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BT CARGO DT 15, Operator'S Manual

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BT CARGO DT 15 Operator'S Manual Download Page 32

Handling the BT DPF-II System (Option)

© BT Industries AB 180424-040

32

3.

During operation
The amount of black smoke trapped is indicated by the trap-
ping indicator lamp, the alarm indicator lamp and the buzzer, 
in that order.

4.

If a malfunction occurs in the DPF System, the alarm indica-
tor lamp comes on and the buzzer rings for 5 seconds.

CAUTION!

When the alarm indicator lamp comes on, stop operation and 
request an inspection from your BT dealer.

5.

Operation completion
Carry out DPF maintenance when a day’s operation is over.

BT DPF-II System maintenance method (Option)

CAUTION ON MAINTENANCE!

• Use a single phase AC200~240V external power source, rated 
10 A or more. Connect securely to a power source earth.
• Have any repairs to the external power supply plug done by 
an electrical specialist.
• Always fit an electromagnetic switch ‘with earth leakage 
breaker) to the external current plug electrical source.
• Do not allow water into the DPF air cleaner when washing the 
vehicle, etc.
• When there is a power cutoff due to power failure etc., the 
system might sense a malfunction making the alarm indicator 
lamp come on. In this case, request an inspection from your 
BT dealer.
• Check that there are no objects that can easily catch fire 
around the DPF System before carrying out maintenance.
Select a location for maintenance which is well ventilated (with 
a draught), away from the rain and not near any waste paper 
etc. that can easily catch fire.
• Do not handle the power plug with wet hands. A high voltage 
is used (single phase AC200~240V), so there is a danger of 
electric shock.
• Before starting DPF maintenance operation, make sure that a 
specified external power is supplied to the machine.
So long as the external power is not supplied, regeneration will 
fail to start, even if attempted.
• During  maintenance operation, combustion smoke is emitted 
out of the tail pipe.

Maintenance operation procedure

1.

Stop the vehicle, put the parking brake on and remove the 
engine switch.

2.

Insert the plug into an external power supply connection 
socket and turn it in the locking direction.

1 Insert
2 Lock

Summary of Contents for CARGO DT 15

Page 1: ...perator s Manual GB WARNING Do not use the truck before first reading through the OPERATOR S MANUAL NOTE Keep for future reference CARGO GT 15 18 20 25 30 CARGO DT 15 18 20 20P 25 25p 30 30P 35 CARGO GT 35 CARGO DT 35 Valid from serial number Order number 180424 040 Issued 2000 10 18 ITS ...

Page 2: ...s series of vehicles The manual has been produced based on a standard vehicle However if you have questions on other types please contact your BT industrial vehicle dealer BT dealer In addition to this manual it is essential that you review the sep arate publication entitled Operator s Manual for Safety Opera tion for forklift truck drivers It contains important information about the safe operatio...

Page 3: ...method 17 Hour meter also serving as an SAS diagnosis indicator SAS models 17 Engine oil pressure warning lamp 17 Sedimenter warning lamp 18 Glow indicator lamp 18 Preheating indicator lamp 18 Air cleaner warning lamp 19 Charge warning lamp 19 Water temperature gauge 19 Fuel gauge 20 Reference 20 SAS warning lamp 20 Swing lock indicator lamp 21 Speed control warning lamp 21 Torque converter oil te...

Page 4: ...6 Tire inspection 36 Hub nut inspection 36 Engine compartment inspection 37 Engine coolant level check and supply 37 Checking hydraulic oil level 38 Engine oil inspection 39 Adding engine oil 39 Leakage inspection 39 On board vehicle inspection 39 Brake fluid inspection 39 Brake pedal inspection 40 Parking brake inspection 40 Inching and brake pedal 40 Instrument inspection 41 Fuel level check and...

Page 5: ... fuel system 51 Draining the sedimenter 51 Maintaining the battery 52 Adjustment of parking brake operating force 52 Fuel Tank Check 53 Frame Serial Number 53 Frame serial number location 53 How to Read the Name Plate 53 Lubrication Chart 54 Periodic Maintenance 55 Periodic Replacement Table 56 Protect Your Investment with BT Genuine Parts 57 Periodic Maintenance Table 58 Service Data 64 Adjustmen...

Page 6: ...e tank 73 Important Information about Properties of LPG 73 Safety Precautions about Operating LPG Powered Forklifts 74 Servicing the Regulator 75 Removing Tar from the Regulator 75 Inspecting and Servicing LPG Powered Forklifts 75 Lubricant and Coolant 77 Engine oil 77 Cooling water 77 Engine Specifications 77 Mast Specifications and Rated Capacities 78 GT 15 DT 15 79 GT 18 DT 18 80 GT 20 DT 20P D...

Page 7: ...e smooth operation and cause an unexpected accident Always wear proper clothing for easy operation Please keep away from live electric power lines Know the locations of inside and outside power lines and maintain suffi cient distance Be sure to perform pre operation check and periodic maintenance This will prevent sudden malfunctions improve work efficiency save money and insure safe working condi...

