Service Manual GB

Minimover LW13
Valid from serial number: 372000AA-

Order number: 179573-040

Issued: 2000-10-02 ITS

© BT Industries AB
 C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

2 © BT Industries AB Service Manual Minimover LW13 Approved by: Iréne Karlsson

 Contents
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

Contents

Operator’s manual ....................................................... 5

1 Issued operator’s manuals ..................................... 5

Technical data ................................................................ 7

Introduction Maintenance ..................................... 11

1 Safety regulations with maintenance work ....... 11
2 Cleaning and washing ........................................... 13
3 Safe lifting ................................................................. 14

Maintenance, Lubrication schedule ................ 15

1 Maintenance schedule .......................................... 15
2 Lubrication schedule .............................................. 19

Oil and grease specification ................................ 21

Drive unit/drive gear ................................................. 23

1 Component parts .................................................... 23
2. Service and repairs ................................................ 26
3 Technical data ......................................................... 29

Electrical systems ...................................................... 31

1 Electrical parts ......................................................... 31
2 List of symbols and electrical wiring diagram ... 33
3 Functional description ........................................... 37
4 Error codes .............................................................. 38
5 Parameters .............................................................. 41
6 Test ............................................................................ 42
7 Technical specifications – SEM zero ................. 45

© BT Industries AB Service Manual Minimover LW13 Approved by: Iréne Karlsson 3

 Contents
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

Hydraulic system ........................................................ 47

1 Hydraulic chart and list of symbols ..................... 47
2 Adjustments W13 .................................................... 48

In-built battery charger ............................................ 51

1 General ..................................................................... 51
2 Charging ................................................................... 51
3 Trouble shooting ..................................................... 51
4 Technical data ......................................................... 52

4 © BT Industries AB Service Manual Minimover LW13 Approved by: Iréne Karlsson

 Operator’s manual
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

Operator’s manual

1 Issued operator’s manuals

T-code Model Serial number Order number Issued

675 LW13 372000AA- 179561-040 2000-10-17

© BT Industries AB Service Manual Minimover LW13 Approved by: Iréne Karlsson 5

 Operator’s manual
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

6 © BT Industries AB Service Manual Minimover LW13 Approved by: Iréne Karlsson

 Technical data
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

Technical data

Model LW13
Drive motor
Type TSL115-16
Output, kW 0.5
Duty cycle S2, 60 min
Minimum carbon brush length, mm 14.5
Nominal commutator diameter, mm 43
Minimum commutator diameter, mm 40
Resistance, shunt field winding, Ω at 25 C° 23.31
Resistance armature winding, Ω at 24 °C 0.0156
Insulation resistance between the windings and motor casing >=1 Mohm
Weight, kg 25
Brake
Type 891.270.0
Braking force, Nm 9
Output, W 28
Resistance coil, Ω 20,8
Minimum thickness brake disc, mm 6,75
Thickness of a new brake disc, mm 6,90
Transmission/drive gear
Type 2-stage drive gear
Gear ratio 24,8:1
Volume of grease, kg 0,3
Type of grease SHELL RETINAX G

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 7

 Technical data
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

Model LW13
Wheels
Drive wheel, mm Dia 250x60
Axle pressure without load, kg 175
Axle pressure at rated load, kg 570
Tightening torque for wheel bolts, Nm 20 Nm
Fork wheel, mm Dia 85x75
Axle pressure without load, kg 2x18
Axle pressure at rated load, kg 2x496
Support castors, mm Dia 100x40
Axle pressure without load 2X30)
Axle pressure at rated load, kg 2x24
Hydraulic system
Output, kW 1.2
Duty cycle,% 10
Minimum carbon brush length, mm 7.5
Minimum commutator thickness/diameter, mm 4.75
Pressure at rated load, bar 110
Overflow pressure, bar 130
Pump flow, litre/minute 4.7
Tank volume, litre 1.0
Oil type Hydraulic oil
Normal temperature ISO-L-HM32
Fuses
Drive motor circuits, A (Common with the pump) 50
Pump motor circuits, A (Common with the drive motor) 50
Control circuits, A 5

8 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Technical data
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

Model LW13
Battery compartment, Batteries
Dimensions LxWxH, mm 278 x 175 x 190
Capacity, Ah 50
Weigh, kg 2X18
Driving speed
Without load, km/t 5.4
Without load, m/s 1.5
With rated load, km/t 4.0
With rated load, m/s 1,1
Lift/lowering speed

