BT LPE Forklift Pallet Mode LWE 180 200 LPE 200 Service Manual PDF

trọn bộ tài liệu hướng dẫn, tháo lắp, sửa chữa chi tiết và full code lỗi cho xe BT Pallet Mode LWE 180 200 LPE 200 dòng xe . Được phát hành từ hãng BT Industries. Mọi thắc mắc xin liên hệ qua mail : Ngoanhquocngogmail.com

External cleaning

• Remove rubbish, etc from the wheels daily

• Use a well-known degreasing agent, diluted to a suitable concentration

• Rinse off loose grime using tepid water

Mechanical components can be damaged

After washing, the truck should be lubricated as set out in the chapter Maintenance and lubrication chart.

Cleaning the motor compartment

• Cover the electric motors, connections and valves before washing

The electrical system can be damaged

Electrical components must not be cleaned with a high pressure washing unit

• Clean the motor compartment using a well-known degreasing agent, diluted to a suitable concentration

• Rinse off loose grime using tepid water

Electrical components

• Blow electric motors down using compressed air

• Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc using a damp cloth and a cleaning agent

Electrical components can be damaged

Do not break the guarantee seal on the electronic board

T-code Valid from serial number Date Order number

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, ensuring stability If the lift involves the brake wheel, chock the other wheels to keep the truck stationary and enhance safety throughout the process.

When lifting a truck, choose a designated lifting point to ensure a safe and balanced lift, ideally focusing on one corner at a time If the truck has marked lifting points underneath the chassis, use these to achieve a well-balanced and secure lift, making the overall process easier and safer.

• Ensure that the surface under the jack is clean and free from oil and grease

• Ensure that your hands and the jack’s lever are free from oil and grease

Use the lever that comes with the jack for optimal performance A lever that is too short requires excessive force, making it difficult to operate efficiently Conversely, using a lever that is too long increases the risk of overloading the jack, potentially causing damage or failure Ensure you select the correct lever length to safely and effectively lift heavy loads.

- 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

A badly supported truck can fall

Never work under a truck that is not supported on trestle-blocks and secured by a lifting device

Order number Date Valid from serial number T-code

I: Inspect, rectify and change if necessary T: Tighten C: Clean L: Lubricate

M: Control measurement, rectify if necessary

Interval in days/weeks/months 1d 1w 1m 6m 12m 36m

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

0000.7 Press grease into grease nipples I/L 6

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/L 6

0380.4 Check the lift limit switch l

0560.1 Check for any cracks or damage l

0560.2 Check gas damper and cup springs l

2550.4 Check the attachment and clearance in steering bearing

2550.5 Change the oil in the drive gear L 4 L

3100.2 Check for wear on the brake disc M

3100.3 Check the clearance in disengaged position M

3500.1 Remove string and other rubbish I

3500.2 Check the drive wheel for wear and the tightening torque on bolts

3500.3 Check that the support wheel turns and rotates freely

3500.4 Check for wear on the support wheel I

4110.2 Check the power in the gas damper I

5000.1 Check the operation of the brake microswitch in the upper and lower brake posi- tions Lubricate the switch head.

5000.2 Check the function of the collision safety switch

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

5110.1 Check the electrolyte level, 10-15 mm over the cell plates

5110.2 Check connections to battery, truck and charger

5110.3 Check that the cell and pole guards are undamaged

5110.4 Check the fluid density and temperature M

5110.5 Remove overflow fluid from the battery trough C

5400.1 Cleaning and checking of mounting in chassis C/T 1 C/T

5400.3 Check the contactor points on K10 and K30 I

5400.4 Check the movement of the contactors I

5700.2 Check all segments on the display I

1 = The connections are re-tightened for the first time after 80 h, and then every 1000 h/12 months.

2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm.

3 = Check for leakage in conjunction with the first oil change.

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months

5 = The oil is changed and the filter cleaned for the first time after 80 h/

1 month, and then every 1000 h/12 months.

6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals.

