BT LWE180 User manual

© BT Europe AB
Service Guide en
LWE180, LWE200, LPE200, LPE240
Valid from serial number: 723984-
Order number: 225553-040
Issued: 2005-05-11 ITS

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 Approved by: L-G Andersson
This manual covers following truck models:
Issue date Resp. Changes
2005-05-11 ITS Completely new issue
T-code Model Serial number
660 LWE180 723984-
661 LWE200 723984-
662 LPE200 723984-
497 LPE240 723984-

Table of contents
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1-1
1-Table of contents
Technical data – M4
LWE 180/200 LPE 200 2-1
Technical data – M4
LPE 240 3-1
Preventive maintenance – P2
LWE 180/200 LPE 200 4-1
Maintenance schedule .................................. 1
Lubrication schedule ..................................... 6
Preventive maintenance – P2
LPE 240 5-1
Maintenance schedule .................................. 1
Lubrication chart............................................ 6
Oil and grease specifica tion – P3
LWE 180/200 LPE 200 6-1
Oil and grease specification – P3
LPE 240 7-1
Tools – P4
LWE 180/200 LPE 200/240 8-1
Super Seal connectors.................................. 1
AMP connectors............................................ 2
8.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors.......................................... 3
Other tools..................................................... 4

1-2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Table of contents
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Electrical System – 5000
LWE 180/200 LPE 200 9-1
Electrical components................................... 1
Symbol List and Wiring Diagram................... 3
9.2.1 Wiring diagram 1(5) ............................................ 5
9.2.2 Wiring diagram 2(5) ............................................ 6
9.2.3 Wiring diagram 3(5) ............................................ 7
9.2.4 Wiring diagram 4(5) ............................................ 8
9.2.5 Wiring diagram 5(5) ............................................ 9
9.2.6 Wiring diagram 1(5) .......................................... 10
9.2.7 Wiring diagram 2(5) .......................................... 11
9.2.8 Wiring diagram 3(5) .......................................... 12
9.2.9 Wiring diagram 4(5) .......................................... 13
9.2.10 Wiring diagram 5(5) .......................................... 14
Operating description................................... 15
9.3.1 Starting truck ..................................................... 15
9.3.2 Driving speed £ 6 km/h ..................................... 15
9.3.3 Braking in neutral mode .................................... 15
9.3.4 Braking in neutral mode on a slope .................. 15
9.3.5 Braking .............................................................. 16
9.3.6 Lifting the forks ................................................. 16
9.3.7 Lowering the forks ............................................ 16
9.3.8 Horn .................................................................. 16
Hour meter................................................... 16
Error codes.................................................. 17
Parameters.................................................. 30
9.6.1 Operator parameters ........................................ 30
9.6.2 Parameter description ....................................... 31
Parameter 1 ...................................................... 31
Parameter 2 ...................................................... 31
Parameter 3 ...................................................... 31
Parameter 4 ...................................................... 31
Parameter 5 ...................................................... 31
9.6.3 Service parameters ........................................... 32
9.6.4 Parameter description ....................................... 33
Parameter 10 .................................................... 33
Parameter 14 .................................................... 33
Parameter 15 - Non-configurable option ........... 33
Parameter 16 - Configurable option #1 ............. 33
Parameter 17 - Configurable option #2 ............. 33
Parameter 18 - Configurable option #3 ............. 34
Parameter 19 - Configurable option #4 ............. 34
Option parameters ............................................ 34

