear wheel off with a puller.
Note that the gear wheel is locked with Loctite to the rotor
shaft.
• Now release the inner locking ring together with the underlying
washer. Pull out the rotor shaft from the bearing (18).
• Release the outer locking ring together with its washer, and re-
move the bearing from the bearing shield.
• Remove the bearing shield’s seal (17) and carefully clean the
bearing shield.
• Fit a new seal in the bearing shield.
$VVHPEOLQJRIPRWRU
Assemble the motor in the reverse order.
• Carefully check that the rotor can move freely in the direction
of rotation and that the carbon brushes are flush with the com-
mutator.
• Check the motor’s insulation resistance (between respective
winding and the motor housing). For a new motor this should
lie between 2 - 3 Mohm. When a used motor has been ex-
posed to impurities an insulation resistance down to approx. 1
Mohm is acceptable.
• Fit a new O-ring in the drive shaft end’s bearing shield and a
new seal on the collar of the bearing shield.
&OHDQLQJ
An extremely critical factor to ensure correct functioning of the
motor is that it is kept as clean as possible. The motor and the
motor compartment must be regularly checked for dust, oil, and
other impurities.
A vacuum cleaner with an appropriate nozzle can be used to
clean the motor if the motor windings and inner compartment are
dry Compressed air can be used in combination with a vacuum
cleaner. In which case the compressed air must be clean and dry.
A cloth of non-fluffing material should be used if the windings
have a coating. The cloth can also be moistened with a grease-
dissolving, organic and volatile detergent that does not damage
the windings. Use detergent sparingly to avoid it penetrating into
the parts of the motor.
(OHFWULFGULYHPRWRU
1760 702 425801AA-
001 2002-01-07 202181-040
Residual detergent should be removed with an appropriate sol-

vent, if it leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to
use a solvent that is sprayed onto the parts. It is important that the
detergent is applied in a way to prevent dirt from penetrating into
the parts of the motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is
done then the rotor must always be dried with the application of
heat. There must be adequate ventilation during the drying proc-
ess, and the drying should continue until a number of measure-
ments of the insulation resistance provide equivalent and
approved results.
7HFKQLFDOGDWD
7\SHRIPDFKLQH 6)6'
Type TSL140S-DS30
Output (kW) 1,2
Intermittence S2 60 min.
Minimum length of carbon brush (mm) 11
Minimum commutator diameter (mm) 47
Resistance, shunt field winding Ω at 26 C° 23,31
Resistance, armature winding,Ω at 26C° 0,0156
Insulation resistance between windings and >= 1Mohm
motor housing
Weight (kg) 14
'ULYHXQLWJHDU
425801AA- 702 2550
202181-040 2002-01-07 001
'ULYHXQLWJHDU
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
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2550 702 425801AA-
001 2002-01-07 202181-040
&RPSRQHQWSDUWV

01 Drive gear complete
2 Air valve
3 Cover
4 Dip stick
5 Washer
6 Gasket
7 Nut Tightening torque 70 Nm
Locked with punch mark
8 Washer
9 Gear wheel Primary gear
10 Conical roller
bearing
11 Shims
12 Screw Top cover and gear housing
Tightening torque 26.6 Nm
Lock with Loctite 242
13 Shims
14 Conical roller
bearing
15 Pinion/ Crown gear Cog clearance 0.09-0.15 mm
Pretension bearing with 2-5/100
Stamped size on pinion adjusted
with shims
17 Shims
18 Conical roller
bearing
19 Shims
20 Screw Bottom cover and gear housing
'ULYHXQLWJHDU
425801AA- 702 2550
202181-040 2002-01-07 001