When points with higher hour intervals are carried out the points with lower hour intervals should also be carried out unless otherwise specified above.

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

6100.4 Check that the oil level is correct I

6100.5 Change the oil and clean the filter L 5 L

6680.1 Check if there is any damage or cracks on the PowerTrak spring

6680.2 Grease in the contact pressure spring’s guides

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months

5= The oil is changed and the filter cleaned for the first time after

80 h/1 month, and then every 1000 h/12 months.

Service point Interval/Operating hours Type of lubricant

Oil and grease specifica tion – P3

5- Oil and grease specifica tion – P3

Pos Type of lubricant

B Hydraulic oil ISO-L-HM32 ISO-L-VG 32 Hydraulic system

C Transmission oil Hypoid oil SAE

Lubricating nipples, Contact pressure spring

Oil and grease specifica tion – P3

This page is intentionally left blank

159232 Tools for fitting pins/sleeves

159230 Tool for fitting secondary locks

159231 Tool for fitting secondary locks

PT = Power Timer (4,8 5,8 6,3 mm) JPT = Junior Power Timer (2,8 mm) MPT = Micro Power Timer (1,5 mm)

151080 (PT) Tools for removing pins/sleeves

213296 (JPT) Tools for removing pins/sleeves

213298 (MPT) Tools for removing pins/sleeves

1!3336 (JPT) 2!3549 (JPT) Tools for fitting pins

AMP Connectors, 040 series

156937 Tools for fitting pins/sleeves

Service instrument for pro- gramme changes

18 Washer (0.5 mm) Number as required

18 Washer (1 mm) Number as required

Dismantling/assembling of motor from truck

• Switch off the truck and pull out the battery plug.

• Remove the covers for the motor compartment.

• Release the cables for the motor and tiller arm.

• Unscrew the four nuts for the attachment of the motor to the drive gear.

• Loosen the cables for the key switch and emergency switch Pull out all the cables from the cover’s cable duct.

• Loosen the cover over the motor compartment and the tiller arm’s mounting from the motor Remove the cover over the motor compartment together with the tiller arm.

• Carefully lift the motor straight up, without damaging the sealing sur- faces to the drive gear and place the motor on a clean surface.

• Protect the drive gear from impurities by covering over its opening in an appropriate manner, e.g with a piece of plastic.

The requisite service and repair of the motor can now be carried out.

Assembling

Assembling is carried out in the reverse order.

• Carefully lift down the motor in the drive gear to avoid damaging the seals and gear wheels.

• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm.

To ensure proper brake functionality, carefully fit and adjust the brakes following the manufacturer's instructions Securely screw the cover and tiller arm in place, then reconnect the cables that were previously removed, verifying that the polarity is correct to ensure safe and effective operation.

Dismantling of motor

To remove the brake disc’s companion flange, start by removing the locking ring along with the washer from the end of the rotor shaft Once these components are removed, the companion flange can be lifted off, which may require unclamping it with a suitable tool for easier removal.

• Remove the four plugs that cover the carbon brushes, move the springs on the carbon brushes to one side and pull out the carbon brushes.

To dismantle the commutator end's bearing shield, remove the eight screws that secure the shield (2), along with the carbon brush bridge (5) and carbon brushes (8) Carefully place the motor on a stable surface against the edge of the bearing shield before gently tapping the rotor to disconnect it.

• Now release the inner locking ring together with the underlying washer Pull out the rotor shaft from the bearing (18).

• Release the outer locking ring together with its washer, and remove the bearing from the bearing shield.

• Remove the bearing shield’s seal (17) and carefully clean the bearing shield.

• Fit a new seal in the bearing shield.

Assembling of motor

Assemble the motor in the reverse order

• Carefully check that the rotor can move freely in the direction of rota- tion and that the carbon brushes are flush with the commutator.

• Check the motor’s insulation resistance (between respective winding and the motor housing) For a new motor this should lie between

2 - 3 Mohm When a used motor has been exposed to impurities an insulation resistance down to approx 1 Mohm is acceptable.