Table of contents
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1-3
General ............................................................. 34
Parameter #15 Non-configurable options ......... 34
Changing non-configurable options .................. 34
Parameter #16 to 19 configurable optional
functions ........................................................... 35
Changing configurable optional functions ........ 36
Parameter 20 .................................................... 40
Parameter 21 .................................................... 40
Recommendation on parameter setting for freely
ventilated batteries ........................................... 41
Instructions for verifying parameter setting ...... 42
Recommendation on parameter setting for
valve-controlled batteries (VRLA) ..................... 43
Instructions for verifying parameter setting ...... 44
Parameter 22 .................................................... 44
Parameter 25 .................................................... 44
Parameter 28 .................................................... 44
Parameter 39 .................................................... 45
Login method and driver parameter access ..... 45
Expanded keypad - General ............................. 45
Expanded keypad - Programming .................... 45
Service indication ............................................. 47
Part number................................................. 50
Transistor panel........................................... 50
9.8.1 General ............................................................. 50
Troubleshooting .......................................... 51
9.9.1 Error codes and troubleshooting ...................... 51
9.9.2 Reset error ....................................................... 52
9.9.3 Safety ............................................................... 52
Technical specifications – Curtis 1243........ 53

1-4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Table of contents
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Electrical systems – 5000
LPE 240 10-1
Electrical parts.............................................. 1
Symbol list and electrical diagram................. 3
10.2.1 Electrical wiring diagram 1(5) ............................. 5
10.2.2 Electrical wiring diagram 2(5) ............................. 6
10.2.3 Electrical wiring diagram 3(5) ............................. 7
10.2.4 Electrical wiring diagram 4(5) ............................. 8
10.2.5 Electrical wiring diagram 5(5) ............................. 9
10.2.6 Electrical wiring diagram Servo (Option) .......... 10
Functional description.................................. 11
10.3.1 Starting the truck .............................................. 11
10.3.2 Driving without using platform and gates,
speed £ 6 km/h ................................................. 11
10.3.3 Driving from platform without using gates,
speed £ 6 km/h ................................................. 11
10.3.4 Driving from platform and using gates,
speed Š 8 km/h ................................................. 11
10.3.5 Neutral speed reduction ................................... 11
10.3.6 Neutral speed reduction on slopes ................... 12
10.3.7 Braking ............................................................. 12
10.3.8 Lifting the forks ................................................. 12
10.3.9 Lowering the forks ............................................ 12
10.3.10 Horn ................................................................ 12
Hour meter................................................... 13
Error codes.................................................. 13
Parameters.................................................. 25
10.6.1 Driver parameters ............................................. 25
10.6.2 Parameter description ...................................... 26
Parameter 1 ...................................................... 26
Parameter 2 ...................................................... 26
Parameter 3 ...................................................... 26
Parameter 4 ...................................................... 26
Parameter 5 ...................................................... 26
10.6.3 Service parameters .......................................... 27
10.6.4 Parameter description ...................................... 28
Parameter 10 .................................................... 28
Parameter 14 .................................................... 28
Parameter 15 - Non-configurable option ........... 28
Parameter 16 - Configurable option #1 ............. 28
Parameter 17 - Configurable option #2 ............. 29
Parameter 18 - Configurable option #3 ............. 29
Parameter 19 - Configurable option #4 ............. 29
Option parameters ............................................ 29

Table of contents
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1-5
General ............................................................. 29
Parameter #15 Non-configurable options ......... 29
Changing non-configurable options .................. 30
Parameter #16 to 19 configurable optional
functions ........................................................... 31
Changing configurable optional functions ........ 32
Parameter 20 .................................................... 36
Parameter 21 .................................................... 36
Recommendation on parameter setting for freely
ventilated batteries ........................................... 37
Instructions for verifying parameter setting ...... 38
Recommendation on parameter setting for
valve-controlled batteries (VRLA) ..................... 39
Instructions for verifying parameter setting ...... 40
Parameter 22 .................................................... 40
Parameter 25 .................................................... 40
Parameter 28 .................................................... 40
Parameter 39 .................................................... 41
Login method and driver parameter access ..... 41
Expanded keypad - General ............................. 41
Expanded keypad - Programming .................... 41
Service indication ............................................. 43
Part numbers............................................... 46
Transistor panel........................................... 46
10.8.1 General ............................................................ 46
Diagnostic and troubleshooting................... 47
10.9.1 Error codes and troubleshooting ...................... 47
10.9.2 Resetting errors ............................................... 48
10.9.3 Safety ............................................................... 48
Technical specifications – Curtis 1243........ 49