Lift without load, s 1.7

Lift with rated load, s 3.0
Lowering without load, s 3.0
Lowering with rated load, s 3.0
Power consumption
Driving without load, A 13
Driving with rated load, A ?
Lift without load, A ?
Lift with rated load, A ?
Incline climbing ability
With rated load 9
Without load% 18
Measurement, L2 420
Turning radius WA, mm 1410
Lift height, mm 205
Weight
Truck without battery, Medium 200

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 9

 Technical data
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

10 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Introduction Maintenance
Valid from serial number T-code C-code
372000AA.- 675
Order number Date Version
179573-040 2000-10-02 001

Introduction Maintenance
All points in the service program should be carried out to attain
the highest safety and the least possible downtime. The service
intervals are only a guide and do not need to be followed to the
letter. The operator may adapt them to local conditions, but it is
important that the intervals comply with BT’s minimum 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.

1 Safety regulations with

maintenance work
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.

WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-
circuiting/burns can occur if a metal object comes into contact
with live electrical connections.
Remove watches, rings or other types of metal jewellery.

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 11

 Introduction Maintenance
C-code T-code Valid from serial number
675 372000AA.-
Version Date Order number
001 2000-10-02 179573-040

• 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. Never use your hand.
• Bear in mind that the oil in the transmission or the hydraulic
system can be hot.

WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil.

WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be dam-
aged.
Always use new and clean oil in the hydraulic system.
• 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.
NOTE!
The battery can be damaged.
When welding using an electric power source the welding cur-
rent can enter the battery.
The battery should therefore be disconnected.
• 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.

CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

12 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Introduction Maintenance
Valid from serial number T-code C-code
372000AA.- 675
Order number Date Version
179573-040 2000-10-02 001

2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the
truck’s reliability.
• Carry out general cleaning and washing weekly.
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the bat-
tery connector.

2.1 External cleaning

• 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.
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the
chapter Maintenance and lubrication chart.

2.2 Cleaning the motor compartment

• Cover the electric motors, connections and valves before
washing.
NOTE!
Risk of short-circuiting.
The electrical system can be damaged.
Electrical components must not be cleaned with a high pres-
sure washing unit.
• 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 Minimover LW13 Approved by: L-G Andersson 13

 Introduction Maintenance
C-code T-code Valid from serial number
675 372000AA.-
Version Date Order number
001 2000-10-02 179573-040

2.3 Electrical components

• 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.
NOTE!
Risk of short-circuiting.
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

3 Safe lifting
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.
• Never lift up the jack in order to lift higher.
• Never work under a lifted truck unless it is well supported.

WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-
blocks and secured by a lifting device.
14 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson
 Maintenance, Lubrication schedule
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

Maintenance, Lubrication schedule

1 Maintenance schedule
I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate
M: Measure, correct if necessary
Pos. Work to carry out
no.
Interval in days/weeks/months - may vary due to 1d 1w 12 m 36 m
application
0000. Chassis
0000.1 Check all links and locking pins I
0000.2 Check wear on battery locking I
0000.3 Check of cracking and damage I
0000.4 Check signs and stickers I
0000.5 Check the mounting, lock and function of the covers I
0380 Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check clearance in bushes and links I
0380.3 Press grease into grease nipples I/L
0380.4 Check the lift limit switch I
1700. Drive motor
1700.1 Check clearance in connections I/T1
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 I4
2550.2 Check for abnormal noise I
2550.3 Check the attachment and clearance in steering I
bearing
2550.4 Change the grease in the drive gear L

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 15

 Maintenance, Lubrication schedule
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

M: Measure, correct if necessary
Pos. Work to carry out
no.
Interval in days/weeks/months - may vary due to 1d 1w 12 m 36 m
application
3100 Brake
3100.1 Clean C
3100.2 Check for wear on the brake disc M
3100.3 Check the function of the brake M
3500. Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tightening I/T3
torque on bolts
3500.3 Check that the support wheel turns and rotates I
freely
3500.4 Check for wear on the support wheel I
4110. Tiller arm
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I
4110.3 Check the touching protection 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 on cabling I
5000.5 Check the function of the driver’s control I I
5000.6 Check the emergency switch off I I
5000.7 Check the charging plug and start block I I
5110. Battery
5110.1 Check connections to battery, truck and charger I
5110.2 Check that the cell and pole guards are undamaged I
5110.3 Check the battery locking I