21 Screw Bottom cover and gear housing
22 Cover
23 Gasket
24 Gear wheel Motor gear
25 Washer
27 Screw Motor and gear housing
28 Nut Tightening torque 26.6 Nm
29 Conical roller
bearing
30 Shims
31 Seal
32 Drive shaft
7HFKQLFDOGDWD
7\SHRIWUXFN 6)6'
Type of gear 2-step angle gear
Gear ratio 14,20:1
Oil volume, litres 1,75
Oil type Hypoid oil
Viscosity, normal temperature SAE 80W90
Viscosity, <-15°C SAE 75W
'ULYHXQLWJHDU
2550 702 425801AA-
001 2002-01-07 202181-040
/HDNDJHIURPWRSFRYHU
'LVPDQWOLQJ
• Lift up the truck, and block up to ensure that it is stable.
• Unscrew the drive wheel.
• Unscrew the M8 nuts (28), that hold the gear and motor, with a
box wrench. Support the gear so that it does not drop.
• Release the M8 bolts (12), that hold the cover (3), with a 6 mm
hex socket wrench.
• Change the gasket (6).
$VVHPEOLQJLVFDUULHGRXWLQWKHUHYHUVHRUGHU
• Tighten the four M8 bolts and the four M8 nuts to a torque of
26.6 Nm Lock with Loctite 242.
• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.
&KDQJLQJRIWKHGULYHVKDIW¶V
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The drive shaft’s sealing ring can be changed with the gear
mounted in the truck.
Follow the instructions below if oil is leaking from the drive shaft.
'LVPDQWOLQJ
• Unscrew the drive wheel 1).
• Remove the lower cover and drain off the oil (22).
• Release the drive shaft nut. Remove the nut and washer
(16,17).
• Carefully tap out the drive shaft with a brass drift and hammer
(32).
• Pull off the bearing from the drive shaft with tool 08-13022 (29).
• Check that the bearing washers are not damaged. If they have
been damaged by the puller tool, measure the total thickness
of the shim washers and change them before assembling (30).
• Remove the sealing ring from the drive shaft (31).
'ULYHXQLWJHDU
425801AA- 702 2550
202181-040 2002-01-07 001
$VVHPEOLQJ
Assembling of the gear after changing the drive shaft’s sealing
ring is carried out in the reverse order to dismantling.
Pay special attention to the following during assembling:
• Fill the sealing ring with grease after fitting it on the drive shaft.
• Make sure that only undamaged shim washers with the same
total thickness as the originals are put on the drive shaft.
• Press the bearing on the drive shaft and make sure not to
damage the bearing’s shim washers.
• When fitting the drive shaft with bearing, shim washers and
seal, make sure that the shaft keys correspond with the crown
gear’s keys and that the bearing and seal are correctly
positioned in the gear housing before the shaft is pressed in
completely.
• Put the distance ring on the drive shaft end, and put on the
shaft nut. AlwaysXVH a new nut. Tighten the shaft nut to a
torque of 300 Nm and lock it with a punch mark in the middle.
The drive shaft nut should be lubricated before it is put on the
shaft.
• Change the gasket before fitting the bottom cover. Make sure
that it is not damaged. Fit the cover and tighten the bolts to a
torque of 26.6 Nm. The bolts should be lubricated before they
are fitted. Fill up with oil in accordance with the instructions for
replenishing the oil.
Fit the drive gear and tighten the bolts to a torque of 65 Nm.
'ULYHXQLWJHDU
2550 702 425801AA-
001 2002-01-07 202181-040
(OHFWURPDJQHWLFEUDNH
425801AA- 702 3370
202181-040 2002-01-07 001
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10 1
2
9
3
4
8
7 6
3RV1R 'HVFULSWLRQ
1 Magnetic coil
2 Cap screws
3 Electrical wire
4 Pressure plate
5 Adjustment locking nut
6 Pressure springs
7 Flange
8 Mounting bolts
9 Brake disc
10 Hub
3370 702 425801AA-
001 2002-01-07 202181-040
0DLQWHQDQFH
Basically the brake is maintenance free in normal work environ-
ments. However it is recommended according to the preventive
maintenance schedule to check the brake disc for wear and the
gap between the magnetic coil housing and the pressure plate on
a regular basis.
%DVLF$GMXVWPHQWRIJDS
5,5 Nm
0,2
The QRPLQDO JDS between the coil housing and the pressure
plate, in applied position, shall be PP. The PD[LPXPJDS
before readjustment is necessary is PP.
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Loosen the tension of the three adjustment bolts .
Turn the lock nuts anti-clockwise and tighten the bolts slightly
while checking the gap RQ WKUHH SRLQWV with a 0.2 mm feeler
gauge.
Tighten the lock nuts 5,5 Nm and recheck the gap with the feeler
gauge.
425801AA- 702 3370
202181-040 2002-01-07 001
([FKDQJHRIEUDNHGLVF
The brake disc shall be exchanged when its total thickness has
been reduced to 5,5 mm.
• Disconnect the electrical wires of the brake.
• Loosen and remove the three mounting bolts and remove the
brake coil.
• Replace the brake disc on the hub and make a visual inspec-
tion of the wear of the friction plate. Replace the friction plate if
the surface is worn uneven.
• Unwind the lock nuts on the coil at least 6 mm to make sure
there is a gap between the coil and the pressure plate when
the coil is refitted.
• Mount the coil on the motor end and carry out adjustment of
the gap according to chapter “Basic Adjustment of gap”.
• Reconnect the electrical wiring.
3370 702 425801AA-
001 2002-01-07 202181-040
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425801AA- 702 4000
202181-040 2002-01-07 001
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1
8
9
10 11
12
14 13
16
15
18 17
19
20
21
22
23

1 Screw 4
2 Washer
3 Handle
4 Screw 4
6WHHULQJ
4000 702 425801AA-
001 2002-01-07 202181-040

5 Washer 2
6 Cable holder
7 Nut
8 Gas damper
9 Bracket
10 Stop screw
11 Screw 4
12 Ball joint
13 Screw
14 Distance
15 Bush 2
16 Damper 2
17 Axle
18 Cam
19 Distance
20 Screw
21 Distance
22 Distance
23 Switch S 10
$GMXVWPHQWV
$GMXVWLQJRIEUDNHPLFURVZLWFK
Switch (23) is always adjusted to its lowest position.
• Unscrew the screws (13, 20) that hold the switch and the dis-
tance.
• Press down the switch and tighten the screws.
• Check that the switch is actuated by the cam (18) in the arm’s
top and bottom position.
6WHHULQJ
425801AA- 702 4000
202181-040 2002-01-07 001
7LOOHUDUPKDQGOH
28
29
27 26
24 14
25 14
23 22
17
21 18
20 16
19 15
14
30 14
31 13
12
10 11
32 9
8
35 33
34
5 6 7
4
1 2
3

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic circuit board
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
6WHHULQJ
4000 702 425801AA-
001 2002-01-07 202181-040

