BT LWE130 User manual

© BT Europe AB
Service Manual en
LWE130
Valid from serial number: 914369-
Order number: 226057-040
Issued: 2005-09-23 ITS
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© BT Europe AB Service Manual LWE130 Approved by: L-G Andersson
This manual covers following truck models:
Issue date Resp. Changes
2005-09-23 ITS Completely new issue
T-code Model Serial number
675 LWE130 914369-
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Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 1
Technical data – M4 1-1
Tightening torque .......................................... 4
Introduction Maintenance – P1 2-1
Safety regulations with maintenance work.... 1
Cleaning and washing................................... 3
2.2.1 External cleaning ................................................ 3
2.2.2 Cleaning the motor compartment ....................... 3
2.2.3 Electrical components ........................................ 3
Safe lifting...................................................... 4
Lifting points.................................................. 5
2.4.1 Using a lifting device .......................................... 5
2.4.2 Lifting points, using another fork lift truck ........... 5
Maintenance, Lubrication schedule – P2 3-1
Maintenance schedule .................................. 1
Lubrication schedule ..................................... 5
Oil and grease specification – P3 4-1
Tools - P4 5-1
Super Seal connectors.................................. 1
AMP connectors............................................ 2
5.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors.......................................... 3
Grease guns.................................................. 4
Other tools..................................................... 5
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2 Service Manual LWE130 © BT Europe AB
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
Drive unit/drive gear – 2000 6-1
Component parts.......................................... 1
Service and repairs....................................... 2
6.2.1 Dismantling the motor from the truck .................. 2
6.2.2 Inspection/replacement of the carbon brushes ... 2
6.2.3 Replacing the drive gear ..................................... 3
6.2.4 Cleaning .............................................................. 3
6.2.5 Brakes, Maintenance .......................................... 4
6.2.6 Replacing the brake disc .................................... 4
Steering system – 4000 7-1
Components ................................................. 1
Electrical system – 5000 12-1
General......................................................... 1
12.1.1 Firmware (truck control software) ....................... 1
Nomenclature ............................................... 1
Electrical equipment overview ...................... 2
12.3.1 Electric component overview .............................. 4
Accessing main electrical panel.................... 6
Electrical circuit overview.............................. 7
Symbol list .................................................... 8
Electrical wiring diagram.............................. 9
Functional description.................................. 14
12.8.1 Theory of operation .......................................... 14
12.8.2 Transistor regulator .......................................... 18
General ............................................................. 18
Safety ................................................................ 18
12.8.3 On-board battery charger ................................. 20
General ............................................................. 20
Charging ........................................................... 20
12.8.4 Battery charge status ....................................... 21
Battery display (option) ..................................... 21
12.8.5 Built-in battery charger for charging on trucks .. 22
General ............................................................. 22
Installation recommendations for ‘connection
point’ on truck ................................................... 22
Installation in truck ............................................ 23
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Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 3
Charging ........................................................... 25
Troubleshooting ................................................ 25
Technical data .................................................. 25
12.8.6 Speed limitation ............................................... 26
12.8.7 Hour meter ....................................................... 26
12.8.8 Hand terminal ................................................... 27
General ............................................................. 27
Connecting the hand terminal .......................... 27
Hand terminal overview .................................... 27
Hand terminal menus ....................................... 29
Diagnostic and troubleshooting................... 30
12.9.1 General ............................................................ 30
12.9.2 Display of error codes ...................................... 30
Direct display of error codes ............................. 30
Hand terminal display of error codes ................ 30
Error code history ............................................. 31
12.9.3 List of error codes ............................................ 32
12.9.4 TESTER function ............................................. 35
Parameters & adjustments.......................... 37
12.10.1 General .......................................................... 37
12.10.2 Adjusting parameters ..................................... 37
12.10.3 List of parameters .......................................... 38