16 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Maintenance, Lubrication schedule
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

M: Measure, correct if necessary
Pos. Work to carry out
no.
Interval in days/weeks/months - may vary due to 1d 1w 12 m 36 m
application
5400 Power system
5400.1 Cleaning and checking of mounting in chassis C/T1
5400.2 Re-tighten cable connections T1
5400.3 Check the contactor points on K10 and K30 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
5700 Electronic circuit board
5700.1 Check connectors and cables T1
6100. Hydraulic system
6100.1 Check hoses and connections for wear I
6100.2 Check hoses for wear and damage I
6100.3 Check the oil tank for cracks, leakage and damaged I
mountings
6100.4 Check that the oil level is correct I I
6100.5 Change the oil and clean the filter L5
6600. Lift cylinder
6600.1 Check for leakage I
6600.2 Check the mountings I
1 = The connections are re-tightened every 12 months.
2 = Retighten securing bolts to 45 Nm every 12 months.
3 = The drive gear is replaced when its diameter is < 235 mm.
Drive gear bolts are retightened every 12 months to 20 Nm.
4 = Check for leakage when changing the grease for the first
time.
5 = The oil is changed and the filter cleaned for the first time after
12 months, and then every 24 months

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 17

 Maintenance, Lubrication schedule
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

When points with higher hour intervals are carried out the points
with lower hour intervals should also be carried out unless other-
wise specified above.
5000
5000

4110

5000

0380

0000

3500

5110

5700
6100

6600

5400

3100
2550
1700

18 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Maintenance, Lubrication schedule
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

2 Lubrication schedule

Pos no Service point Interval/Running hours Lubricant

12 m 36 m
0380 Lubricating nipples L D
2550 Drive gear C G4 C
6100 Hydraulic system O5 B
L = Lubrication C = Check O = Oil change F=Grease
4= The grease is changed every 36 months.
5= The oil is changed and the filter cleaned for the first time after
12 months, and then every 24 months.

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 19

 Maintenance, Lubrication schedule
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

0380

6100

2550

20 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Oil and grease specification
Valid from serial number T-code C-code
372000AA- 675
Order number Date Version
179573-040 2000-10-02 001

Oil and grease specification

Pos. Type of lubricant Specification Application
>0°C
A Grease BT 26777 Bearings and bushes
(Spray)
B Hydraulic oil ISO-L-HM32 Hydraulic system
C Grease SHELL RETINAX G Gears
D Grease BT 73942XX5 Lubricating nipples
TOTAL N3942

0380

6100

2550

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 21

 Oil and grease specification
C-code T-code Valid from serial number
675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

22 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Drive unit/drive gear
Valid from serial number T-code C-code
372000AA- 675 2550
Order number Date Version
179573-040 2000-10-02 001

Drive unit/drive gear

Complete
1 Component parts
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28

40 24 24 29 30 31 32

4 33 5 34 35 36 4 37 38 39

Pos Benämning Anm.

1 Screw 7 st
2 Washer 7 st
3 Cap
4 Locking ring
5 Ball bearing
6 Key
7 Axle
8 Venting nipple
9 Gear housing
10 Screw 8 st
11 Sealing ring
12 Gear ring
13 O-ring
14 Ball bearing
15 Locking ring
16 Drive track
17 Ring
18 Screw 8 pcs. Tight-
ened to 20Nm
19 Locking ring

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 23

 Drive unit/drive gear
C-code T-code Valid from serial number
2550 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

Pos Benämning Anm.

20 Magnetic coil
21 Key
22 Rotor
23 Carbon brush 4 st
24 Locking ring
25 Ball bearing
26 Driver
27 Screw
28 Connector
29 Guide pin
30 Locking ring
31 Stropping
32 Brake complete
33 Gear wheel
34 Locking ring
35 Gear wheel
36 Sealing ring
37 Locking ring
38 Washer
39 Ball bearing
40 Sealing ring

1.1 Dismantling the motor from the truck

• Shutdown the truck, pull out the plug from the start block.
• Remove the hoods from the battery compartment.
• Loosen the battery connections.
• Lift out the batteries.
• Loosen the two screws holding the instrument panel.
• Place the instrument panel in the truck.
• Seal the oil-filling plug.