15 Spring
16 Pushbutton Not used
17 Arm
18 Holder
19 Spring
20 Control switch
21 Axle
22 Sliding bearing
23 Control stop
24 Arm
25 Spring holder
26 Spring
27 Spring holder
28 Sliding bearing
29 Control switch
30 Button for safe reversing
31 Arm
32 Spring
33 Lower cover
34 Screw M4x40
35 Screw 2xM5x45 - 2xM5x60
6WHHULQJ
425801AA- 702 4000
202181-040 2002-01-07 001
'LVPDQWOLQJ$VVHPEOLQJ
• Dismantle cover (2), (keyboard option).
• Remove the screws (35), hold top cover firm (7).
• Disconnect the cable connected to the electronic circuit board
(4).
• Remove the screws (34).
• Carefully lift off the lower cover (33), and place a finger be-
tween the lower cover (33) and button (30) to hold the button
(30) in place.
Assembling is carried out in the reverse order.
127(
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• Dismantle the button as per the diagram.
• Disconnect the connection for the switch on the electronic cir-

cuit board (4).
• Press out the switch from its mounting.
6WHHULQJ
4000 702 425801AA-
001 2002-01-07 202181-040
&KDQJLQJRIOLIWORZHULQJEXWWRQ
• Remove the button by placing a screwdriver in the hole (A) as
per the diagram below.
A A
• Unscrew the holder (18) so that the arm (12) comes loose.
&KDQJLQJRISXVKEXWWRQ
• Press the button by hand sideways.
• Place a screwdriver as per the diagram and carefully pry the
button loose.
• Unscrew the button’s holder and arm.

(OHFWULFDOV\VWHPV
425801AA- 702 5000
202181-040 2002-01-07 001
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© BT Europe AB Service Manual Ixion S12F, S16D Approved by: L-G Andersson 49
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5000 702 425801AA-
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50 © BT Europe AB Service Manual Ixion S12F, S16D Approved by: L-G Andersson
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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
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5000 702 425801AA-
001 2002-01-07 202181-040
6\PERO 'HVFULSWLRQ )XQFWLRQ 1RWHV
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
S42 Switch Manual fork lowering
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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425801AA- 702 5000
202181-040 2002-01-07 001
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5000 702 425801AA-
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202181-040 2002-01-07 001
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001 2002-01-07 202181-040
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202181-040 2002-01-07 001
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5000 702 425801AA-
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6WDUWLQJWKHWUXFN
• Battery connector plugged in.
• S21 closed.
• S17 on.
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A1
B-
S1
T1 • S10 closed .
Ish S2
- M- • The speed control activated in any direction.

A2
+
Shunt
A
Ia A1
1HXWUDOVSHHGUHGXFWLRQ
T2
K10 B+
• The speed control to neutral position, motor starts to work as gene-