12.10.4 Description of parameters .............................. 39
Acceleration ramp time (ACC.DELAY) ............. 39
Deceleration ramp time (DECELER.DELAY) ... 39
Neutral braking intensity (RELEASE BRAKING) .... 39
Reverse braking intensity (INVERSION BRAKING) 39
Maximum travel speed (CUTBACK SPEED 3) 39
Reset service counter (CHECK UP DONE) ..... 39
Select service warning type (CHECK UP TYPE) .. 39
“Time to next service” (CHECK UP HOURS) ... 40
12.10.5 Transferring parameter sets ........................... 40
General ............................................................. 40
From the truck to the hand terminal ................. 41
From the hand terminal to the truck ................. 42
12.10.6 Calibrating the speed potentiometer .............. 42
General ............................................................. 42
Procedure ......................................................... 43
Technical specifications .............................. 44
12.11.1 Transistor regulator SEM-X ........................... 44
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4 Service Manual LWE130 © BT Europe AB
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
Hydraulic system – 6000 13-1
Hydraulic chart and list of symbols................ 1
Description.................................................... 2
Lift ....................................................................... 2
Lower .................................................................. 2
Operating pressure ............................................. 2
Pressure limit valve ............................................. 2
Adjustments.................................................. 3
Adjustment of the pressure limit valve ................ 3
Tools............................................................. 4
Destruction instructions 14-1
General......................................................... 1
Procedure..................................................... 1
Abbreviations................................................ 2
Sorting .......................................................... 2
Chassis (0300).............................................. 3
Hoods, hatches (0340) ................................. 3
Electric Pump Motor (1710) ......................... 3
Drive assembly/drive motor (1760/2550)...... 4
Wheels (3500) .............................................. 5
Tiller arm (4110) ........................................... 5
General electrical equipment (5100)............. 6
Hydraulic unit (6100)..................................... 7
Hydraulic cables/cylinders (6230/6610)........ 7
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Technical data – M4
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 1-1
1-Technical data – M4
Model LW13
Drive motor
Type TSL115-16
Output 0,5 kW
Duty cycle S2, 60 min
Minimum carbon brush length 14,5 mm
Nominal commutator diameter 43 mm
Minimum commutator diameter 40 mm
Resistance, shunt field winding at 25 C° 1,3 Ω
Resistance armature winding at 24 °C 0,0156 Ω
Insulation resistance between the windings and motor casing >=1 Mohm
Weight 25 kg
Brake
Type 891.270.0
Braking force 9 Nm
Output 28 W
Resistance coil 20,8 Ω
Minimum thickness brake disc 6,75 mm
Thickness of a new brake disc 6,90 mm
Transmission/drive gear
Type 2-stage drive gear
Gear ratio 24,8:1
Volume of grease 0,3 kg
Type of grease SHELL RETINAX G
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1-2 Service Manual LWE130 © BT Europe AB
Technical data – M4
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
Wheels
Drive wheel Ø250x60 mm
Axle pressure without load 175 kg
Axle pressure at rated load 570 kg
Tightening torque for wheel bolts 20 Nm
Fork wheel Ø85x75 mm
Axle pressure without load 2x18 kg
Axle pressure at rated load 2x496 kg
Support castors Ø100x40 mm
Axle pressure without load 2x30 kg
Axle pressure at rated load 2x24 kg
Hydraulic system
Output 1,2 kW
Duty cycle 10 %
Minimum carbon brush length 7,5 %
Minimum commutator thickness/diameter 4,75 mm
Pressure at rated load 110 bar
Overflow pressure 130 bar
Pump flow 4,7 litre/minute
Tank volume 1,0 litre
Oil type Hydraulic oil
Normal temperature ISO-L-HM32
Fuses
Drive motor circuits (Common with the pump) 50 A
Pump motor circuits (Common with the drive motor) 50 A
Control circuits 5 A
Battery charger 10 A
Model LW13
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Technical data – M4
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 1-3
Battery compartment, Batteries
Dimensions LxWxH 278x175x190 mm
Capacity 50 Ah
Weigh 2x18 kg
Driving speed
Without load 5,4 km/h (1,5 m/s)
With rated load 4,0 km/h (1,1 m/s)
Lift/lowering speed
Lift without load 1,7 s
Lift with rated load 3,0 s
Lowering without load 3,0 s
Lowering with rated load 3,0 s
Power consumption
Driving without load 13 A
Driving with rated load ?
Lift without load ?
Lift with rated load ?
Incline climbing ability
With rated load 5 %
Without load 10 %
Measurement, L2 420 mm
Turning radius WA 1410 mm
Lift height 205 mm
Weight
Truck without battery, Medium 200 kg
Model LW13
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1-4 Service Manual LWE130 © BT Europe AB
Technical data – M4
Tightening torque
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
1.1 Tightening torque
Description Amount Tightening
torque Procedure
Screws 820 Nm
Wheel bolts 20 Nm
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Introduction Maintenance – P1
Safety regulations with maintenance work
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 2-1
2-Introduction Maintenance – P1
All points in the serviceprogram should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with BT’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00
(60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is depend-
ent on the service and maintenance it is given.