Page 8: ...aged and in some cases ignited by a hot exhaust sys tem or hot exhaust gases To minimize the possibility for such damage or fire the operator must obey the following recommended prac tices Do not operate lift truck over or near flammable and or com bustible materials including dried grass and paper scraps Park lift truck with rear end at least 12 away from lumber veneer board paper products and ot...

Page 9: ...e control rear stabilizer When the vehicle makes a turn on the spot a centrifugal force will be generated in the lateral direction of the vehicle In such event this feature will operate so that rear wheels will be locked from swinging to support the vehicle on four wheels Thus the vehicular stability will be enhanced in both right and left direc tions CAUTION With the vehicle locked from swinging ...

Page 10: ...th a high load at a high lift while the engine is running at a high speed This will lead to a hazard Some specialty models onto which a heavy attachment is mounted may not be equipped with the automatic fork leveling control Confirm a BT dealer in advance Note The mast will not move if it is tilted forward by pressing the tilt lever knob switch with a high load at a high lift more than 2 m As long...

Page 11: ...Never tilt the mast forward with a load moved up Some specialty models onto which a heavy attachment is mounted may not be equipped with the mast forward tilt con trol Confirm a BT dealer in advance Once you have mounted or replaced any attachment on a fork lift model ask a BT dealer for an inspection If you use two or more removable attachments alternately the heaviest one should be used to carry...

Page 12: ...ift interlock With the engine killed the ignition switch positioned at OFF the fork will not move down even if the lift lever is so operated Active steering synchronizer If the steering wheel knob is not angularly matched with tires such an out of position will be automatically corrected while turning the steering wheel Thus the knob is kept at a constant position relative to tires If SAS feature ...

Page 13: ...e vehicle by operating it similarly to a non SAS model Move the vehicle to a safe location and ask a BT dealer for a repair If any phenomenon different from normal operations failure to run or the like among others should take place ask a BT dealer for an inspection Note Once a torque converter model has had its control lever abnor mal it is impossible to manually operate the vehicle which need be...

Page 14: ...B 180424 040 14 Main Components Main Components 1 Mast 2 Chain 3 Fork 4 Tilt cylinder 5 Operator s seat 6 Head guard 7 Lift cylinder 8 Steering wheel 9 Counter weight 10 Rear axle 11 Engine hood 12 Frame 13 Front axle ...

Page 15: ...rol lever 3 Steering wheel 4 Integrated monitoring center 5 Horn button 6 Turn signal and light control switch 7 Lift lever 8 Tilt lever 9 Tilt lever knob switch SAS models 10 Attachment lever 11 Ignition switch 12 Accelerator pedal 13 Brake pedal 14 Inching and brake pedal 15 Tilt steering adjust lever 16 Engine hood lock release lever 17 DPF display Option ...

Page 16: ...also to diagnose the SAS 2 Engine oil pressure warning lamp 3 Sedimenter warning lamp Diesel models 4 Glow Indicator lamp 1DZ II engine models Preheating indicator lamp 2Z engine models Standard in designate area 5 Air cleaner cleaning warning lamp 6 Charge warning lamp 7 Water temperature gauge 8 Fuel gauge 9 SAS warning lamp SAS models 10 Swing lock indicator lamp SAS models 11 Vehicular speed c...

Page 17: ...e right most digit is 1 10 hour Please use this meter to grasp the timing for periodic mainte nance and record the operating hours SAS models The hour meter display will alternately indicate an error code and an hour meter reading in the SAS CAUTION Should an error code be displayed park the vehicle at a safe location and receive an inspection by a BT dealer Engine oil pressure warning lamp Comes ...

Page 18: ...f automatically when glow plug heating is complete The engine will start easily once the glow plugs are heated Note The glow indicator lamp is on for 2 seconds when the engine coolant temperature exceeds 50 C Preheating indicator lamp 2Z engine models standard in designated area Indicates preheating of the intake heater 1 When the ignition switch is turned on the lamp comes on and preheating start...

Page 19: ...omes on while the engine is running stop the operation immediately inspect the fan belt for cuts or loos ening adjust it and restart the engine If lamp does not go off the generation system may be faulty Please ask a BT dealer immediately for inspection and repair Water temperature gauge Indicates the temperature of the engine cooling water 1 Operates when the ignition switch is on 2 In normal sta...

Page 20: ...s lamp should come on After the engine has started up the SAS warning lamp should go out Then the SAS may be deemed operating normally Should an SAS feature be abnormal the buzzer will sound thereby informing the operator of the abnormality If this warning lamp falls in any of the cases referred to below the system may be deemed abnormal Then receive an inspec tion by a BT dealer The SAS warning l...