rator. Brake energy comes back to battery.
• Y1 will be applied when the truck comes to a stand still even if the
tiller is in drive position.
3LFWXUH
Energy back to the battery.
The transistors (T2) for the generated brake current are not
live.
A1
B-
S1
T1
Ish S2
- M-
A2
+
Shunt
A
Ia A1
T2
K10 B+
(OHFWULFDOV\VWHPV
425801AA- 702 5000
202181-040 2002-01-07 001
1HXWUDOVSHHGUHGXFWLRQRQVORSHV
If the driver release the speed control on a slope and the truck doesn’t
come to a stop within a certain time the electrical brake will be applied
by the system.
%UDNLQJ
The brake is always applied when the truck is started with the
tiller in it’s upper or lower position (S10 open). The brake is released in
the same moment as the conditions for driving are fulfilled and the truck
starts to move.
Conditions to brake the truck:
• S10 open.
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• A2:S19 activated.
• Battery status OK (if battery capacity >20% left).
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• A2:S21 activated
• Battery status OK (if battery capacity >20% left).
/RZHULQJWKHIRUNV
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• S18 activated.
(OHFWULFDOV\VWHPV
5000 702 425801AA-
001 2002-01-07 202181-040
+RXUPHWHU
• Press S18 and turn S17 to “on” at the same time.
• Press S18 until you read H= hour meters.
• You have now choosen H=hourmeters the symbol “B” will be high-
lighted.
• You can now choose type of hourmeter by pressing the speed con-
trolt.
A= Key time.
b= Drive motor time.
c= Pump motor time.
d= Activity time.
A
s= Time to service.
E D C B
)DXOWFRGHV
• 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 :
----.
(OHFWULFDOV\VWHPV
425801AA- 702 5000
202181-040 2002-01-07 001
&RGH &
Description Default parameter warning.
Possible fault Parameter area is probably corrupt.
reason Default values have been down loaded, i.e spe-
cial parameter settings must be restored.
&RGH &
Description Butterfly warning
Possible fault Problem with butterfly sensor.
reason Butterfly may have been activated during start up
or faulty sensor.
&RGH &
Description Emergency switch warning
Possible fault Emergency switch activated
reason No voltage supply to motor controller.
Harness problem.
&RGH &
Description Service time warning
Possible fault Time to make service
reason Service counter not reset after latest service
&RGH &
Description Battery undervoltage warning
Possible fault Battery voltage < 17 volts
reason Battery parameter not correct adjusted
Time to charge battery
(OHFWULFDOV\VWHPV
5000 702 425801AA-
001 2002-01-07 202181-040
&RGH &
Description Battery overvoltage warning
Possible fault Battery voltage > 33 volts
reason Fully charged battery and regenerative braking.
&RGH &
Description Power amplifier thermal cutback
Possible fault Too intensive driving
reason Defect motor controller
&RGH (
Description Motor controller does not correspond with the type
of truck
Possible fault Check that the right type of motor controller is fitted
reason
&RGH (
Description Brake switch transistor shorted
Possible fault Defect motor controller
reason Check the cables and magnetic coil to the brake
&RGH (
Description Digital output or field over current
Possible fault Attempt to drive more current than specified from
reason outputs.
Problem to regulate field currrent.
Internal controller fault.
(OHFWULFDOV\VWHPV
425801AA- 702 5000
202181-040 2002-01-07 001
&RGH (
Description Contactor off
Possible fault Problem with main contactor tips or cabling (open
reason circuit).
Contactor control wire not connected.
Contactor drive output in controller faulty (off).
&RGH (
Description Contactor welded
Possible fault Main contactor tips welded.
reason Contactor drive output in controller faulty (on).
&RGH (
Description System error
Possible fault Possible fault in the motor controller. Restart the
reason machine
&RGH (
Description Checksum error
Possible fault Internal microcontroller fault (tiller head), faulty
reason software or pcb.
&RGH (
Description Software problem
Possible fault Internal microcontroller fault (tiller head),faulty
reason software or pcb.
&RGH (
Description Drive communication error
Possible fault Broken CAN-cable.
reason Motor controller broken
(OHFWULFDOV\VWHPV
5000 702 425801AA-
001 2002-01-07 202181-040
&RGH (
Description Drive communication Tx error
Possible fault Motor controller does not answer, bad connec-
reason tions or faulty motor controller.
&RGH (
Description Bus off error
Possible fault CAN-bus problem, harness or hardware problem.
reason
&RGH (
Description Over run error
Possible fault CAN-bus problem, harness or hardware problem.
reason
&RGH (
Description Error in safety reversing
Possible fault Critical sensor element faulty
reason
&RGH (
Description Field open
Possible fault Shuntfield open, harness broken, motor controller
reason defect.
&RGH (
Description M minus error
Possible fault Problem with switch transistor in armature circuit
reason inside motor controller.
(OHFWULFDOV\VWHPV
425801AA- 702 5000
202181-040 2002-01-07 001
&RGH (
Description Power amplifier sensor error
Possible fault Armature current sensor fault in motor controller.
reason
&RGH (
Description Power amplifier CAN-timeout
Possible fault Motor controller reports unexpected loss of data
reason flow from tiller head.
3DUDPHWHUV
• 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.
127(
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5000 702 425801AA-
001 2002-01-07 202181-040
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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
(OHFWULFDOV\VWHPV
425801AA- 702 5000
202181-040 2002-01-07 001
6HUYLFHSDUDPHWHUV
• Connect CAN-key in X41
• Choose parameter
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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.
(OHFWULFDOV\VWHPV
5000 702 425801AA-
001 2002-01-07 202181-040
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The speed when using the tortoise button can be adjusted.
3DUDPHWHU
The maximum speed can be adjusted.
3DUDPHWHU
The lower value of the parameter the longer time it takes to accelerate
the truck to top speed.
3DUDPHWHU
Defines motor brake force when the speed control goes to neutral posi-
tion. The lower value of parameter the longer time to reduce speed.
3DUDPHWHU
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.
3DUDPHWHU
10 drivers can have it’s own PIN-code to get access to the truck. Each
driver have possibility to set all the driver parameters individual.
Code 0 is not accepted as a solitary code.
When you wish to start the truck enter your code and press the green
button with the number 1.
To turn the truck to off press the red no.0 button.
When you have the CAN-key connected you can turn the truck on by
just pressing the green no. 1 button. You turn it to off by pressing the
red no. 0 button.
3DUDPHWHU
Defines the speed you will get when you reach the first speed sensor.
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425801AA- 702 5000
202181-040 2002-01-07 001
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You choose wich hour meter you want to display.
1(A) = Key time.
2(b) =Activity time.
3(c) = Drive motor time.
4(d = Pump motor time.
5(s) = Time to service.
3DUDPHWHU
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.
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5000 702 425801AA-
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The acid concentration can vary depending of battery brand.
9DOXH )XQFWLRQ %DWWHU\$K

1
2
3
4
5
6
7 140
8 240
9
10 ↑
11 Less discharged
12
13 More discharged
14 ↓
15
16
17
18
19
20
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With this parameter you can set a time limit to next service from 0 to
2000 hours in step of 50 hours. When it’s time for service you will get
caution 29 (C29) on the display.
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425801AA- 702 5000
202181-040 2002-01-07 001
3DUDPHWHU
Using this parameter you can choose which button should be used for
lifting/lowering.
1 = Lower lifting/lowering button activated for fork lift
Upper lifting/lowering button activated for support arm lift (Standard)
2 = Lower lifting/lowering button activated for support arm lift
Upper lifting/lowering button activated for fork lift
3DUDPHWHU
This parameter can be adjusted like:
1= Key connected, driver parameters open.
2= Key connected, driver parameters must be opened with
CAN-key.
3= Key pad connected, driver parameters open.
4= Key pad connected, driver parameters must be opened with
CAN - key.
6HUYLFHGLVSOD\
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
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5000 702 425801AA-
001 2002-01-07 202181-040
See table below.
)ODVKLQJV\PERO 'LVSOD\HGGDWD
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
6HJPHQW )XQFWLRQ
A S32, input A1:13. No lifting limit
E D C B B
C P2, input A1:15.Pressure switch fork lift
D S10, input A1:12
$
E P1, input A1:10. Pressure switch support arm lift
) %
* F S42, input A1:11. Manual lowering of the forks
G S10, input A1:5
( &
'3 DP
'
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425801AA- 702 5000
202181-040 2002-01-07 001
• The second most significant figure active (marked with arrow).