• Fit a new O-ring in the drive shaft end’s bearing shield and a new seal on the collar of the bearing shield.

Cleaning

Maintaining a clean motor is essential for optimal performance; regularly inspecting the motor and its compartment for dust, oil, and impurities helps prevent malfunctions.

Using a vacuum cleaner with an appropriate nozzle is effective for cleaning a dry motor, including the motor windings and inner compartment For optimal results, compressed air can be used in conjunction with the vacuum cleaner, ensuring that the compressed air is clean and dry to prevent damage and maintain motor performance Proper cleaning techniques help prolong the lifespan of your motor and ensure efficient operation.

Use a non-fluffing cloth to ensure cleanliness when handling windings with a coating, preventing fiber contamination For effective cleaning, moisten the cloth with a grease-dissolving, organic, and volatile detergent that will not damage the windings Apply the detergent sparingly to prevent it from penetrating into the motor components, ensuring safe and efficient maintenance.

Residual detergent should be removed with an appropriate solvent, if it leaves a greasy surface.

When motor parts are heavily fouled, applying a suitable solvent is essential for effective cleaning To prevent dirt from infiltrating critical components, such as the rotor, it is important to spray the detergent carefully and strategically onto the affected parts Proper application of cleaning agents ensures thorough removal of grime while protecting the motor's internal parts from further contamination.

To effectively clean a rotor, it should be dipped in solvent, followed by thorough drying with heat Adequate ventilation is essential during the drying process to ensure safety and efficiency The drying should continue until multiple insulation resistance measurements confirm consistent and approved results, ensuring optimal electrical performance and safety.

Type of machine LWE180 LWE200, LPE200-6 LPE200-8

Type TSL140S-DS20 TSL140S-DS30 TSL140B-DS40

Minimum length of carbon brush (mm)

Resistance, shunt field winding Ω at 26 C° 0,55 0,55 0,498

Insulation resistance between windings and motor housing

12 Screw Top cover and gear housing

Tightening torque 26.6 Nm Lock with Loctite 242

15 Pinion/ Crown gear Cog clearance 0.09-0.15 mm

Pretension bearing with 2-5/100 Stamped size on pinion adjusted with shims

20 Screw Bottom cover and gear housing

21 Screw Bottom cover and gear housing

Technical data

Locked with punch mark Lock with Loctite 603

27 Screw Motor and gear housing

Type of truck LWE180, LWE200,

Type of gear 2-step angle gear 2-step angle gear

Oil type Hypoid oil Hypoid oil

• Lift up the truck, and block up to ensure that it is stable.

• Unscrew the M8 nuts (28), that hold the gear and motor, with a box wrench Support the gear so that it does not drop.

• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex socket wrench.

• Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm Lock with Loctite 242.

• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

9.3 Changing of the drive shaft’s sealing ring

The drive shaft’s sealing ring can be changed with the gear mounted in the truck.

Follow the instructions below if oil is leaking from the drive shaft.

• Remove the lower cover and drain off the oil (22).

• Release the drive shaft nut Remove the nut and washer (16,17).

• Carefully tap out the drive shaft with a brass drift and hammer (32).

• Pull off the bearing from the drive shaft with tool 08-13022 (29).

Ensure that the bearing washers are free from damage; if the puller tool has caused any harm, measure the total thickness of the shim washers and replace them prior to reassembling to maintain optimal performance.

• Remove the sealing ring from the drive shaft (31).

Changing of the drive shaft’s sealing ring

Assemble the gear after changing the drive shaft’s sealing ring in reverse order.

Pay special attention to the following during assembling:

• Fill the sealing ring with grease after fitting it on the drive shaft.

• Make sure that only undamaged shim washers with the same total thickness as the originals are put on the drive shaft.

• Press the bearing on the drive shaft and make sure not to damage the bearing’s shim washers.

When installing the drive shaft with flange bearing, shim washers, and seal, ensure that the shaft keys align with the crown gear’s keys for proper engagement Verify that the bearing and seal are correctly positioned within the gear housing before pressing the shaft fully into place, to guarantee optimal performance and prevent misalignment.