Page 21: ...at the speed controller is abnormal CAUTION Once the warning lamp has come on during the operation dis continue the operation in progress and park the vehicle at a safe location Then ask a BT dealer for an inspection Torque converter oil temperature gauge Option Indicates the torque converter oil temperature 1 Operates when the ignition switch is on 2 Indicates the green zone if the oil temperatur...

Page 22: ...d It may cause over discharge of the battery Do not turn the switch to the START position while the engine is running This may damage the starter motor For the sake of safety it is recommended to always start the engine of a vehicle with the transmission gear shift lever shifted in the neutral position Do not operate the starter motor for more than 30 seconds continuously Return the switch to the ...

Page 23: ...ed It may cause overdischarge of the battery to make engine start ing impossible Turn signal switch Makes the turn signal lamps blink Left turn Push forward Right turn Pull backward The turn signal lever returns automatically to the original position after making a direction change Vehicular speed limiter Option The highest vehicular speed may be set within a range of 9km h to the maximum CAUTION ...

Page 24: ...shifting between forward and reverse Horn button Press the button in the center of the steering wheel to sound the horn The horn will sound even when the ignition switch off Lift lever Raises and lowers the forks Raise Pull backward Lower Push forward The lifting speed can be adjusted by the degrees of accelerator pedal depression and lever operating stroke The lowering speed can be adjusted only ...

Page 25: ... lever knob switch SAS models With this switch pressed change tilting from backward to for ward and the fork will automatically stop at its horizontal posi tion It is also possible to slow down the backward tilt speed at a low lift Automatic fork leveling control With the fork positioned at the backward lift use the lever to tilt the fork forward while pressing the tilt lever knob Then the mast ca...

Page 26: ...ing the lever for starting on a slope for example hold the grip at above the pro trusion When parking on a slope apply wheel chocks to the wheels Traveling without releasing the brake will spoil the brake per formance Tilt steering adjustment 1 The steering wheel position may be adjusted back and forth while the tilt steering adjust lever is kept lowered 2 Raising the lever at the proper position ...

Page 27: ...or a heavier body weight Turn the knob counterclockwise to adjust for a lighter body weight Adjustment can be made for body weights between 50 kg and 130 kg ö Seat belt CAUTION After adjustment lightly shake the seat forward and backward to confirm that the seat is firmly locked in position Seat belt To fasten your seat belt pull it out of the retractor and insert the tab into the buckle You will ...

Page 28: ...ld the engine hood using the clearance underneath and raise it 3 Fully open the engine hood and release it after checking sure locking of the hood stay Closing Press the lock release button of the damper stay and close the engine hood Holding the hood until it is locked to the position with a checking sound Pull the steering wheel backward to return it to the original position CAUTION Operating th...

Page 29: ...ed at the back of the counterweight and is used to pull the vehicle should its tires drop into a gutter or become stuck in mud It can also be used for loading the forklift onto a truck or another vehicle CAUTION The draw bar should not be used for towing the forklift or for towing another vehicle using the forklift Vehicle hoisting method When hoisting the vehicle use the lifting holes near the to...

Page 30: ... except in an emergency If the display s alarm lamp goes on and the alarm buzzer rings to an abnormality during maintenance have the device inspected by your BT dealer Do not allow water to get into the DPF System when your vehicle is being washed The DPF System uses a high voltage single phase AC200 240V so be careful of electric shocks The DPF System reaches high temperatures during operation so...

Page 31: ... maintenance is underway 4 Maintenance Switch Starts maintenance Explanation of display 1 Turn on the ignition switch 1 All the display lamps come on so check if any are off and the buzzer rings 2 1 second later the display shows the amount of black smoke trapped 2 Starting up the engine CAUTION Do not start up the engine with the external power connector plugged in If so the buzzer will sound and...

Page 32: ...ir cleaner when washing the vehicle etc When there is a power cutoff due to power failure etc the system might sense a malfunction making the alarm indicator lamp come on In this case request an inspection from your BT dealer Check that there are no objects that can easily catch fire around the DPF System before carrying out maintenance Select a location for maintenance which is well ventilated wi...

Page 33: ... your fingertip to operate the switch panel on the display If the maintenance indicator lamp should come on without the buzzer sounding ask a BT dealer for an inspection 4 When maintenance starts the maintenance indicator lamp and the trapping indicator lamps all six come on Note The microcomputer ECU automatically carries out mainte nance so the operator does not have to attend to the vehicle 5 T...

Page 34: ...er cable immediately when the buzzer sounds When interrupting soot combustion in progress is unavoidable press the mainte nance switch for about 5 seconds until the buzzer sounds Then the left green lamp and the maintenance lamp will come on After about three minutes when all the indicator lamps are off the engine can be activated again Plug out the power cable after the maintenance lamp is off Do...

Page 35: ...loose parts exterior damage Wheels Tire pressure wear or damage rims hub nuts Lamps Lamp condition damaged lamps Hydraulic oil Oil level contamination consistency Radiator Coolant level antifreeze requirement Engine Oil level contamination consistency noise exhaust Clutch Engagement pedal play Brake pedal Pedal play braking effect Brake fluid Fluid level Parking brake Operating force braking effec...