1-6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Table of contents
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Hydraulic/Pneumatik – 6000
LWE 180/200 LPE 200 11-1
General......................................................... 1
Hydraulic chart and list of symbols................ 1
11.2.1 List of Symbols ................................................... 1
Adjustments LWE180................................... 2
11.3.1 Adjusting the pressure limit valve ....................... 2
11.3.2 Tools ................................................................... 3
Adjustments LWE200................................... 4
11.4.1 Adjusting the pressure limit valve ....................... 4
Hydraulic chart and list of symbols................ 5
11.5.1 List of Symbols ................................................... 5
Adjusting the pressure limit valve.................. 6
Hydraulic, pneumatic – 6000
LPE 240 12-1
General......................................................... 1
12.1.1 Hydraulic diagram .............................................. 1
12.1.2 Symbol list .......................................................... 2
Adjustments.................................................. 3
12.2.1 Adjustment of the pressure limit valve ................ 3
Cleaning the filter.......................................... 4

Technical data – M4 LWE 180/200 LPE 200
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 2-1
2-Technical data – M4
LWE 180/200 LPE 200
Model LWE180 LWE200,
LPE200-6 LPE200-8
Drive motor
Type TSL140S-DS20 TSL140S-DS30 TSL140S-
DS40
Output, kW 1.0 1.2 1,7
Duty cycle S2, 60 min S2,60 min S2,60 min
Minimum carbon brush length, mm 13 13 13
Nominal commutator diameter, mm 47 47 60
Minimum commutator diameter, mm 47 47 60
Resistance, shunt field winding , Ω at 25 C° 0,55 0,55 0,4498
Resistance armature winding, Ω at 24 °C 0.0156 0,0156 0,0161
Insulation resistance between the windings
and motor casing >=1 Mohm >= 1Mohm >= 1Mohm
Weight, kg 14 14 17
Broms
Type BFK457-08 BFK457-08 BFK458-12
Braking force, Nm 16 16 32
Output, W 25 25 40
Resistance coil, Ω 23 23 14.4
Nominal play in actuated position, mm 0.2-0.4 0.2-0.4 0.3-0.5
Minimum thickness brake disc, mm 5.5 5.5 8.8
Thickness of a new brake disc, mm 7.0 7.0 10.0
Transmission/drive gear
Type 2-stage angle
transmission 2-stage angle transmission 2-stage angle transmission
Gear ratio 19,14:1 19,14:1 16,29:1
Oil volume, litre 1.0 1.0 1.0
Oil type
at normal temperature
at temperature < -15oC
Hypoid oil
SAE 80W/90
SAE 75W
Hypoid oil
SAE 80W/90
SAE 75W
Hypoid oil
SAE 80W/90
SAE 75W

2-2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Technical data – M4 LWE 180/200 LPE 200
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Wheels
Drive wheel, mm Dia 215x70 Dia 215x70 Dia 215x70
Axle pressure without load, kg 200 374 374
Axle pressure at rated load, kg 650 565 565
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm 65 Nm
Fork wheel, mm Dia 85x75 Dia 85x75 Dia 85x75
Axle pressure without load, kg 2x40 (240) 2x65 (240) 2x65 (240)
Axle pressure at rated load, kg 2x710 (240) 2x790 (240) 2x790 (240)
Support castors, mm Dia 125x40 Dia 125x40 Dia 125x40
Axle pressure without load 2X70 (240) 2X75 (240) 2x75 (240)
Axle pressure at rated load, kg 2x80 (240) 2x210 (240) 2x210 (240)
Hydraulic system
Output, kW 1.2 2.2 2.2
Duty cycle,% 10 10 10
Minimum carbon brush length, mm 7.5 12 12
Minimum commutator thickness/diameter, mm 4.75 4.7 4.7
Pressure at rated load, bar 110 150 150
Overflow pressure, bar 130 170 170
Pump flow, litre/minute 4.7 4.6 4,6
Tank volume, litre 0,5 1,0 1,0
Oil type:
at normal temperature
at temperature < -15oC
Hydraulic oil
ISO-L-HM32
ISO-L-HV32
Hydraulic oil
ISO-L-HM32
ISO-L-HV32
Hydraulic oil
ISO-L-HM32
ISO-L-HV32
Fuses
Drive motor circuits, A 125 125 125
Pump motor circuits, A 125 125 125
Control circuits, A 7,5 7,5 7,5
Model LWE180 LWE200,
LPE200-6 LPE200-8