To install the drive shaft, first place the distance ring onto the drive shaft end, then secure it with a new shaft nut Ensure the nut is lubricated before installation Tighten the shaft nut to a torque of 300 Nm and lock it securely with a punch mark in the middle to prevent loosening during operation.

• Change the gasket before fitting the bottom cover Make sure that it is not damaged Fit the cover and tighten the bolts to a torque of 26.6

Nm The bolts should be lubricated before they are fitted Fill up with oil in accordance with the instructions for replenishing the oil.

Fit the drive gear and tighten the bolts to a torque of 65 Nm

Changing of the drive shaft’s sealing ring

Basically the brake is maintenance free in normal work environments However it is recommended according to the preventive maintenance schedule to check the brake disc for wear.

Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been reduced to 5,5 mm.

• Disconnect the electrical wires of the brake.

• Undo and remove the two fastening bolts.

• Loosen the brake disc from the hub and check for wear and tear Re- place the brake disc if the surface is unevenly worn.

In standard work environments, the brake is generally maintenance-free However, to ensure optimal performance and safety, it is recommended to follow a preventive maintenance schedule, including regular inspections of the brake disc for wear and checking the gap between the magnetic coil housing and the pressure plate.

Basic Adjustment of gap

The nominal gap between the coil housing and the pressure plate, in applied position, shall be 0.3 mm The maximum gap before readjust- ment is necessary is 0.8 mm.

• Loosen the tension of the three mounting bolts

• Turn the lock nuts anti-clockwise and tighten the bolts slightly while checking the gap on three points with a 0.3 mm feeler gauge.

• Tighten the mounting bolts 9,5 Nm and recheck the gap with the feeler gauge.

Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been reduced to 6 mm.

• Disconnect the electrical wires of the brake.

• Loosen and remove the three mounting bolts and remove the brake coil.

• Replace the brake disc on the hub and make a visual inspection of the wear of the friction plate Replace the friction plate if the surface is worn uneven.

• Unwind the lock nuts on the coil at least 6 mm to make sure there is a gap between the coil and the pressure plate when the coil is refitted.

• Mount the coil on the motor end and carry out adjustment of the gap according to chapter “Basic Adjustment of gap”.

Adjusting of brake microswitch

Switch (23) is always adjusted to its lowest position.

• Unscrew the screws (13, 20) that hold the switch and the distance.

• Press down the switch and tighten the screws.

• Check that the switch is actuated by the cam (18) in the arm’s top and bottom position.

Dismantling/Assembling

• Remove the screws (35), hold top cover firm (7).

• Disconnect the cable connected to the electronic card (4).

• Carefully lift off the lower cover (33), and place a finger between the lower cover (33) and button (30) to hold the button (30) in place. Assemble in reverse order.

Risk of static discharge that can damage the electronics

Make sure to take the necessary precautions before working with the electronics

Change from ignition key to keyboard (2)

• Connect the CAN-key to the truck.

• Change parameter 39 to value = 3 or 4.

• Set the required PIN-code by using parameter 10.

• Dismantle the cover(2) on the tiller arm.

• Remove the ignition key, fit the strap.

• Fit the cover in the key hole.

• Start the truck using the chosen PIN-code.

Change from keyboard to ignition key (2)

• Connect the CAN-key to the truck.

• Change parameter 39 to value = 1 or 2.

• Remove the keyboard (2) on the tiller arm.

Changing of signal button/switch (9, 10)

• Dismantle the button as per the diagram.

Changing of lift/lowering button (13)

• Remove the button by placing a screwdriver in the hole (A) as per the diagram below.

• Unscrew the holder (18) so that the arm (12) comes loose.

• Press the button by hand sideways.

• Place a screwdriver as per the diagram and carefully pry the button loose.

• Unscrew the button’s holder and arm.