Page 36: ...ce data section for the proper inflation pres sure Do not raise the pressure beyond the proper level 2 After the adjustment check if air is not leaking from the valve Damage crack and wear of tires and rims Check the tires for damage and wear and the rims for bend ing If the tires are damaged or there is a marked difference in the wearing of tires between the front and rear or between the left and...

Page 37: ...er limit 3 The concentration of the long life coolant LLC in the engine coolant must be 50 Note If no engine coolant remains in the reservoir tank be sure to check the coolant level in the radiator too Checking the engine coolant level in radiator 1 Remove the radiator cover 2 Remove the cap and check the coolant level from the filler port 3 If the engine coolant is not visible through the filler ...

Page 38: ...gauge and the capacity vary with the model Measure at the full mark on the side with the tonnage indication With the 2Z engine vehicles the tonnage indication is on the Z side With vehicles other than the 2Z engine models use 1 2 or 3 ton nage indication 4 If the oil level is insufficient add oil Spilled and splashed oil must be wiped off thoroughly Adjust the oil level so that it will fall within...

Page 39: ...0 C 14 F 32 F CAUTION Always use the same brand of oil if possible Leakage inspection Check the engine compartment for any oil or fuel leakage Clean the radiator if it is clogged and check if there are any foreign objects such as paper or other onto the radiator grill On board vehicle inspection Brake fluid inspection With the engine off check the level of the brake fluid in the res ervoir tank Th...

Page 40: ...r inspection if the play is excessive pedal movement is abnormal or brake performance is improper Parking brake inspection 1 Check the operating force required for pulling the parking lever fully Note See the service data section for the operating force WARNING Ask a BT dealer for inspection if any abnormality is found Inching and brake pedal Torque converter models 1 Manually depress the inching ...

Page 41: ...Carefully prevent entrance of water and dirt into the tank dur ing fueling Engine inspection Start the engine and warm it up sufficiently 1 Check each meter and warning lamp to see there is no abnormality 2 Check if the engine is generating abnormal sound or vibra tion 3 Check the exhaust gas color to see it is normal Colorless or light blue exhaust indicates complete combus tion black exhaust inc...

Page 42: ...no looseness 3 Push the horn button to check if the horn sounds normally 4 If any abnormality is found ask a BT dealer for inspection While moving slowly Clutch disengagement and slipping Torque converter models Press the inching pedal and check clutch engagement while moving CAUTION Insure that the control lever operates properly in each gear and then make above checks while moving slowly Brake e...

Page 43: ...the buzzer will stop sounding in 2 seconds 2 Check the mast to make certain that it can be properly tilted either forward or backward and moved up Besides make certain that the mast can automatically stop at its horizontal position CAUTION If you should feel something abnormal even slightly or when the SAS warning lamp comes to blink or once an error code has appeared on the hour meter display imm...

Page 44: ...pect each component for warping scratches dents or cracks 3 Clean the air filter element and lubricate parts as required 4 Raise the forks all the way up and down to lubricate the inside of the lift cylinder CAUTION Even a small malfunction can cause a serious accident Do not operate the vehicle until repairs have been completed If you sensed anything unusual during operation notify the supervisor...

Page 45: ...After element cleaning remove any dust in the evacuator valve Note 1 Always replace the element if the filter paper is torn or dam aged 2 Wash the element if heavily contaminated How to wash the element 1 Soak the element in water containing neutral detergent for approximately 30 minutes and then wash Use care not to scratch the filter paper 2 After washing rinse the element with clean water water...

Page 46: ...an belt for cracks fraying and tension If any abnormalities are found have the belt replaced or adjusted at a BT dealer Refer to service data for tension Battery electrolyte check 1 The battery electrolyte should be between the upper and lower levels 10 to 15 mm from the top of the plates 2 If the electrolyte level is below the lower level remove the cap and add distilled water to the upper level ...

Page 47: ...oil to the F line Retightening of bolts and nuts Retighten each bolt and nut on the chassis and load handling system Greasing mast and steering linkage Grease in accordance with the lubrication table CAUTION Clean the grease fitting tips thoroughly prior to greasing After greasing wipe off excess grease When the battery is dead When a booster cable is available it is possible to start the engine u...

Page 48: ...the wheels Locate the jack up point on the bottom surface of the frame in the rear of a front tire Securely insert the jack there Confirm that the jack is properly positioned 3 Jack up to just prior to the wheels coming up off the ground and loosen the hub nuts 4 Jack up until the wheels come off the ground Completely remove the air pressure from the tire then remove the hub nuts and remove the wh...