• Power amplifier outputs.
A
6HJPHQW )XQFWLRQ
A Y41, output A1:9 Lowering valve
B
E D C B
C Y34, output A1:2 Lift/lowering valve, forks
D Y52, output A1:3. Lift/lowering valve, support
$ arm
E K10, output A1:4
) %
*
F H1, output A1:7
( & G Y1 , output A1:5

'3 DP K30, output A1:6
'
• The third most significant figure active (marked with arrow)

• Digital input from control sensors.
A
6HJPHQW )XQFWLRQ
A
E D B B
C
C
D Forks up
$
E Forks down
) %
* F Support arms up
G Support arms down
( &
'3 DP Horn
'
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5000 702 425801AA-
001 2002-01-07 202181-040
• The fourth most significant figure active (marked with arrow).
A 6HJPHQW )XQFWLRQ
A Extra function 6
B Extra function 5
C Extra function 4
E D C B
D S113 Turtle function
E Extra function 2
F Extra function 1
G
DP
3DUWQXPEHUV
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.
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425801AA- 702 5000
202181-040 2002-01-07 001
7UDQVLVWRUSDQHO
STATUS
MODEL VOLTAGE
SERIAL CURRENT
*HQHUDO
B+ M- Curtis 1243 is a regulator for controlling shunt motors. Varying the volt-
age applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
involves varying the “on” time of the MOS-FET transistors regulating
the armature current.
A1
M A2 Switching of the rotational direction is achieved by switching the polari-
ty on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
tor bridge for the armature winding.
S1 S2
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5000 702 425801AA-
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STATUS
MODEL VOLTAGE
SERIAL CURRENT
The table below describes the error codes that may be shown by the
STATUS LED or read using the handheld terminal.
67$786/(' +DQGKHOGWHU ([SODQDWLRQ 3RVVLEOHFDXVH

PLQDOGLVSOD\
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 ¤¤ &855(17 Built-in current shunt Armature current sensor fault in
6+817)$8/7 defective motor controller.
1,2 ¤ ¤¤ +:)$,/6$)( Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head
1,3 ¤ ¤¤¤ 06+257(' Internal M- short to Problem with switch transistor in
B- armature circuit inside motor control-
ler.
3,1 ¤¤¤ ¤ &217&2,/)/' Too high current for Attempt to drive more current than
6+257 contactor feeding or specified from outputs.
shorted field winding Problem to regulate field currrent.
Internal controller fault.
3,3 ¤¤¤ ¤¤¤ ),(/'23(1 Open field winding Shuntfield open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ /2:%$77(5< Low battery voltage 1. Battery voltage <17 volts
92/7$*( 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions
4,2 ¤¤¤¤ ¤¤ 29(592/7$*( Overvoltage 1. Battery voltage > 33 volts
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4,3 ¤¤¤¤ ¤¤¤ 7+(50$/ Over-/under-temper- 1. Temp. >85oC or < - 25oC
&87%$&. ature reduction 2. Truck overloaded
3. Wrong installation of transistor reg-
ulator
4. Operation under extreme condi-
tions
5HVHWWLQJHUURUV
To reset an error turn S17 to off and then on again.
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29(592/7$*( Battery voltage falls below 33 V
7+(50$/&87%$&. The temperature is within allowed range
7+5277/()$8/7 Error has been fixed
/2:%$77(5<92/7$*( When battery voltage exceeds 16 V
6DIHW\
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
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5000 702 425801AA-
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Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature winding * 150 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 20 Amps for 2 minutes
20 for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 2 Amps Max (current limit at 2.5 amps)
KSI input voltage, Min. 16.8 Volts
KSI input current 50 mA
Logic input voltage >7.5; High Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C
* During specific test conditions.
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425801AA- 702 6000
202181-040 2002-01-07 001
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n
2 1
4 G H
J K
3 B C
A
E
D
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F
F
0DLQFRPSRQHQWV
3RV1R 'HVFULSWLRQ 5HPDUN
1 Lift Cylinders Fork lift
2 Lift Cylinders Support arm lift
3 Hydraulic Unit A = Non return valve
B = Lowering valve, man-
ual
C = Lowering valve, el
D = Overflow valve
E = Flow control valve
F = Filter
M = Pump motor
P = Pump
+\GUDXOLFV\VWHP
6000 702 425801AA-
001 2002-01-07 202181-040
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4 Pressure switches/ G = Support arm lift
lift functions Load >750 kg
Speed = 5,3 km/h
Load > 1200 kg
Speed = 4,4 km/h
H = Fork lift
Load > 750 kg
Speed = 5,3 km/h
J = Valve, support arm lift
K = Valve, fork lift
'HVFULSWLRQ
/LIW
When the pump motor starts, the oil flows through the non return
valve to the lift cylinders.
/RZHULQJ
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 lower-
ing lever on the chassis. Lowering using the button on the tiller
arm gives a constant lower speed.
2SHUDWLQJSUHVVXUH
The operating pressures at rated load are:
• S 12F: 191 bar
• S 16D: 191 bar
5HOLHIYDOYH
The relief valve opens at the following pressures:
• S 12F: 220 bar
• S 16D: 190 bar
3UHVVXUHVZLWFK
The pressure switch is used to regulate the speed and is influ-
enced by the load. It only has an off/on operation.
Load < 750 kg. Speed = 6,0 km/h
Load > 750 kg. Speed = 5,3 km/h
Load > 1200 kg – support arms. Speed = 4,4 km/h.
%DWWHU\FKDUJHU,QEXLOW
425801AA- 702 8340
202181-040 2002-01-07 001
*HQHUDO
SMCI is a battery charger intended for valve-regulated or freely
ventilated lead acid batteries. It is adapted for batteries from
about 100 Ah up to 320 Ah.
The charger which uses advanced switch techniques is connect-
ed to a normal (grounded 230 V single phase) socket (B) and the
built-in micro controller then controls charging following the pre-
$ % set charging curve. During charging the charging process is dis-
played with a status indicator on the standby housing (A).
The micro controller also controls charging with respect to charg-
ing time and temperature in the charger so that charging can be
limited, e.g. if a fault occurs in some cell in the battery or when
there is insufficient cooling of the charger.
SMCI 300 is delivered pre-set for 24 v and with software intended
for charging valve-regulated or freely ventilated lead acid batter-
ies.
The size and type of the battery are selected using the switch on
the side of the fan(C) which is accessible via a slotted head
screwdriver.
&
&KDUJLQJ
Connect the charger to the mains. When charging starts after a
few seconds, the orange status indicator on the standby hous-
ing(A) lights up. Yhis indicator remains lit until the battery is fully
charged and the indicator turns to green.
Charging time varies depending on the type of battery and the
degree of discharge. Normally the charger is started after work-
ing hours and the battery is fully charged the next morning. A
highly discharged freely ventilated battery of 320 Ah may need up
to 14 hours re-charging time, a VR battery even longer.
Some time after charging (depending on, for example, type of
battery) SMCI 300 switches to maitenance charging. The green
indicator remains lit to show that the battery is fully cgarged.
When charging is completed, the mains plug is placed in the
standby housing.
8340 702 425801AA-
001 2002-01-07 202181-040
7URXEOHVKRRWLQJDQGVHUYLFH
First check whether the charger indicates an error. A red, blinking
indicator means that the charger cannot detect that any battery is
connected.Check the cables, pole terminals and other connec-
tions to the batteries. Measure battery voltage.
If the charger still doesn´t work, send it to your supplier for repair.
7HFKQLFDOGDWD
Size 250x115x67 mm
Weight 1,6 kg
Ambient temperature -25°C till +40°C
Mains voltage 90-255 V AC 45-400 Hz
(Reduced charging current for mains volt-
age below 200 V
Rated voltage 24 V DC
Rated current 30 A
Max output 750 W
Efficiency > 86%
Battery type Freely ventilated lead batteries (with
water refilling). Valve regulated (VR) lead
batteries.
Protection IP 20
General Temperature regulated cooling fan, pro-
tected against faulty polarisation
425801AA- 702 8340
202181-040 2002-01-07 001
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)UHHO\YHQWLODWHGEDWWHULHV
6ZLWFK %DWWHU\VL]H 2XWSXW ,FXU 0D[FXUUHQWPDLQ