Symbol List and Wiring Diagram

13.2 Symbol List and Wiring Diagram

A6 Display Display of truck functions

A17 Keypad Login with PIN code Option

S10 Inductive switch Mechanical activation of the brake

S19 Switch Man on the platform (Applies to LPE200-8)

A2:S21 Switch Fork lift (Alternative, see parameter 28)

A2:S20 Switch /Fork lowering (Alternative, see parameter 28)

S53 Switch Gates (Applies to LPE200-8)

S59 Switch Platform in folded position (Applies to LPE200-8)

X9 Connection point CAN communication (Extra

X41 Connection point CAN communication (Exter- nal)

Starting truck

To enable the truck to be started, the battery plug must be connected, the emergency switch (S21) closed and the start key (S17) in the ON position.

Driving speed ≤ 6 km/h

When driving at a speed of 6 km/h

- the switch for driving brake (S10) must be closed, and the

- Speed controls must be activated in any direction.

Braking in neutral mode

• when the speed controls are in neutral mode, the engine functions as a generator The braking energy is fed back to the battery.

• The brake (Y1) is engaged when the truck stops completely even if the tiller arm is in drive position.

• Energy is fed back to the battery (see diagram below).

• The transistors (T2) for the brake circuit generated are not live.

The truck's brake remains engaged when started with the tiller arm in the top or bottom position (S10 open) The brake is automatically released once all driving requirements are satisfied, allowing the truck to begin moving smoothly Proper understanding of this safety mechanism is essential for safe operation and efficient forklift handling.

Requirements for the truck to be able to brake:

• Battery status OK (if battery capacity remaining is > 20 %).

• Press and hold S18 while turning S17 to “ON” position.

• Press and hold S18 until H = hour meter is displayed.

• You have now selected H = hour meter The “B” symbol lights up.

• You can now select type of hour meter by pressing the speed control.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time remaining until service

• Press and hold S18 until E = error codes is displayed.

• When E is selected, the “E” symbol will light up as an indication of what is shown in the display.

• The 50 most recent error codes are stored The latest error is displayed first The display shows the error code first, followed by the time when the error occurred.

• The error codes are divided into two groups, C = caution and E = error.

• C codes are not stored They are only cautions and remain lit in the display as long as the fault remains.

• If there is only one error registered in the memory, the other empty entry lines appear as follows: Error: E - - - and time: - - - -

Description TLS: Shock sensors registered values outside the limits

A shock sensor has reported values that exceed the truck’s tolerance values.

Driving may be too hard Check that the shock sensor’s limit values are correctly set.

Check that the shock sensor is correctly positioned./The brake engages and stops the truck

The TLS reset command activates the truck

Description TLS: Use of the truck has been blocked

Truck use can be “blocked” by a TLS command /

The truck cannot be used until a new TLS command cancels the blocking of the truck

Description Parameter caution Displayed for 5 seconds.

The parameters have probably been changed When changing/updating the program the parameters have automatically been changed to default values (only applies to old program versions).

In later program versions the parameters are only changed if they are outside the values permitted by the new program.

Action 1 This means that the special parameters must be reset manually.

Problem with the speed control sensors.

The toggle switch may have been activated when starting or there may be a fault on one of the sensors on the electronic card (tiller arm head)

Action 1 Restart with the speed control in neutral position.

The emergency switch has been activated.

No current to the travel regulator, input A1/16.

3 Check the cables from the battery and the battery contacts

4 If PTC resistor R1 is very hot, remove the battery contact and allow the resistor to cool.

The service counter has not been reset since the last service.

A problem with the pressure switch Check that the voltage is approximately 24 V between cables

24 and 40 connected to the pressure sensor. Check the voltage between cable 40 and 63 connected to the pressure sensor The output voltage should be 0.5 Volt (unloaded machine) - 5 Volt (max load).

Description Warning of low battery voltage

The battery parameters are not correctly set. Time to charge up the battery.

Action 1 Check parameter 21, battery size and type.