Page 49: ...oving in reverse order The hub nuts should be tightened evenly and in the same sequence as for the front wheels 6 After replacing the wheel check and adjust the tire air pres sure Adding antifreeze If the vehicle is left in an area where the temperature is less than 0 C the cooling water will freeze and may damage the radiator and or cylinder block In such cases antifreeze coolant must be used Whe...

Page 50: ...l up the remaining space with clean water 5 When warm weather arrives and there is no longer any dan ger of freezing drain the cooling water containing the anti freeze except LLC LLC is every 2 years in replacement Flush out the radiator and engine block and fill with clean water Fuse replacement If a lamp does not come on or an electrical device does not func tion the corresponding fuse may be bl...

Page 51: ...he fuel system be sure to perform air purge in the following sequence 1 Open the engine hood 2 Operate the priming pump up and down to perform air bleeding Draining the sedimenter Diesel engine models The sedimenter separates the water contained in the fuel It is integrated with the fuel filter If the sedimenter warning lamp comes on immediately drain water according to the following procedure bec...

Page 52: ...a short circuit on the battery nor nearing fire such as smoking fire because the battery emitted gas is inflammable 4 Be cautious enough not to contact the battery electrolyte When it comes into contact with an eye or skin wash it off immediately with plenty of water and then see a doctor 5 Charge the battery with the lids off in a well ventilated area 6 When battery electrolyte is spilt be certai...

Page 53: ...on or fire Frame Serial Number Frame serial number location The frame serial number is stamped on the front cross plate Please refer to the frame serial number when making inquiries about your vehicle How to Read the Name Plate The load capacity is engraved on the name plate Make sure of the load center and capacity before starting the operation 1 Vehicle type 2 Special vehicle type Attachment typ...

Page 54: ...rear pin 12 Tilt steering locking mechanism 13 Mast support bushing 14 Tilt cylinder front pin 15 Propeller shaft 16 Swing lock cylinder lower pin 17 Tie rod end pin 18 Rear axle cylinder end pin I Inspect every 8 hours daily II Inspect every 40 hours weekly III Inspect every 170 hours monthly IV Inspect every 1000 hours 6 monthly V Inspect every 2000 hours annually Inspect and service Replace MP ...

Page 55: ...ours Annually Every 2 000 hours If operation time exceeds 170 hours in a month use the number of hours as the guide for performing periodic inspection Pre operation checks and weekly inspections should preferably be performed by the user Monthly 3 month 6 month and annual inspection should be performed by a BT dealer since high level technology and special tools are required Refer to the periodic ...

Page 56: ... oil Torque converter oil filter Manual transmission oil Differential gear oil Hydraulic oil Hydraulic oil filter Wheel bearing grease Spark plugs Master cylinder wheel cylinder cap and seals Brake fluid DPF inline filter Option Power steering hose Every 2 years Power steering rubber parts Every 2 years Hydraulic hose Every 2 years Reserve tank hose Every 2 years Fuel hose Every 2 years Torque con...

Page 57: ...nd Brake Shoe Call your BT authorized shop for after sale service With high quality BT genuine parts and superior service technol ogy BT help keep customers forklifts in the best condition for efficient work and higher productivity We deliver satisfaction to the customers with BT genuine part IF YOU USE A NON GENUINE ENGINE OIL FILTER 1 Clogging may result which can lead to engine seizure 2 The en...

Page 58: ...n I 5 Air cleaner element C 6 Valve clearance M 7 Compression M 8 Cylinder head bolt T 9 Muffler rubber mount I Blow by gas reduction device 10 Clogging and damage of PCV valve and piping I Governor 11 Maximum no load stabilized ratation speed M Lubrication system 12 Oil leakage I 13 Oil level I 14 Clogging and fouling of oil filter I Fuel system 15 Fuel leakage I 16 Carburetor link mechanism oper...

Page 59: ...MENT Wheels 1 Tire air pressure M 2 Tire cuts damage and uneven treads I 3 Loose rim and hub nuts T 4 Tread depth M 5 Metal fragments stones or other foreign objects in tires I 6 Rim side ring and disc wheel damage I 7 Front wheel bearing unusual noise and looseness I 8 Rear wheel bearing unusual noise and looseness I Front axle 9 Housing cracks and damage I Rear axle 10 Beam cracks damage and def...

Page 60: ... wheel cylinder 8 Function war damage and mounting looseness I Brake drum and brake shoe 9 Clearance between drum and lining M 10 Shoe sliding portion and lining wear I 11 Drum wear and damage I 12 Shoe operating condition I 13 Anchor pin rusting I 14 Return spring wear etc M 15 Automatic adjusting function operation I Backing plate 16 Deformation cracking and damage I 17 Mounting looseness T LOAD...

Page 61: ... I HYDRAULIC SYSTEM Cylinder 1 Cylinder mounting looseness and damage T 2 Rod and rod screw and rod end deformation and damage I 3 Cylinder operation I 4 Natural drop and natural forward tilt M 5 Oil leakage and damage I 6 Pin and cylinder shaft support wear and damage I 7 Lifting speed M 8 Uneven movement I Oil pump 9 Oil leakage and unusual noise I Hydraulic oil tank 10 Oil level and contaminati...