24 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Drive unit/drive gear
Valid from serial number T-code C-code
372000AA- 675 2550
Order number Date Version
179573-040 2000-10-02 001

• Loosen the connections on the tiller arm.

• Dismantle the cover plate and the two nuts on the tiller arm.
• Lift off the tiller arm.
• Place the truck on its side.
• Loosen the four bolts on the motor’s chassis mounting.
• Carefully lift out the motor and place on a clean surface.
Essential service and repair work can now be carried out on the
motor.

1.2 Assembling
Assembly takes place in the reverse order.

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 25

 Drive unit/drive gear
C-code T-code Valid from serial number
2550 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

2. Service and repairs

2.1 Inspection/replacement of the carbon

brushes
• Shut down the truck, pull out the plug from the start block.
• Remove the hoods from the battery compartment.
• Loosen the battery connections.
• Lift out the batteries.
• Loosen the two screws holding the instrument panel.
• Place the instrument panel in the truck.
• Seal the oil-filling plug.
• Refit the instrument panel.
• Place the truck on its side.
• Dismantle the covers from the carbon brushes.
• Loosen the cable connections are push back the carbon brush
springs.
• Pull out the carbon brushes and inspect/measure the wear.
(See table)
• Assembly takes place in the reverse order.

2.2 Replacing the drive gear

• Shut down the truck, pull out the plug from the start block.
• Remove the hoods from the battery compartment.
• Loosen the battery connections.
• Lift out the batteries.
• Loosen the two screws holding the instrument panel.
• Place the instrument panel in the truck.
• Seal the oil-filling plug.
• Refit the instrument panel.
• Place the truck on its side.
• Loosen the cable connections on the motor.

26 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Drive unit/drive gear
Valid from serial number T-code C-code
372000AA- 675 2550
Order number Date Version
179573-040 2000-10-02 001

• Loosen the 8 bolts holding the drive gear.

• Carefully lift off the gear, avoid damaging the seals.
• NOTE! The securing bolts should always be replaced when re-
placing the drive gear.
• Assembly takes place in the reverse order.

2.3 Cleaning
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.
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.

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 27

 Drive unit/drive gear
C-code T-code Valid from serial number
2550 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

2.4 Brakes, Maintenance

In general the brakes require no maintenance when used in a
normal working environment. However, according to the chart for
preventive maintenance it is recommended that the brake discs
are regularly inspected with regard to wear.

2.5 Replacing the brake disc

The brake disc should be replaced when its overall thickness has
decreased to 5.5 mm.
• Disconnect the electrical cables routed to the brake.
• Loosen and remove the two securing bolts.
• Loosen the brake disc from the hub and check the wear. Re-
place the brake disc if the surface shows signs of uneven
wear.
• Assemble the brake again.
• Connect the electrical cables.

28 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Drive unit/drive gear
Valid from serial number T-code C-code
372000AA- 675 2550
Order number Date Version
179573-040 2000-10-02 001

3 Technical data
Truck type LW13
Drive motor
Type TSL115-16
Output, kW 0.5
Duty cycle S2, 60 min
Minimum carbon brush length, mm 14.5
Nominal commutator diameter, mm 43
Minimum commutator diameter, mm 40
Resistance, shunt field winding, Ω at 25°C 23.31
Resistance armature winding, Ω at 24 °C 0.0156
Insulation resistance between the windings and motor casing >=1 Mohm
Weight, kg 25
Brake
Type 891.270.0
Braking force, Nm 9
Output, W 28
Resistance coil, Ω 20,8
Minimum thickness brake disc, mm 6,75
Thickness of a new brake disc, mm 6,90
Transmission/drive gear
Type 2-stage drive gear
Gear ratio 24,8:1
Volume of grease, kg 0,3
Type of grease SHELL RETINAX G
Wheels
Tightening torque for wheel bolts, Nm 20 Nm

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 29

 Drive unit/drive gear
C-code T-code Valid from serial number
2550 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

30 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

Electrical systems
1 Electrical parts

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 31

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

S41

S18

S34

S15 S16

S20

32 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

2 List of symbols and electrical

wiring diagram
Symbol Description Function Notes
A1 Transistor regulator
A30 Integrated charger 230 V

