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Service Manual LWE180, LWE200, LPE200-6/8 Valid from serial number: 723984- Order number: 221609-040 Issued: 2004-12-16 ITS © BT Europe AB en Issue date Resp Changes 2004-12-16 ITS Completely new issue (Prel.) This manual covers following truck models: T-code Model Serial number 660 LWE180 723984- 661 LWE200 723984- 662 LPE200 723984- Some chapters in this manual covers only certain of the T-codes above © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8Approved by: L-G Anders- Table of contents Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 1- Table of contents Technical data – M4 2-1 Introduction Maintenance – P1 3-1 Safety regulations with maintenance work Cleaning and washing 3.2.1 External cleaning 3.2.2 Cleaning the motor compartment 3.2.3 Electrical components Safe lifting Preventive maintenance – P2 4-1 Maintenance schedule Lubrication schedule Oil and grease specifica tion – P3 5-1 Tools – P4 6-1 Super Seal connectors AMP connectors 6.2.1 AMP Connectors, 040 series Molex connectors Other tools Engine suspension– 0450 7-1 Component parts 7.1.1 Component List © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- Table of contents T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 Electric drive motor – 1760 8-1 Component parts 8.1.1 Dismantling/assembling of motor from truck 8.1.2 Assembling Service/Repairs 8.2.1 Dismantling of motor 8.2.2 Assembling of motor 8.2.3 Cleaning Technical data Mechanical drive gear unit – 2550 9-1 Component parts 9.1.1 Technical data Leakage from top cover Dismantling Assembling Changing of the drive shaft’s sealing ring Dismantling Assembling Electro magnetic brake – 3370 10-1 Main components Maintenance 10.2.1 Exchange of brake disc Electro magnetic brake – 3370 11-1 Main components Maintenance 11.2.1 Basic Adjustment of gap Adjustment: 11.2.2 Exchange of brake disc 1- Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Table of contents Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 Steering system – 4000 12-1 Component parts, tiller arm Adjustments 12.2.1 Adjusting of brake microswitch Tiller arm handle 12.3.1 Dismantling/Assembling Change from ignition key to keyboard (2) Change from keyboard to ignition key (2) Changing of signal button/switch (9, 10) Changing of lift/lowering button (13) Changing of pushbutton (16) Electrical System – 5000 13-1 Electrical components Symbol List and Wiring Diagram Operating description 13.3.1 Starting truck 13.3.2 Driving speed ≤ km/h 13.3.3 Braking in neutral mode 13.3.4 Braking in neutral mode on a slope 13.3.5 Braking 13.3.6 Lifting the forks 13.3.7 Lowering the forks 13.3.8 Horn 15 15 15 15 15 16 16 16 16 Hour meter 16 Error codes 17 Parameters 30 30 31 31 31 31 31 31 13.6.1 Operator parameters 13.6.2 Parameter description Parameter Parameter Parameter Parameter Parameter © BT Europe AB 5 6 Service Manual LWE180, LWE200, LPE200-6/8 1- Table of contents T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 13.6.3 Service parameters 32 13.6.4 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 34 Parameter 18 - Configurable option #3 34 Parameter 19 - Configurable option #4 34 Option parameters 34 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 valvecontrolled 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 13.8.1 General 50 Troubleshooting 51 13.9.1 Error codes and troubleshooting 51 13.9.2 Reset error 52 13.9.3 Safety 52 Technical specifications – Curtis 1243 1- Service Manual LWE180, LWE200, LPE200-6/8 53 © BT Europe AB Table of contents Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 Hydraulic/Pneumatik – 6000 14-1 General Hydraulic chart and list of symbols 14.2.1 List of Symbols Adjustments LWE180 14.3.1 Adjusting the pressure limit valve 14.3.2 Tools Adjustments LWE200 14.4.1 Adjusting the pressure limit valve Hydraulic chart and list of symbols 14.5.1 List of Symbols Adjusting the pressure limit valve PowerTrak cylinder – 6680 15-1 Component parts Dismantling of PowerTrak cylinder Battery charger (Inbuilt) – 8340 16-1 General Charging Troubleshooting and service Technical data Charging settings 16.5.1 Freely ventilated batteries 16.5.2 Valve regulated batteries Control/computer equipment – 8700 17-1 General Connection Layout 17.3.1 Main program screen 17.3.2 Nodes 17.3.3 Icons © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- Table of contents T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 17.3.4 Tool buttons and menu bar 17.3.5 Information window 17.3.6 Status bar Connection function Disconnection function Downloading program function 17.6.1 Normal downloading (truck with key) 17.6.2 Normal downloading (truck with keypad) 17.6.3 Emergency downloading (truck with keypad) 17.6.4 Downloading in old versions of logic card 17.6.5 Emergency downloading (truck with keypad) 5 6 Truck report function Parameters function Diagnostics function 17.9.1 Representation of signal colours 17.9.2 “Tiller arm” tab 17.9.3 “Drive Controller” tab (transistor regulator - travel) 10 17.9.4 “Pump controller” tab (transistor regulator - pump) 11 17.9.5 “EPS” steering servo tab 12 Other menu functions 1- 17.10.1 Save to file 17.10.2 Download from file 17.10.3 Reset CAN adapter 17.10.4 Delete error code log 17.10.5 Reset hour meter 17.10.6 Read error code log 17.10.7 Adjust date and time 17.10.8 Adjusting the hour meter on older cards 17.10.9 Help About the TruckCom application 17.10.10 Exit 13 13 13 13 13 13 13 14 14 14 14 14 Specifications 14 Installation 15 17.12.1 Installation on a PC with Windows® 95/98 15 17.12.2 Installation on a PC with Windows XP/2000 17.12.3 Installation on a PC with Windows NT 17.12.4 In case of communication problems with CAN 17.12.5 To uninstall 16 21 21 21 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Technical data – M4 Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 2- Technical data – M4 Model LWE180 LWE200, LPE200-6 LPE200-8 Type TSL140S-DS20 TSL140S-DS30 TSL140S-DS40 Output, kW 1.0 1.2 1,7 Duty cycle S2, 60 S2,60 S2,60 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 0,55 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 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 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 Drive motor Broms Transmission/drive gear © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 2- Technical data – M4 T-code 660,661,662 Valid from serial number 723984- Model Date 2004-12-16 Order number 221609-040 LWE180 LWE200, LPE200-6 LPE200-8 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) 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 Drive motor circuits, A 125 125 125 Pump motor circuits, A 125 125 125 Control circuits, A 7,5 7,5 7,5 Wheels Hydraulic system Fuses 2- Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Diagnostics function T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 17.9.3 “Drive Controller” tab (transistor regulator - travel) Clicking on the Drive Controller tab will display a dialogue showing the following: • Status of digital inputs and outputs of the transistor regulator pin refers to the motor controller pin designations as given in the circuit diagram • Field PWM - The effective power output supplied to the field circuit as a percentage • Armature PWM - The effective power output supplied to the armature circuit as a percentage • Field current - The current flowing in the field circuit in Amperes • Armature current - The current flowing in the Armature circuit in Amperes • Raw throttle data - The received speed control signal as a percentage • Temperature - The temperature of the output stage of the transistor controller in degrees Celsius • Inp pin 10 - The input voltage from the mode/pressure sensor “digital o” indicates the digital status of the input • Inp pin 11-The input voltage from the man-on platform sensor “digital o” indicates the digital status of the input 17- 10 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Diagnostics function Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 17.9.4 “Pump controller” tab (transistor regulator - pump) If the truck is equipped with a lift/lower transistor regulator, the Pump controller tab displays the following: • Status of digital inputs and outputs of the transistor regulator pin refers to the motor controller pin designations as given in the circuit diagram • Field PWM, Armature PWM, Field current, Armature current, Temperature - Measured values from the transistor regulator for the pump motor See the explanation on page 10 • Raw throttle data - The received lift/lower signal as a percentage • Out pin9 - The output signal to the proportional lowering valve as a percentage • Inp pin 10 - The input voltage from the pressure sensor “digital o” indicates the digital status of the input • Inp pin 11 - The input voltage from the pressure sensor “digital o” indicates the digital status of the input © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 11 Control/computer equipment – 8700 Diagnostics function T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 17.9.5 “EPS” steering servo tab Clicking on the “EPS” tab will display a dialogue showing the following: “Status” • “Operational” - Indicates the status of the servo’s control system • “EPS enabled” - Indicates the status of the servo’s power stage output • “Reference switch reached” - indicates status of drive wheel in centre reference switch • “Reference position found” - indicates whether a successful steering in centre has been performed • “EPS in power save mode” - Shows whether the steering servo is in the standby mode (following a certain amount of inactivity) “Actual values” (Measured values) • “Temperature EPS” - The temperature of the steering servo output stage in degrees Celsius • “DC bus voltage” - Supply voltage to steering servo • “Wheel position” - Shows the estimated steering angle of the drive wheel • “Voltage analog input 1, pin5”- The measured DC input signal (0) from the steering potentiometer 17- 12 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Other menu functions Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 • “Voltage analog input 2, pin13”- The measured DC input signal (1) from the steering potentiometer • “Current” - the measured current supplied to the steer servo motor in Ampere • “Actual velocity” -The measured rotational speed of the steer servo motor shaft in r.p.m 17.10 Other menu functions 17.10.1 Save to file The truck parameters can be saved in the PC for downloading at a later date Select All parameters in the nodes which are connected to the bus will be scanned in and saved in a file If only the hour meters are needed, select 17.10.2 Download from file A set of parameters can be downloaded from the PC to the truck Select The parameters in the file will be copied to the nodes connected to the bus If only the hour meter settings are needed, select 17.10.3 Reset CAN adapter If problems should occur when resetting the CAN adapter connected to the PC, this can normally be done manually by making sure that the adapter is supplied with voltage and then selecting 17.10.4 Delete error code log To delete the truck’s error code log, start the truck in parameter mode and then select < Tools | Erase error log > 17.10.5 Reset hour meter To reset the truck’s hour meter, start the truck in drive mode and then select < Tools | Reset hour meters > 17.10.6 Read error code log To show the truck’s error code log, select < Tools | Read error log > © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 13 Control/computer equipment – 8700 Specifications T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 17.10.7 Adjust date and time To quickly adjust the truck’s data and time, select < Tools | Adjust date & time > The time given in the PC will now be downloaded into the truck NOTE! This does not apply to trucks without a real-time clock 17.10.8 Adjusting the hour meter on older cards To adjust the hour meter on trucks with older cards, select < Tools | Adjust Hour meters > The time given in the PC will now be downloaded into the truck 17.10.9 Help About the TruckCom application To see program information, select or use the tool button [Information] 17.10.10 Exit To exit the program, select or use the tool button [Exit] 17.11 Specifications Table 6: CAN interface specification 17- 14 Description Value Unit Power consumption 40-120 mA Supply voltage 11-28 V Transfer rate 125 kbit/s Storage temperature -20-80 Operating temperature 0-60 Service Manual LWE180, LWE200, LPE200-6/8 C C © BT Europe AB Control/computer equipment – 8700 Installation Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 17.12 Installation NOTE! The program must be installed from the hard disk NOTE! The software application in the computer can be damaged, which is why the PC installation should be performed by someone with the required knowledge BT does not accept any responsibility for any errors that occur during the installation NOTE! All references to PC operating system actions, menus and commands are based on the English language version of Windows® 17.12.1 Installation on a PC with Windows® 95/98 If a previous version of the TruckCom application has been installed on the PC, it will be necessary to edit the System.ini file Start the Msconfig.exe application by selecting the Start button, selecting Run and then typing msconfig Click on System.ini and open the folder (386Enh) Unmark the option at Device=C:\Windows\Cpcppvd.vxd Save the change and close the application Now continue with installation The software application is supplied on a CD or via a network Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found Then follow the on-screen instructions © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 15 Control/computer equipment – 8700 Installation T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 17.12.2 