2 Check the battery contact and the pole connections on the battery

3 Check the key switch, S17, poor contact causes unpermitted voltage drop.

The electrical system measures the voltage inside the travel regulator.

Description Warning of high battery voltage

Energy return feed to battery during motor braking with a fully-charged battery.

Action 1 The fault disappears after a few lifts, once the battery has been run down slightly.

2 Check the cabling, the battery contact and the contact points on main contactor K10.

Description The travel regulator shuts off due to excess or subnormal temperature.

Too intensive operation or ambient temperature too cold.

Error in the travel regulator.

Temperature levels below -25 o C or above +85 o C reduce running speed.

Action 1 Check that the M12 fan is functioning (Ap-

Description Extra I/0 (0) CAN communication error

Data from extra I/0 box /(0) not being received by

[A2]/ Check the CAN-bus cable and the connections [A2] Restart the truck.

Description Extra I/0 (1) CAN communication error

Data from extra I/0 box /(1) not being received by

[A2]/ Check the CAN-bus cable and the connections [A2] Restart the truck.

Incorrect setting of options in the extra I/0 box (0) Check the outputs’ allocation on the I/0 expansion box (0)

Incorrect setting of options in the extra I/0 box (1) Check the outputs’ allocation on the I/0 expansion box (1)

Description Travel regulator does not correspond with the type of truck

An incorrect travel regulator or electronic card has been installed in the vehicle The truck is equipped with a built-in control system that verifies the correct combination of the travel regulator and electronic card, preventing improper installation and ensuring proper operation.

Action Check travel regulator and electronic card.

Description Switch-transistor to brake is short-circuited

Error in the travel regulator, output A1/3.

Action Check cabling and contacts Measure Ohms on the magnet coil (Y1) for the brake Value 13-15 ohm.

Description Digital outputs short-circuited or exceeding field current limit.

Problem regulating the field current.

Action 1 Check the output for main contactor K10 (A1/

Ensure the cabling and contacts are properly checked, and measure the ohms for the brake coil K10 (A1/3), which should be between 13-15 ohms Additionally, inspect the coil's output, confirming it falls within the standard resistance range of 25-30 ohms, to maintain optimal performance and troubleshoot effectively.

2 Check the output for horn (A1/7), check cabling and contacts.

Verify the drive motor’s shunt winding, wiring, and contacts to ensure proper operation Note that measuring the field winding with a standard multimeter is not feasible, as its resistance is very low—around 0.3 ohms—requiring specialized testing methods for accurate assessment.

Description Contactor K10 does not close.

Problem with main contactor points or coil.

Contactor’s operating cabling off/not connected. Interruption in the travel regulator’s output, A1/4.

Action 1 Check if the contactor is activated.

2 If the contactor is working, check the contact points and accompanying cabling.

3 If the contactor is not working, check the coil and accompanying cabling Measure Ohms for the coil Value 25-30 ohm.

4 Check the travel regulator’s output, A1/4.

Description Contactor K10 does not open.

Short circuit in the travel regulator’s output A1/4.

Action 1 Check that the contactor’s contact points are not welded together.

2 Check that the R1 resistor is not short- circuited.

3 If the contact points are OK, but the contactor engaged, check cable 64 and the travel regulator’s output A1/4.

Temporary error/error in the travel regulator.

Description Error in control total.

Fault on the internal micro-monitoring (tiller arm head), incorrect software or circuit board.

Fault on the internal monitoring (tiller arm head), incorrect software or circuit board.

Description Fault in the data communication.

Break on the CAN cable.

Action 1 Check the 119 and 120 cables and their contacts.

Description Tx error in data communication.

Action 1 Check 119 and 120 cables and the connections on the travel regulator.

Possible error CAN bus problem.

Action 1 Check 119 and 120 cables and the connections on the travel regulator.

Description Error in safety reversing function

Error in important sensor part.

Action 1 Replace the electronic card

Action 1 Check the field winding connections E1 and

E2 Unfortunately it is not possible to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm.

2 Check cables 4 and 5 and outputs S1 and S2

Problem with switch transistor in the armature circuit inside the travel regulator.