F1 Fuse Drive motor circuit 50 A

F 50 Fuse Operating circuit A5 5A
F 51 Fuse Battery charger 10 A
G1 Battery 24 V
G2 Battery 12 V
H1 Horn

K10 Contactor Main contactor

K30 Contactor Pump motor

M1 Motor Drive motor

M3 Motor Pump motor

S10 Switch Travel brake Brake lever

S17 Switch Key
S18 Switch Horn button
S20 Switch Safety reversing
S21 Switch Emergency switch off
S31 Switch Lift height limiter
S34 Switch Fork lifting
S41 Switch Fork lowering
S170 Switch Start block
Y1 Brake
Y41 Magnetic valve Fork lowering

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 33

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

2.1 Electrical diagram

34 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 35

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

36 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

3 Functional description

3.1 Starting the truck

• Start block S170 should be engaged.
• S21 closed.
• S17 on.

3.2 Driving
• S10 closed.
• L1 activated in any direction.
• S15 closed. Driving in the direction of the drive wheel.
• S16 closed. Driving in the direction of the forks.

3.3 Neutral speed reduction

• L1 to neutral position, motor starts to work as generator.
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.

3.4 Braking
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 ful-
filled and the truck starts to move.
Conditions to brake the truck:
• S10 open.

3.5 Lifting the forks

• S10 closed.
• S34 activated.
• S31 closed.
• Battery status OK (if battery capacity >20% left).
• Simultaneous driving gives reduced speed.

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 37

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

3.6 Lowering the forks

• S10 closed.
• S41activated.

3.7 Horn
• S10 closed.
• S18 activated.

4 Error codes

4.1 Diagnosis and trouble shooting

The Status LED is dimmed under normal operating conditions
without faults. If the regulator discovers a fault, a single digit code
flashes until the fault is rectified, see the table below.
When a hand terminal is used in diagnostic mode for trouble
shooting, information regarding the diagnosis can be read off on
the terminal’s display, see the table below.

LED-code Hand terminal Description Possible cause

LCD-display
1 ¤ Logic failure #1 Problem with Logic or Electronic card failure
main contactor
1 ¤ Watch-dog Electronic card and/or
software failure
1 ¤ EEPROM KO EEPROM or Logic
problem
2 ¤¤ INCORRECT Starting sequence for ENABLE micro switch fused
START travel not correct or faulty
Operator starting sequence
error Wiring error

38 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

LED-code Hand terminal Description Possible cause

LCD-display
2 ¤¤ FORW+BACK Multiple direction Wiring error
orders Direction switch fused or
faulty
Operator starting sequence
error
3 ¤¤¤ CAPACITOR Power Block problem Capacitors are not charged
CHARGE within 500 ms after Key switch
is closed
3 ¤¤¤ VMN NOT OK Chopper problem Incorrect motor connection
Short circuit, motor windings
to chassis
Power unit defect
3 ¤¤¤ VFIELD NOT OK Field Voltage problem Motor´s field winding short-cir-
cuit or interruption
Field winding incorrectly con-
nected to the electronic card
Electronic card failure in the
section relative to the field
4 ¤¤¤¤ VACC NOT OK Potentiometer wiper The track of the potentiometer
has become open
The potentiometer is not wired
correctly
The potentiometer itself is
defective
The values set in PROGRAM
VACC routine have not remai-
ned or made correctly
4 ¤¤¤¤ PEDAL WIRE KO Pedal wire not OK
5 ¤¤¤¤¤ NO FIELD CUR Defective field wiring
Defective field current sensor
Field power unit failure
5 ¤¤¤¤¤ HIGH FIELD CUR Defective field wiring
Defective field current sensor
Field power unit failure

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 39

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

LED-code Hand terminal Description Possible cause

LCD-display
5 ¤¤¤¤¤ STBY I HIGH High armature stand- Defective current sensor
by current Electronic card failure
Power unit failure
5 ¤¤¤¤¤ I=0 EVER No armature current Defective current sensor
Defective armature or carbon
brushes
Electronic card failure
Power unit failure
6 ¤¤¤¤¤¤ CONTACTOR Faulty contactor driver The contactor coil is either
DRIVER short-circuit, open circuit or
not connected
Contactor coil driver short-cir-
cuit
Defective contactor wiring
Electronic card failure
6 ¤¤¤¤¤¤ COIL SHORTED Contactor coil shorted The contactor coil is either
short -circuit, open or not con-
nected
Contactor coil driver short-cir-
cuit
Defective contactor wiring
Electronic card failure
6 ¤¤¤¤¤¤ CONTACTOR Faulty main contactor Main contactor power points
CLOSED points are fused
Field circuit problem
Problem detected by the
safety micro processor
7 ¤¤¤¤¤¤¤ TH. PROTEC- Temperature outside Defective temperature sensor
TION range >70°C or <10°C Bad temperature sensor con-
nection
Defective electronic card
32 ¤...........¤ BATTERY LOW Low battery voltage Battery voltage less than 50%
of nominal value