Technical data – M4 LWE 180/200 LPE 200
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 2-3
Battery compartment, Batteries
Dimensions LxWxH, mm 193x642x450 193x642x450-
510 193x642x450- 510
Capacity, Ah 160-320 240-320 240-320
Weigh, kg 165-250 210-250 210-250
Driving speed
Without load, km/t
Without load, m/s 6,0 1.7 6,0 1.7 8,0 2.22
With rated load, km/t
With rated load, m/s 6,0 1,7 6,0 1,7 7.2 2.0
Lift/lowering speed
Lift without load, s 2.2 1.7 1.7
Lift with rated load, s 3.4 2.3 2.3
Lowering without load, s 2.6 1.4 1.4
Lowering with rated load, s 3.1 1.5 1.75
Power consumption
Driving without load, A 38 28 46
Driving with rated load, A 45 46 65
Lift without load, A 39 49 49
Lift with rated load, A 80 52 52
Incline climbing ability
With rated load 8 % 9% 9%
Measurement, L2
Short
Medium
Lång
519
565
613
519(LWE200)
660
1008
660
1008
Turning radius WA 1466 1960 1960
Lift height 205 205 205
Weight
Truck without battery, Medium 295 420 440
Model LWE180 LWE200,
LPE200-6 LPE200-8

2-4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Technical data – M4 LWE 180/200 LPE 200
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
This page is intentionally left blank

Technical data – M4 LPE 240
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3-1
3-Technical data – M4
LPE 240
Model LPE240
Drive motor
Type TSL160 A DS60
Output, kW 2.5
Duty cycle S2, 60 min
Minimum carbon brush length, mm 11
Nominal commutator diameter, mm 71
Minimum commutator diameter, mm 68
Resistance, shunt field winding, Ω at 24 C° 0.346
Resistance armature winding, Ω at 24 °C 0.0098
Insulation resistance between the windings
and motor casing >= 1 Mohm
Weight, kg 23
Brakes
Type 1EB46-11
Braking force, Nm 48
Output, W 44
Resistance coil, Ω 12
Nominal play in actuated position, mm 0.25-0.38
Minimum thickness brake disc, mm 7.7
Thickness of a new brake disc, mm 9.7
Transmission/drive gear
Type 2-stage angle
transmission
Gear ratio 14.20:1
Oil volume, litre 1.75
Oil type
at normal temperature
at temperature < -15oC
Hypoid oil
SAE 80W/90
SAE 75W

3-2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Technical data – M4 LPE 240
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Wheels
Drive wheel, mm
Drive wheel for servo, mm 250x75 250x105
Axle pressure without load, kg 460
Axle pressure at rated load, kg 770
Wheel pressure at rated load, kg/cm230
Tightening torque wheel bolts, Nm 130
Fork wheel, Bogie, mm 80x74
Axle pressure without load, kg 175-320
Axle pressure at rated load, kg 1800-2300
Wheel pressure at rated load, kg/cm247-55
Swivel wheel, mm 150x50
Axle pressure without load 175-605
Axle pressure at rated load, kg 120-790
Wheel pressure at rated load, kg/cm212-37
Hydraulic system
Output, kW 2.0
Duty cycle 10%
Minimum carbon brush length, mm 8
Minimum commutator diameter, mm 45
Minimum commutator diameter, mm 43
Pressure at rated load, bar 130
Overflow pressure, bar 145
Pump flow, cc/r 2.5
Tank volume, litre 1.2
Oil type:
at normal temperature
at temperature < -15oC
ISO-L-HM32
ISO-L-HV32
Model LPE240