Page 62: ... 10 Specific gravity M Electrical wiring 11 Wiring harness damage I 12 Fuses I Preheater 13 Glow plug heat coil breakage I 14 Open circuit in intake heater I Engine stopping system 15 Diesel engine key stop device function I DPF Option 16 Filter I 17 Inline filter for back pressure sensor I SAFETY DEVICES etc Head guard 1 Welded portion cracking I 2 Deformation and damage I Back rest 3 Mounting lo...

Page 63: ...eakage at functional parts and loosening mounting I 13 Looseness at and or damage to wire harnesses I 14 Performance of lock cylinder and or accumulator I 15 Rust and or corrosion in load handling sensor I Seat 16 Mounting looseness and damage I 17 Damage to and or operation of seat belts I Body 18 Frame cross member etc damage and cracking I 19 Bolt looseness T Rear view mirror Option 20 Dirt dam...

Page 64: ...ompression kPa rpm kg cm2 rpm psi rpm Stan dard value 4Y 1226 12 5 178 250 1DZ II 2850 29 0 412 260 2Z 3230 33 469 260 Limit 4Y 883 9 0 128 250 1DZ II 1960 20 284 260 2Z 1960 20 284 260 Tire air pressure kg cm2 psi Front wheels 700 7 0 100 850 8 5 121 Rear wheels 800 8 0 114 700 7 0 100 775 7 75 110 900 9 0 128 Steering wheel play When idling mm in 20 50 0 79 1 97 Oil control valve set pressure kP...

Page 65: ...trolyte specific gravity 20 C F 1 28 68 Models 1 5 1 75 ton 2 2 5 ton 3 ton J3 5 ton Type Item Engine oil O US gal Gasoline 4Y 4 0 1 06 API SH SJ Diesel 1DZ II 7 9 2 09 API CE CF 2Z 9 0 2 38 9 0 2 38 9 0 2 38 Torque converter O US gal 9 0 2 38 ATF GM Dexron II Differential gear O US gal 6 3 1 66 7 1 1 87 7 7 2 03 API GL 4 Hypoid gear oil API GL 5 Hypoid gear oil Fuel tank O US gal 45 11 9 65 17 2 ...

Page 66: ...ies AB 180424 040 66 LPG Device Option LPG Device Option Names of LPG Device Components 1 Tank clamp 2 LPG tank 3 Tank bracket 4 Filter 5 Solenoid valve 6 Regulator 7 Filter solenoid valve 8 LPG switch Impco brand ...

Page 67: ... switch to turn on and off the LPG or gasoline fuel feeder OFF horizontal position Engine cannot be started up since no fuel is fed LPG low position LPG fuel is fed while lamp comes on GAS upper position Gasoline fuel is fed while lamp comes on Note With the engine switch OFF no fuel will be fed even if the fuel switch is positioned at LPG or GAS LPG low fuel warning light France spec OPT Once LPG...

Page 68: ...d by an LPG filling station attendant Be sure that this valve is shut tightly at all times during use Pipe Valve When the fuel hose needs to be disconnected for tank replace ment etc close this valve to prevent the liquid from running out of the hose This valve is normally left open To open the valve turn it counterclockwise To shut the valve turn it clockwise Relief Valve Australian market type T...

Page 69: ...ion to turn the starter on If it should be difficult to start up the engine press the fuel injec tion switch for 2 or 3 seconds Then restart the engine CAUTION Never depress the accelerator pedal repeatedly or hold it down completely during starting The engine will not start easily 5 Wait for an initial ignition of the engine and depress the accelerator pedal lightly Wait for the engine to start r...

Page 70: ...ine stop naturally 4 Set the fuel switch to the LPG position and start the engine again as you would start the engine of LPG models CAUTION Never change the fuel switch setting from GAS to LPG posi tions while the engine is running It will increase the engine rpm sharply and cause a serious damage to the engine To prolong the Engine Life Refrain from handling and driving the vehicle roughly especi...

Page 71: ... until all smell of gas is gone If truck will not restart get a mechanic to inspect it Filling tanks requires special procedures Make sure some one explains them all to you ENGINE HOOD Opening 1 Pull the set pin at the bottom left portion of the tank bracket 2 Bring the clamped tank with the bracket down toward the rear side of the vehicle 3 Move the seat to the front position 4 When the engine ho...

Page 72: ...et pin is locked Removing the tank WARNING Only qualified mechanics are allowed to replace the tank 1 With the engine running close the service valve and wait until the engine stops before turning off the ignition switch 2 Disconnect the piping from the LPG tank turn the screw counterclockwise 3 Pull the set pin at the bottom left portion of the tank bracket 4 Bring the clamped tank with the brack...