FXUUHQW UHQW WHQDQFH
0 No charging (red LED is - - -
lit)
1 100-119 Ah 30 A 5,5 A 0,5 A
2 120-144 Ah 30 A 6,6 A 0,6 A
3 145-174 Ah 30 A 8A 0,8 A
4 175-209 Ah 30 A 9,6 A 1,0 A
5 210-249 Ah 30 A 11,5 A 1,2 A
6 250-299 Ah 30 A 13,7 A 1,4 A
7 300-350 Ah 30 A 16,2 A 1,6 A
9DOYHUHJXODWHGEDWWHULHV
6ZLWFK %DWWHU\VL]H 2XWSXW ,FXU 0D[FXUUHQWPDLQ

FXUUHQW UHQW WHQDQFH
8 No charging (red LED is - - -
lit)
9 300-350 Ah 30 A 3,9 A 1,6 A
A 250-299 Ah 30 A 3,3 A 1,4 A
B 210-249 Ah 30 A 2,75 A 1,2 A
C 175-209 Ah 30 A 2,3 A 1,0 A
D 145-174 Ah 25 AA 1,9 A 0,8 A
E 120-144 Ah 21 A 1,58 A 0,6 A
F 100-119 Ah 17 A 1,32 A 0,5 A
8340 702 425801AA-
001 2002-01-07 202181-040
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425801AA- 702 8700
202181-040 2002-01-07 001
8VHU0DQXDOIRU7UXFN&RP
*HQHUDO
TruckCom is a communication program which communicates
with trucks equipped with CAN (Controller Area Network)
communication. It enables functions such as downloading
programs, adjusting parameters and displaying measuring data
etc. to be carried out.
This Manual is valid for program number 182145-001.
The program is a Windows program run under Windows® 95/98.
3URGXFWLRQPRGH
Truck Com can be started with the variable “p”. This starts the
program in production mode.
A choice is made whether downloading is to be made in “Walkie”
or “Rider” trucks. An “authorisation file” is needed to access
production mode for ORION trucks.
A short text is shown in English during the time it takes to
download the program in the card.
&RQQHFWLRQ
A CAN interface of the CPC-PP type is needed to connect it to
the truck, with attendant cable. The interface is connected to the
printer port on a PC, and the cable is connected between the
interface and truck’s CAN connection.
The CAN interface is supplied with power from the truck
electronics and is protected from any high voltages in the truck if
a fault should occur.
© BT Europe AB Service Manual Ixion S12F, S16D Approved by: K-G Andersson 85
8700 702 425801AA-
001 2002-01-07 202181-040
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0DLQZLQGRZ
A main window opens when the program is started, consisting of
menu bar, tool buttons, workspace, log window and status
window.
1RGHV
The nodes detected on the bus are shown in the node window.
The current node status and input component/information is
show with different icons.
86 © BT Europe AB Service Manual Ixion S12F, S16D Approved by: K-G Andersson
425801AA- 702 8700
202181-040 2002-01-07 001
,FRQV
,FRQ 'HVFULSWLRQ
1RGH2. is shown when contact is made with
a node and no errors have been reported.
1RGHQRWFRQQHFWHG is shown when there is

no contact with a node in the network.
1RGHQRW2. is shown when an error has been

reported by a node. Click on node to obtain
more information.
3URJUDPYHUVLRQ is shown when information is
available on which software is installed. Click to
obtain more information.
,QIRUPDWLRQ is shown when a node has
information on, for example, error codes.
3DUDPHWHUV is shown when a node has

information on a parameter.
7RROEXWWRQV
Search for units, disconnect from PC, download, truck report,
parameters, diagnostics, information and exit.
,QIRUPDWLRQZLQGRZ
The right section of the main window contains a status window
where different messages are shown.
To see previous messages, use the scroll arrows in the right
margin.
8700 702 425801AA-
001 2002-01-07 202181-040
6WDWXVEDU
There is a status bar at the bottom of the main window, which
shows variable status when the program is run.
REC MACHINE
The following are shown from the left:

Help text "pop-up" via the mouse cursor, connected/not
connected to network, truck type connected, initiation result of
CAN interface and the present time.
)XQFWLRQ
&RQQHFWLRQ
To connect the PC the network, select the "Scan units" function.
This can be done with the menu <Nodes | Scan units> or with the
tool button [Scan nodes].
This should also be done when the truck is supplied with voltage
and in normal drive mode.
The program will now run a check and installation of the CAN
interface. A diagnosis will also be carried out to check which units
are connected in the system. The result of this diagnosis is shown
in the Node window.
'LVFRQQHFWLRQ
Select the Disconnect function to disconnect from the network.
This can be done with the menu <Nodes | Set PC off-Line > or
with the tool button [Set PC off-Line].
The CAN interface is then reset and the CAN cable can be
disconnected if so required.
The objective is to enable connection to another truck without
having to close the program.
425801AA- 702 8700
202181-040 2002-01-07 001
'RZQORDGLQJSURJUDP
To download a new program to one of the nodes, select the
Download function. This can be done with the menu <Tools |
Download software... > or with the tool button [Download].
Type
123456
1RUPDOGRZQORDGLQJ
Select Open.. to open the file to be downloaded into a node. The
file name, file type and version number are shown in the window
for “file information”. If it is file for a controller, indicate which type
of controller is to receive the file. Start downloading by selecting
Start... and by restarting the truck by turning the key off and on
twice.
Restart must be made within 10 seconds from when the Start
button has been activated.
Close the download window when the download is ready, and
then disconnect the PC from the network. A new connection can
now be made to verify the new program.
'RZQORDGLQJLQROGYHUVLRQVRIORJLFFDUG
To download to older versions of electronic cards which do not
support restart with key, the button Old card... should be used
instead of Start...
Downloading is carried out in the same way, except that restart is
done by using the battery lug instead of the key.
8700 702 425801AA-
001 2002-01-07 202181-040
(PHUJHQF\GRZQORDGLQJ
E141 will be shown in the truck’s display when starting, if for any
reason there is no program in the electronics card (interrupted
downloading). Communication with the truck via the PC will then
be minimised. Use “E141” to download the program in the card.
ORION:
If there is no program a counter will be shown in the display,
which continuously counts up.
127(
7KHORJLFFDUGVIRU25,21FDQRQO\EHXSJUDGHGZLWKWKH
VDPHEDVLFSURJUDPVZKHQWKH\KDYHEHHQSURJUDPPHG,WLV
WKHUHIRUQRWSRVVLEOHWRFKDQJHEDVLFSURJUDPVRWKHU
PDFKLQHW\SH
425801AA- 702 8700
202181-040 2002-01-07 001
7UXFNUHSRUW
It is possible to generate a report to a file or disk with the truck’s
configuration and status. Select menu <Tools | Generate truck
report...> or with the tool button Truck report. Save the report in
Report.file.
NAME
Example of information generated in the truck report:

[GENERAL] [ERROR LOG]
REPORT DATE-TIME=1999-12-09 07:42:14 01=55 99-12-09 06:11
CPC-PP SERIAL No=8002008 02=55 99-12-08 20:54
MACHINE NUMBER=392179 03=55 99-12-08 14:26
CUSTOMER=CUSTOMER 1 04=231 99-12-08 14:16
TECHNICIAN=NONAME 05=55 99-12-08 14:11
COMPANY=COMPANY 1 .
NOTES=Test report .
.
[CAN NODES] 50=55 99-12-08 14:40
MAIN CARD=125
FORK CARD=-1 [DRIVER PARAMETERS]
TRUCK TRACKER=-1 1=3
ACC LIFT CONTROLLER=0 2=100
ACC DRIVE CONTROLLER=0 3=100
CURTIS LIFT CONTROLLER=-1 .
.
[MAIN CARD CONFIGURATION] .
SOFTWARE=169942-001 100=0
HARDWARE=169937-001
SERIAL NO=12112
[TRUCK PARAMETERS]
[HOUR METERS] 11=100
A IGNITION TIME=1 12=80
B TOTAL MOVEMENT=0 13=10
C DRIVE MOTOR TIME=0
D PUMP MOTOR TIME=0
S SERVICE TIME=9
8700 702 425801AA-
001 2002-01-07 202181-040
3DUDPHWHUV
To change the truck parameters, select the Parameter function.
This can be done with the menu <Tools | Change parameters >
or with the tool button [Parameters].
127(
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PRGH
This must therefore be done when the truck is in parameter
mode. When the truck is in normal drive mode the parameter
window is locked and no information can be changed.
Nevertheless, it is possible to unlock the window by restarting the
truck in parameter mode and then selecting Unlock... without
closing the window first.
The parameter numbers follow the description in the respective
truck Service Manuals.
425801AA- 702 8700
202181-040 2002-01-07 001
'LDJQRVWLFV
To access diagnostics, select the Diagnostic function. This can
be done with the menu <Tools | Diagnostic...> or with the tool
button [Diagnostic].
127(
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Several analogue values will be shown on the Analogue side:
Inputs, outputs and the drive/lift converter values. The input/
output values are read directly from the in/out directory in the
main card and are then shown as voltages and number of
revolutions.
12725,21
“Cmd” is the requested number of revolutions from the main card
sent to the drive/lift converters via the CAN bus.
“Actual” is the number of revolutions the drive/lift converters have
detected and sent back to the main card.
8700 702 425801AA-
001 2002-01-07 202181-040
7HPSHUDWXUH
The actual temperatures of the electronic units and motors are
shown. The values are shown in degrees Celsius.
127(
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HOHFWURQLFXQLWDQGPRWRU
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The digital inputs are read directly from the input directory on the
main card. It is assumed that the input is activated if the colour of
the LED is green. If the LED is white/transparent the input is not
activated.
The digital outputs are read directly from the out-directory on the
main card and are shown with red LEDs.
8VHUVHWWLQJV
Not entered in version 3.1.
425801AA- 702 8700
202181-040 2002-01-07 001
2WKHUIXQFWLRQV
6DYHWRILOH
The truck parameters can be saved in the PC for downloading at
a later date.
Select <File | Save to file | Parameters >. All parameters in the
nodes which are connected to the bus will be scanned in and
saved in a file.
If only the hour meters are needed, select <File | Save to file |
Hour meters >.
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A set of parameters can be downloaded from the PC to the truck.
Select <File | Load from file | Parameters >. The parameters in
the file will be copied to the nodes connected to the bus. If only
the hour meter settings are needed, select <File | Load from file |
Hour meters >.
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If problems should occur when resetting the CAN adapter
connected to the PC, this can normally be done manually by
making sure that the adapter is supplied with voltage and then
selecting <Nodes | Reset CPC-PP >.
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To delete the truck’s error code log, start the truck in parameter
mode and then select < Tools | Erase error log >.
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To reset the truck’s hour meter, start the truck in drive mode and
then select < Tools | Reset hour meters >.
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To show the truck’s error code log, select <Tools|Read error log>.
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To quickly adjust the truck’s data and time, select < Tools | Adjust
date & time >. The time given in the PC will now be downloaded
into the truck.
127(
1RWWUXFNVZKLFKGRQRWKDYHUHDOWLPHFORFN25,21
8700 702 425801AA-
001 2002-01-07 202181-040
$GMXVWLQJWKHKRXUPHWHURQROGHUFDUGV
To adjust the hour meter on trucks with older cards, select
< Tools | Adjust Hour meters >. The time in the PC will then be
downloaded to the truck.
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To see program information, select <Help | About TruckCom... >
or tool button [About].
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If the computer has an Internet connection and web browser,
connect to BT’s home-page by selecting<Help | BT on the web...
>
There is also a link to product support’s e-mail address under the
menu <Help | Program support... >.
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To exit the program, select <File | Exit > or the tool button [Exit].
425801AA- 702 8700
202181-040 2002-01-07 001
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'HVFULSWLRQ 9DOXH 8QLW
Power consumption 40-120 mA
Supply voltage 11-28 V
Transfer rate 125 kbit/s
Storage temperature -20-80 0C
0C
Operating temperature 0-60
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The program is delivered on disks or over the network, and the
installation is started by running A:\SETUP.EXE.
Follow the instructions shown on the screen.
Make sure that the computer settings for the printer port in setup
(BIOS) are as follows:
Port address: 0378
IRQ: 7
Mode: Output only
For information on how the settings in setup are changed, see the
user manual from the computer manufacturer.
7RXQLQVWDOO
If you wish to uninstall TruckCom this can be done from Windows
< Setup| Control Panel| Add/delete program > .
8700 702 425801AA-
001 2002-01-07 202181-040

6Huylfh0Dqxdo %: Valid From Serial Number: 425801AA

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6Huylfh0Dqxdo %: Valid From Serial Number: 425801AA

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© BT Industries AB Service Manual S12F, S16D Approved by: L-G Andersson 7

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Lift without load, m/s 0.19 0.19

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10 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Andersson

© BT Industries AB Service Manual S12F, S16D Approved by: 11

• Always disconnect the battery by pulling out the battery isola-

12 © BT Industries AB Service Manual S12F, S16D Approved by:

© BT Industries AB Service Manual S12F, S16D Approved by: 13

14 © BT Industries AB Service Manual S12F, S16D Approved by:

© BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson 15

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

16 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson

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

© BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson 17

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

18 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson

© BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson 19

L = Lubrication C = Check O = Oil change

20 © BT Industries AB Service Manual S12F, S16D Approved by: L-G Anddersson

© BT Europe AB Servicemanual S12F, S16D Godkänd av: L-G Andersson 21

22 © BT Europe AB Servicemanual S12F, S16D Godkänd av: L-G Andersson

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159229 Tool for release of lock (1)

159230 Tool for application of secondary

159231 Tool for application of secondary

159228 Tool for removal of pins/sleeves

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1=163787 Tool for application of sleeves

1=163793 Service instrument for

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• Release the brake disc’s companion flange by first removing

• After dismantling the motor’s bearing shields and removing the

Residual detergent should be removed with an appropriate sol-

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• Disconnect the connection for the switch on the electronic cir-

• Unscrew the button’s holder and arm.

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F1 Fuse Drive motor circuit 125 A

K10 Contactor Main contactor

A2:S1-S9 Speed control Forwards/Reverse

M1 Motor Drive motor

P1 Pressure switch Pressure switch support arm 70 bar

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R1 PTC-resistor Power supply 15 Ohm

S111 Switch Option

- M- • The speed control activated in any direction.

• The speed control to neutral position, motor starts to work as gene-

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