40 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

5 Parameters
The following parameters can be changed.
NOTE !
Truck handling.
Modifying specific truck parameters will change the driving
characteristics of the truck.
Do not change any parameters without the necesarry know-
how.

5.1 Parameters

Parameter Min Max Std Description

ACC. DELAY 0 9 Determines the acceleration ramp
MAX SP BACK 0 9 Maximum speed, fork direction, fine adjustment
FINE
MAX SP FORW 0 9 Maximum speed, steer wheel direction, fine
FINE adjustment
INVERSION BRA- 0 9 Determines the deceleration ramp when the
KING direction switch is inverted during driving
RELEASE BRA- 0 9 Determines the deceleration ramp when the tra-
KING vel request is released
DECELER DELAY 0 9 Determines the deceleration ramp according to
the speed controller position

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 41

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

6 Test
BT
CONSOLE V1.0

CONNECTED TO:
SEM 0 BT 1.03

SEM 0 BT 1.03
24v 75A 00000

ENTER

* MAIN MENU * ENTER

PARAMETER CHANGE

OUT
ROLL

* MAIN MENU * ENTER NOT AVAILABLE

STEER TABLE

ROLL

* MAIN MENU * ENTER

PROGRAM VACC

ROLL

* MAIN MENU * ENTER

ALARMS

ROLL

* MAIN MENU * ENTER

RESTOR PARAM.

ROLL

* MAIN MENU * ENTER

SAVE PARAM.

ROLL

* MAIN MENU * ENTER

TESTER

OUT ROLL

42 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

6.1 Test functions

Display Function
BATTERY VOL- Level of the battery voltage measured at
TAGE the input to the key switch
MOTOR VOL- The voltage appearing across the drive
TAGE motor as measured between B+ and VMN
MOTOR CUR- Drive motor armature current
RENT
FIELD CURRENT Drive motor field current
VMN Voltage drop across the MOS as measu-
red between B- and VMN
TEMPERATURE The temperature measured on the alumi-
nium heat sink holding the MOSFET devi-
ces
ACCELERATOR The voltage of the accelerator potentiome-
ter wiper (CPOT)
Left hand of the display indicates voltage
level and the right hand the value in per-
cent
FORWARD The level of the steer wheel direction digi-
SWITCH tal input MA (pin B6):
ON/+VB = active input, switch closed
OFF/GND = non active input, switch open
BACKWARD The level of the fork direction digital input
SWITCH MI (pinB4):
ON/+VB = active input, switch closed
OFF/GND = non active input, switch open
HANDLE/SEAT The level of the tiller arm micro switch digi-
SWITCH tal input (pinA5):
ON/+VB = active input, switch closed
OFF/GND = non active input, switch open
QUICK INVER- The level of the digital input from Belly but-
SION SWITCH ton micro switch (pin B5):
ON/+VB = active input, B SW closed
OFF/GND = non active input, B SW open

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 43

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

Display Function
CUTBACK The level of the speed reduction 1 micro
SWITCH 1 switch SR1:
ON/GND = active input
OFF/+VB = non active input

6.2 Safety
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 pro-
tectors, avoiding use of lose-fitting clothes, removal of watches
and jewellery, and use of insulated tools only.

WARNING!
Risk of short-circuiting.
Remove all watches, jewellery and always use insulated tools
only.