Action 1 Check cable and connections between A1/M on the travel regulator and connection A2 on drive motor.

Description Fault on sensor in travel regulator

Fault on armature current sensor in travel regulator

Description CAN timeout in power amplifier.

Possible error The motor monitor is reporting an unexpected

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

• Press L1 up or down and scroll to the parameter you want to change or view

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine

Truck handling When you change specific truck parameters, the truck’s driving char- acteristics are also changed

Do not change any parameters unless you really know what you are doing

Parameter Description Unit Min Max Step Std Description

04 Braking in neutral mode

5 100 5 50 Specifies motor braking once the lever is put into neutral.

5: weak braking power 100: maximum break- ing power

The "Logout 1min" setting determines the time it takes for the truck to shut off when the keypad is activated This countdown begins immediately after the last power-consuming unit is used, ensuring an efficient shutdown process Setting the value to 0 results in immediate shutdown, optimizing energy conservation and operational efficiency.

The speed of use of the turtle button can be adjusted.

The maximum speed can be adjusted.

The lower the parameter value, the longer it takes for the truck to achieve maximum speed.

Specifies the motor braking power when the lever (L1) is put into neutral The lower the parameter value, the longer the braking time.

The time it takes for the truck to switch off when the keypad is used The time counts down from the moment the last power-consuming unit is used

• Connect the CAN key to X41.

• Press and hold S18 until P = parameters is displayed.

• You have now selected P = parameters and the symbol “C” is lit as an indication of what is now shown in the display.

• Press L1 up or down and scroll to the parameter you want to change or view

• Press S18 once to access the parameter.

• Press L1 up or down to specify the parameter value.

• Press S18 once to confirm the change.

• Turn S17 to the off position.

You have now changed the parameter and the new setting will come into force the next time you start the machine

Truck handling When you change specific truck parameters, the truck’s driving char- acteristics are also changed

Do not change any parameters unless you really know what you are doing

10 PIN-code 0 9999 1 1 Facility for specifying up to 10

-10 10 1 0 The amount of power the monitor should emit when you reach the first speed sensor can be specified here.

-10: low speed for the first speed sensor.

10: high speed for the first speed sensor

See “Option parameters” on page 34,

Parameter #10 functionality is disabled when parameter #39 is set to 5, 6, 7, or 8 PIN codes are managed using the expanded keypad, offering enhanced security and ease of access For detailed instructions on using the expanded keypad, refer to the "Expanded keypad - General" section on page 45.

Ten drivers can have their own PIN code to gain access to the truck Each driver can set all driver parameters individually.

On delivery the PIN code is set to 1 and this only applies for driver no 1. Code 0 is not accepted as a solitary code.

When you wish to start the truck enter your code and press the green button numbered 1.

When you want to switch off the truck, press the red button numbered 0.

When the CAN key is connected, you can start the truck by simply pressing the green button numbered 1 Switch off by pressing the red button numbered 0.

21 Battery size 1 20 1 95 Selection of battery size.

1h 0 2000 50 100 Option for setting service timer

39 Password 1 12 1 1 States which level of authoriza- tion the driver has for the parameters.

Odd values specify open driver parameters, even values specify that driver parameters must be opened using the CAN key

See “Option parameters” on page 34,

It is essential not to alter these parameters unless you have detailed knowledge of the truck's options or modifications, as this manual covers only the standard equipment Specially modified trucks may need specific service information to ensure proper maintenance Improper adjustments of option parameters can lead to incorrect truck function, highlighting the importance of following the manufacturer’s guidelines.

Parameters #15 to #19 are reserved in the truck control system for additional options and custom modifications, typically configured by the manufacturer It is advisable to load existing parameter settings from the truck before making any modifications, especially when replacing main electronic components like the electronic card [A2], to ensure all special features function properly.

Parameter #15 encompasses up to 16 sub-parameters, each with a status of either ON or OFF These sub-parameters do not require any additional configuration, as they are pre-set and considered non-configurable options.