Page 73: ...report to the supervi sor for repair by a qualified mechanic or your BT dealer Tag truck out of service CAUTION Always wipe soapy water off after the inspection Important Information about Properties of LPG LPG normally contains a substance that gives it a noticeable odor in concentration of 1 200 or more in air If a large amount of the LPG is leaking from the tank of the system it can be detected...

Page 74: ...s using fire do not approach the vehicle Remove the ignition key from an LPG powered forklift before parking or storing it so that no unauthorized person can oper ate it Use only soap water or neutral detergent to check the vehicle for gas leaks Do not use any other fluid If the gas leak inspection must be performed at night with the help of a flashlight turn the flashlight on far away from the ve...

Page 75: ...cting and Servicing LPG Powered Forklifts Inspect and service LPG powered forklifts as you would conven tional forklifts In addition inspect and service them as written below Inspection before Starting Operation LPG gas leak check CAUTION Never perform LPG gas leak checks near fire Make certain that there is no source of fire in the area throughout the gas leak check WARNING To avoid serious injur...

Page 76: ... water or neutral detergent Lock for gas leak After the gas leak check is completed wipe off the soap water or neutral detergent from the wet parts If a gas leak is detected immediately put out any fire venti late the area and keep the area in a strictly firefree condition Then call a qualified BT dealer or service garage n Monthly Inspection and Maintenance n Quarterly Inspection and Maintenance ...

Page 77: ...pecifications a 4Y engine powered 1 5 1 8 ton class pneumatic tire vehicles b 4Y engine powered 2 0 J3 5 ton class pneumatic tire vehicles Item Engine 4Y a b Gasoline LPG models Max power PS rpm 48 2400 52 2600 Max torque kg rpm 15 1600 Ignition timing BTDC rpm 7 750 Idling speed rpm 750 Max no load rpm rpm 2600 2800 LPG models Max power PS rpm 50 2400 54 2600 Max torque kg rpm 16 1800 Ignition ti...

Page 78: ...ard Lift Two Stage Mast Lift Three Stage Mast load backrest is 1220 mm 48 in T Mast type B Overall Height G Free Lift J Single Tire O Dual Tire A Maximum Fork Height C Lowered D Extended H Without Load Backrest I With Standard Load Back rest K Tilt Range N Load Capac ity at 500 mm LC P Tilt Range S Load Capacity at 500 mm LC E Without Load Backrest F With Stand ard Load Backrest L FWD M BWD Q FWD ...

Page 79: ...1 1410 55 5 780 30 7 6 10 1500 3000 7 9 1500 3000 3300 130 2145 84 4 3860 152 4520 178 0 1560 61 4 930 36 6 6 10 1500 3000 7 9 1500 3000 3500 138 2245 88 4 4060 159 8 4720 185 8 1660 65 4 1030 40 6 6 10 1500 3000 7 9 1500 3000 3700 145 2405 94 7 4260 167 7 4920 193 7 1820 71 6 1190 46 9 6 10 1500 3000 7 9 1500 3000 4000 157 5 2595 102 2 4560 179 5 5220 205 5 2010 79 1 1380 54 3 6 10 1500 3000 7 9 ...

Page 80: ... 1410 55 5 780 30 7 6 10 1750 3500 7 9 1750 3500 3300 130 2145 84 4 3860 152 4520 178 0 1560 61 4 930 36 6 6 10 1750 3500 7 9 1750 3500 3500 138 2245 88 4 4060 159 8 4720 185 8 1660 65 4 1030 40 6 6 10 1750 3500 7 9 1750 3500 3700 145 2405 94 7 4260 167 7 4920 193 7 1820 71 7 1190 46 9 6 10 1750 3500 7 9 1750 3500 4000 157 5 2595 102 2 4560 179 5 5220 205 5 2010 79 1 1380 54 3 6 10 1650 3400 7 9 1...

Page 81: ...0 4000 6 10 2000 4000 3300 130 2145 84 4 3890 153 1 4520 178 0 1550 61 925 36 4 6 10 2000 4000 6 10 2000 4000 3500 138 2245 88 4 4090 161 4720 185 8 1650 65 1025 40 4 6 10 2000 4000 6 10 2000 4000 3700 145 2405 94 7 4390 172 8 4920 193 7 1810 71 3 1185 46 7 6 10 2000 4000 6 10 2000 4000 4000 157 5 2595 102 2 4590 180 7 5220 205 5 2000 78 4 1375 54 1 6 10 2000 4000 6 10 2000 4000 FSV 3700 145 1795 ...

Page 82: ...0 5000 6 10 2500 5000 3300 130 2145 84 4 3890 153 1 4520 178 0 1550 61 925 36 4 6 10 2500 5000 6 10 2500 5000 3500 138 2245 88 4 4090 161 4720 185 8 1650 65 1025 40 4 6 10 2500 5000 6 10 2500 5000 3700 145 2405 94 7 4390 172 8 4920 193 7 1810 71 3 1185 46 7 6 10 2500 5000 6 10 2500 5000 4000 157 5 2595 102 2 4590 180 7 5220 205 5 2000 78 7 1375 54 1 6 10 2500 5000 6 10 2500 5000 FSV 3700 145 1795 ...