44 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Electrical systems
Valid from serial number T-code C-code
372000AA- 675 5000
Order number Date Version
179573-040 2000-10-02 001

7 Technical specifications – SEM zero

Value Unit Description

Rated operating voltage 24 Volts
Overvoltage limit 36 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 3 minutes
100 Amps for 1 hour
Max. current of field winding 35 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 -30 to +40 °C
Overtemperature, reduction 70 °C Reduced in proportion to the
rise in temperature
Undertemperature, reduction to 80% -10 °C
Maximum temperature limit 80

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 45

 Electrical systems
C-code T-code Valid from serial number
5000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

46 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Hydraulic system
Valid from serial number T-code C-code
372000AA- 675 6000
Order number Date Version
179573-040 2000-10-02 001

Hydraulic system
1 Hydraulic chart and list of symbols

Y41
4

M3 P 5

1.1 List of Symbols

Pos No Description Function Remarks
1 Lift cylinder Lifting the forks
2 Preasure relief valve
3 Flow control valve
4 Non-return valve
5 Filter
M3 Motor Pump motor
P Pump
T Tank 1,2 litre
Y41 Valve Lowering valve for the forks

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 47

 Hydraulic system
C-code T-code Valid from serial number
6000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

2 Adjustments W13

2.1 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory,
but may need to be adjusted if the valve or the complete hydraulic
unit is replaced.
The machine should be capable of lifting a load of between
1350-1400 kg.

1. Locking nut. Use special tool, see drawing in chapter “Tools”.

2. Adjuster screw, pressure limit.
Adjusting clockwise results in increased pressure.
Adjusting anticlockwise results in decreased pressure.
3. Pressure limit valve. Use special tool, see drawing in chapter
“Tools”.
• Loosen the locking nut (1) using a special tool (see drawing).
Place a load of 1300 kg on the forks and check that the ma-
chine can lift it.
• If the machine lifts 1300 kg, place a further 100 kg on the forks.
Check whether the machine can lift the load.
• If the machine lifts 1400 kg, adjust the pressure limit by turning
the adjuster screw (2) anticlockwise using a 4 mm allen key
until the machine cannot lift the load.

48 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 Hydraulic system
Valid from serial number T-code C-code
372000AA- 675 6000
Order number Date Version
179573-040 2000-10-02 001

2.2 Tools
• Use a 22 mm standard socket and turn it down to the values
shown below in drawing A, when you wish to loosen or tighten
the pressure limit valve.
• Use a 10 mm standard socket and turn it down to the values
shown below in drawing B, when you wish to loosen or tighten
the locking nuts.

A B

12

8
26,5 13,5

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 49

 Hydraulic system
C-code T-code Valid from serial number
6000 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

50 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson

 In-built battery charger
Valid from serial number T-code C-code
372000AA- 675 8340
Order number Date Version
179573-040 2000-10-02 001

In-built battery charger

1 General
The LEAB CHAMP charger is optimised for valve regulated lead
batteries. The charger is protected against dust and water jets
(IP65).
The charger is connected to a normal earthed 230 V single-
phase wall socket. The charging process is automatic.

2 Charging
Connect the charger (A) to the mains supply. If a discharged bat-
B
tery is connected, the charger will start with the main charge (yel-
low LED (B) and 28,8 V). When the battery is fully charged, main-
tenance charging starts (yellow and green LED (B) and 27.6 V).
This continues until the charger switches off. If a fully charged
battery is connected to the charger or if the charger does not find
a connected battery the maintenance charge is started (yellow
and green LED 27.6 V). The charger starts with the main charge
(yellow LED and 28,8 V) after a power failure if a discharged bat-
tery is connected.
The truck’s mains lead can be connected to the mains supply
whenever the truck is not in use to ensure the batteries are
always fully charged. The charging process is gentle and conse-
quently does not shorten the life of the battery. It is also beneficial
if the truck can be recharged over night or for 12 hours at least
once a week.

3 Trouble shooting
• Check the mains supply to the charger.
• Check the fuse on the charger’s battery cable.
• Check whether the charger is overheated.
• If the charger still does not work, replace the charger.

© BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson 51

 In-built battery charger
C-code T-code Valid from serial number
8340 675 372000AA-
Version Date Order number
001 2000-10-02 179573-040

4 Technical data

Dimensions 195x100x46 mm
Weight 1.6 kg
Ambient temperature -25°C to +50°C
Mains supply 230 V
Rated voltage 24 V DC
Rated current 7A
Degree of efficiency >85%
Battery types Valve regulated lead battery (gelade)
Protection class IP 65
Miscellaneous The charger switches off automatically when there is risk of over-
heating
It restarts automatically when the temperature drops

52 © BT Industries AB Service Manual Minimover LW13 Approved by: L-G Andersson