Installation on a PC with Windows XP/ 2000 To make the application work, it is necessary to first enter a value in the Windows® Registry and then make a few changes in the Windows® Control panel Due to the built-in Windows® security, this must be done manually The instructions below provide step-by-step guidance to enable these changes and make the interface operate under Windows XP and Windows 2000 The changes can be made either before or after TruckCom is installed • Open the Registry Editor To this, select the Start button, then Run, type regedit and hit Enter • Mark the Enum folder which can be found under HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the Registry Editor 17- 16 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Installation Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 Select the Edit option, then Find and type PortName to search for the correct folder NOTE! The location of the folder differs between different computers (some may be \Enum\Root\ , while others could be \Enum\ACPI\ etc.) Thus be sure to search for the correct folder When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in the PortName data field and that the folder name is Device Parameters © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 17 Control/computer equipment – 8700 Installation T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 Right-click with the mouse in the right box to enter a new value of the DWORD type and with the name EnableConnectInterruptIoctl 17- 18 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Installation Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 Change the value in data field by right-clicking on the name and selecting Modify EnableConnectInterruptIoctl The Device Parameters folder should look like the one in the picture The Registry change is now complete Close the Registry Editor © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 19 Control/computer equipment – 8700 Installation T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 Changes in Windows® Control Panel Select the Start button Choose Settings, then Control Panel and double-click on System, then select Hardware Click on Device Manager and open Ports (Com & LPT) 17- 20 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Installation Order number 221609-040 Date 2004-12-16 Valid from serial number 723984- T-code 660,661,662 Double-click on the LPT port to be changed, and select the Port Settings tab Check the "Use any Interrupt assigned to the port" option and click on OK The software application is supplied on a CD or via a network Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found Then follow the on-screen instructions 17.12.3 Installation on a PC with Windows NT The software application is supplied on a CD or via a network Start installation by running X:\SETUP.EXE, where X:\ is the drive on which the installation application can be found Then follow the on-screen instructions 17.12.4 In case of communication problems with CAN Make sure the computer settings for the printer port in the BIOS Setup are as follows: Port address:0378 IRQ: Mode: Output only For detailed information on how to change the Setup settings, refer to the User's Guide supplied with the computer 17.12.5 To uninstall To uninstall TruckCom under Windows®, select the Start button, Settings, Control Panel, Add/Remove Programs To uninstall you must then select the TruckCom Program and click Change/Remove © BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 21 Control/computer equipment – 8700 Installation T-code 660,661,662 Valid from serial number 723984- Date 2004-12-16 Order number 221609-040 This page is intentionally left blank 17- 22 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB Control/computer equipment – 8700 Installation Order number 221609-040 © BT Europe AB Date 2004-12-16 Valid from serial number 723984- Service Manual T-code 660,661,662 LWE180, LWE200, LPE200-6/8 17- 23 © BT Europe AB SE-595 81 Mjưlby Sweden www.bt-industries.com ... Service Manual LWE1 80, LWE2 00, LPE2 00-6/8 © BT Europe AB Technical data – M4 Order number 221609-040 Date 2004 -12-16 Valid from serial number 723984- Model T-code 660,661,662 LWE1 80 LWE2 00, LPE2 00-6... © BT Europe AB Service Manual LWE1 80, LWE2 00, LPE2 00-6/8 2- Technical data – M4 T-code 660,661,662 Valid from serial number 723984- Model Date 2004 -12-16 Order number 221609-040 LWE1 80 LWE2 00,... in this manual covers only certain of the T-codes above © BT Europe AB Service Manual LWE1 80, LWE2 00, LPE2 00-6/8Approved by: L-G Anders- Table of contents Order number 221609-040 Date 2004 -12-16