Page 83: ...05 153 7 4520 178 0 1550 61 950 37 4 6 10 3000 6000 6 10 3000 6000 3500 138 2270 89 5 4105 161 6 4720 185 8 1650 65 1050 41 3 6 10 3000 6000 6 10 3000 6000 3700 145 2430 95 7 4305 169 5 4920 193 7 1810 71 3 1210 47 6 6 10 3000 6000 6 10 3000 6000 4000 157 5 2620 103 1 4605 181 3 5220 205 5 2000 78 7 1400 55 1 6 10 3000 6000 6 10 3000 6000 FSV 3700 145 1920 75 6 4305 169 5 4920 193 7 1305 51 4 700 ...

Page 84: ... 178 0 1575 62 1085 42 7 6 10 3500 7000 6 10 3500 7000 3500 138 2405 94 7 4230 166 5 4720 185 8 1675 65 9 1185 46 7 6 10 3500 7000 6 10 3500 7000 3700 145 2505 98 6 4430 174 4 4920 193 7 1775 69 9 1285 50 6 6 10 3500 7000 6 10 3500 7000 4000 157 5 2755 108 5 4730 186 2 5220 205 5 2025 79 7 1535 60 4 6 10 3500 7000 6 10 3500 7000 FSV 3700 145 2035 80 1 4430 174 4 4920 193 7 1305 51 4 815 32 1 6 6 3...

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Page 86: ... Dual 6 00 9 9x4 00E O Rear 5 00 8 8x3 00D N 8x3 00D O 1 75 ton Front Single 6 50 10 10x5 00F O Dual 6 00 9 9x4 00E O Rear 5 00 8 8x3 00D N 8x3 00D O 2 2 5 ton Front Single 7 00 12 12x5 00S O Dual 7 00 12 12x5 00S O Rear 6 00 9 9x4 00E 9x4 00E N O 3 ton Front Single 28x9 15 15x7 00T O Dual 7 00 15 15x6 00S O Rear 6 50 10 10x5 00F O J3 5 ton Front Single 2 50 15 15x7 00T O Dual 7 00 15 15x6 00S O R...

Page 87: ...40 48 8 1290 50 8 B 900 35 4 990 39 0 1040 40 9 1060 41 7 C 890 35 0 960 37 8 1010 39 8 1040 40 9 D 180 7 1 225 8 9 275 10 8 E 80 3 2 100 3 9 125 4 9 F 895 35 2 965 38 0 G 1960 77 2 1980 78 0 2170 85 4 2240 88 2 2400 94 5 2500 98 4 H 1835 72 2 1845 72 6 1965 77 4 1990 78 3 2085 82 1 2130 83 9 I 4420 166 1 J 3000 118 K 1995 78 5 2020 79 5 2125 83 7 L 150 5 9 135 5 3 ...

Page 88: ...135 44 7 S 2080 81 9 2110 83 1 2170 85 4 2180 85 8 T 1095 43 1 U 1000 39 4 V 410 16 1 470 18 5 485 19 1 495 19 5 W 1410 55 5 1600 63 0 1700 66 9 X 430 16 9 460 18 1 475 18 7 530 20 9 560 22 0 615 24 2 Y 2250 88 6 2280 89 8 2545 100 2 2600 102 4 2745 108 1 2810 110 6 GT 15 GT 18 GT 20 GT 25 GT 30 GT 35 DT 15 DT 18 DT 20 DT 25 DT 30 DT 35 ...

Page 89: ... Coolant VEEDOL Veedol Super S Veedol Diesel Star Veedol Inte grate Veedol Tur bomax Veedol Dynastar Veedol Die sel Star Veedol Inte grage Veedol Die sel HDC Veedol Die sel HDB Veedol Multi gear Veedol Inte grate Veedol Multi gear Veedol Inte grate Veedol Multi gear B Veedol Multi gear C Veedol ATF Dexron II Veedol ATFType F Veedol Ali thek MP2 Veedol Disc Brake Fluid Veedol Brake Fluid Heavy Duty...

Page 90: ...ran smission TM TOTAL Dexron Total ATF 33 TOTAL Multis 2 TOTAL Multis EP2 TOTAL HBF TOTAL Azolla ZS32 TOTAL MUl tis MS 2 TOTAL Anti freeze TOTAL Coo lant VALVOLINE XLD All Climate HD HD Super HPO All Fleet S 3 Hydro Lube X 18MD Multi Purpose Gear Oil X 18MD Multi Purpose Gear Oil HP Gear Lube GM Dexron II type fluid ATFType FA Mulri Lube Lithium EP Gre ase Brake Fluid Hydraulic Oil Special Moly EP...

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