Only use BT approved spare parts when service and repair work are
carried out.
2.1 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.
• Donotcarry outanymaintenance workonthetruck unlessyouhave
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 electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
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 cov-
ers on the drive unit or electrical system.
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system.
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2-2 Service Manual LWE130 © BT Europe AB
Introduction Maintenance – P1
Safety regulations with maintenance work
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. 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 damaged.
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 current 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.
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Introduction Maintenance – P1
Cleaning and washing
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 2-3
2.2 Cleaning and washing
Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• 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 battery con-
nector.
2.2.1 External cleaning
• Remove rubbish, etc. from the wheels daily.
• Use a well-known degreasing agent, diluted to a suitable concentra-
tion.
• Rinse off loose grime using tepid water.
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, thetruck shouldbe lubricated as set out in the chapter
Maintenance and lubrication chart.
2.2.2 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 pressure
washing unit.
• Cleanthemotorcompartmentusingawell-knowndegreasingagent,
diluted to a suitable concentration.
• Rinse off loose grime using tepid water.
2.2.3 Electrical components
• Blow electric motors down using compressed air.
• Clean the electrical panels, electronic boards, contactors, connec-
tions, 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.
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2-4 Service Manual LWE130 © BT Europe AB
Introduction Maintenance – P1
Safe lifting
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
2.3 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 isclean 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 re-
quires 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.
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Introduction Maintenance – P1
Lifting points
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 2-5
2.4 Lifting points
2.4.1 Using a lifting device
WARNING!
Risk of overturning.
The truck can overturn if it is lifted from the wrong lifting points.
Always lift the truck from the marked lifting points.
2.4.2 Lifting points, using another fork lift
truck
WARNING!
Risk of overturning.
The truck can overturn if it is lifted incorrectly.
Always lift the truck secured to, and with the centre of gravity
between, the lifting truck’s forks.
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2-6 Service Manual LWE130 © BT Europe AB
Introduction Maintenance – P1
Lifting points
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
This page is intentionally left blank
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Maintenance, Lubrication schedule – P2
Maintenance schedule
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 3-1
3-Maintenance, Lubrication
schedule – P2
3.1 Maintenance schedule
I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate
M: Measure, correct if necessary
Pos.
no. Work to carry out
Interval in days/weeks/months - may vary due to
application 1 d 1 w 12 m 36 m
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 Visual inspection of the bolt joint between the chassis
and the support arms. 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/T
1700.2 Check the carbon brushes in the drive motor M
1700.3 Clean the drive motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing I
2550 Drive gear
2550.1 Check for leakage I4
2550.2 Check for abnormal noise I
2550.3 Check the attachment and clearance in steering bearing I
2550.4 Change the grease in the drive gear L
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3-2 Service Manual LWE130 © BT Europe AB
Maintenance, Lubrication schedule – P2
Maintenance schedule
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
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 torque
on bolts I/T3
3500.3 Check that the support wheel turns and rotates freely I
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
5000.8 Check the battery indicator (option) I
5110 Battery
5110.1 Check connections to battery, truck and charger I
5110.2 Check that the batteries are not damaged I
5110.3 Check the battery locking I
I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate
M: Measure, correct if necessary
Pos.
no. Work to carry out
Interval in days/weeks/months - may vary due to
application 1 d 1 w 12 m 36 m
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Maintenance, Lubrication schedule – P2
Maintenance schedule
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 3-3
2 = Retighten securing bolts to 45 Nm every 12 months.
3 = The drive gear is replaced when its diameter is < 235 mm. Drive
wheel 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
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.
5400 Power system
5400.1 Cleaning and checking of mounting in chassis C/T
5400.2 Re-tighten cable connections T
5400.3 Check the cable insulation I
5700 Electronic circuit board
5700.1 Check connectors and cables T
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
mountings I
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
I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate
M: Measure, correct if necessary
Pos.
no. Work to carry out
Interval in days/weeks/months - may vary due to
application 1 d 1 w 12 m 36 m
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3-4 Service Manual LWE130 © BT Europe AB
Maintenance, Lubrication schedule – P2
Maintenance schedule
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
2550
0380
6600
3500
0000
5400
5700
3100
17
00
5000
4110
5000
5000
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