Technical data – M4 LPE 240
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3-3
Servo steering, Motor (Option)
Type MET 3B 24 V
Output, W 160
Torque constant 0.6 Nm/A
Max current 55 A
Speed, rpm 2550
Minimum carbon brush length, mm -
Minimum commutator diameter, mm -
Resistance,Ω,armature 0.27
Fuses
Control circuits, F50, F51 7.5 A
Drive motor 125 A
Pump motor 160 A
Servo steering (Option) 20 A
Battery compartment, Batteries
Battery compartment
Dimensions LxWxH, mm
Short
Long
212x790x775
296x790x775
Capacity, Ah 292-600
Weight, kg 240-500
Driving speed
Without load, km/h
Without load, m/s 12 3.33 +5%
With rated load, km/h
With rated load, m/s 9,5 2.63 +5%
Lift/lowering speed
Lift to top with load, s 2.0
Lowering without load, s 2.3
Model LPE240

3-4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Technical data – M4 LPE 240
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Power consumption
Driving without load, A 82
Driving with rated load, A 92
Lift without load, A 49
Lift with rated load, A 116
Incline climbing ability
Without load 15%, 8.5°
With rated load 8%, 4.5°
Measurement
L2
Short
Long
730 mm
814 mm
Wa with 1170 mm forks and lift fork -
Wa with 1170 mm forks and lift fork,
fixed side gates -
Wa with 1170 mm forks and lift fork,
fixed back rest -
Lift height 225 mm
Weight
Truck without battery, Max 600 kg
Fixed gates - kg
Fixed back rest - kg
Model LPE240

Technical data – M4 LPE 240
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3-5
1451
1050
185
422 L2 800-2350
959
85
790
180
450-685
Wa

3-6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Technical data – M4 LPE 240
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
This page is intentionally left blank

Preventive maintenance – P2 LWE 180/200 LPE 200
Maintenance schedule
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4-1
4-Preventive maintenance – P2
LWE 180/200 LPE 200
4.1 Maintenance schedule
I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary
Pos.
No. Work to carry out
Interval in hours 520 80 500 1000 3000
Interval in days/weeks/months 1d 1w 1m 6m 12m 36m
0000 Chassis
0000.1 Check all links and locking pins l
0000.2 Check wear on cover/battery locking l
0000.3 Check of cracking and damage l
0000.4 Check the cover locks I
0000.5 Check finger guard I
0000.6 Check signs and stickers I
0000.7 Press grease into grease nipples I/L6
0380 Fork carriage
0380.1 Check for crack formation and damage l
0380.2 Check clearance in bushes and links I
0380.3 Press grease into grease nipples (Option) I/L6
0380.4 Check the lift limit switch l
0560 Platform and mountings
0560.1 Check for any cracks or damage l
0560.2 Check gas damper and cup springs l
1700. Drive motor
1700.1 Check clearance in connections I/T1I/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 l

4-2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB
Preventive maintenance – P2 LWE 180/200 LPE 200
Maintenance schedule
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
2550 Drive gear
2550.1 Check for leakage I3I
2550.2 Check the oil level I
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in
steering bearing I
2550.5 Change the oil in the drive gear L4L
3100. Brake
3100.1 Clean C
3100.2 Check for wear on the brake disc M
3100.3 Check the clearance in disengaged position M
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tight-
ening torque on bolts I/T
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
5000 Electrical functions
5000.1 Check the operation of the brake micros-
witch in the upper and lower brake positions.
Lubricate the switch head.
II/L
5000.2 Check the function of the collision safety switch I
5000.3 Check the function of the gate switches I I
5000.4 Check the function of platform switch I I
5000.5 Check the function of the horn I I
5000.6 Check for wear on cabling I
5000.7 Check the function of the driver’s control I I
5000.8 Check the error code log and operating times I I
I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary
Pos.
No. Work to carry out
Interval in hours 5 20 80 500 1000 3000
Interval in days/weeks/months 1d 1w 1m 6m 12m 36m