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

The first set-up of sub-parameters is displayed

The next set-up of sub-parameters is displayed if you continue to activate the speed control L1 Ensure that only the relevant sub-parameters are displayed.

The value of the sub-parameters is displayed after 1 second.

• Enter the sub-parameter value by repeatedly operating the speed control L1 in either direction See Table 1: for more information.

• Press the S18 horn button once to confirm the new setting.

The parameter symbol is lit (i.e stops flashing).

• Switch off the truck by pressing on the keypad.

The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back in operation.

Parameter #16 to 19 configurable optional functions

Parameters no #16, #17, #18, and #19 can be adjusted to activate up to four pre-programmed functions, allowing customization of the truck's optional equipment Refer to “Table 2: List of Configurable Optional Functions” on page 37 for detailed options, enabling operators to tailor the vehicle's features to their specific needs.

Table 1: Parameter #15 Non-configurable option

Function ON Function OFF B asic setting

To activate a configurable optional function, first assign a parameter from #16 to #19 by setting independent variable #0 to the corresponding pre-programmed option number After selecting the option, ensure the independent variables for that function are properly configured by adjusting the values of independent variables #1 and subsequent relevant parameters Proper setup of these variables is essential for successful activation and operation of the optional function.

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

The independent variable value is displayed after 1 second The value

“0” means that an optional function has not been assigned to this parameter, and the speed control L1 in this case displays the next parameter if you continue to activate it.

• Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction See Table 2:

Parameter no (range 16-19) Independent variable: #0 is the option designation Independent variable value (range 0-63)

0= no option has been activated for this parameter

1 to 63 = Pre-programmed option number See separate table.)

The independent variables #1, #2, #3, and #4 each contain optional function values, with their specific ranges depending on the selected function The assigned values vary based on the chosen option and the corresponding independent variable For detailed information, please refer to the separate table outlining the value ranges and options for each variable.

• Select independent variable #1 by activating the speed control L1. Independent variable value #1 is displayed after 1 second.

• Enter the independent variable value #1 by repeatedly operating the speed control L1 in either direction See the list of optional functions in Table 2:

Adjust independent variables #2, #3 and #4 in the same way as above.

• Switch off the truck by pressing on the keypad.

The optional function is now activated.

• Check that the optional function works correctly before the truck is put back in operation.

Table 2: List of configurable optional functions

Independent variable #0 = 1: The option button controls the spider output

0:Digital output 1 1:Digital output 2 2: :Digital output 3 3: :Digital output 4

1-6:option button 1-6 Type of function:

0:instantaneous1:butterfly switchIndependent variable #0 = 2:Reduced running speed controlled by the spider’s digital input

Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input

Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs

0: Lift, digital input 1 Lowering, digital input 2

Blocking of lowering, input 3

0: Blocking of lowering disconnected 1: Blocking of lowering connected

0: Fork lift/lowering 1: Support arm lift/lowering

Independent variable #0 = 6:Lift height limitation with by-pass

0-7: Limit switch for digital input 1-8

Table 2: List of configurable optional functions

Table 3: Option 3 – Choice of movement

Fork lift or driving forward 5

Fork lift or driving backward 6

Fork lift or driving forward or driving backward

Fork lowering or driving forward 9 Fork lowering or driving backward 10

Fork lowering or driving forward or driving backward

Fork lift or fork lowering 12

Fork lift or fork lowering or driving forward 13 Fork lift or fork lowering or driving backward 14

Fork lift or fork lowering or driving forward or driving backward

Driving forward or driving backward or AOM 19

You decide yourself what the hour meter will show.

1A = Key time 2b = Movement time 3c = Drive motor time 4d =Pump motor time 5s = Time for service

You must specify the type of battery the truck is equipped with.

In order to set the meter for the battery’s level of discharge, the following should be taken into account:

• Acid concentration when the battery is fully charged, to check the grade of the battery Must be between 1.27-1.29.

• When the lifting capacity is disconnected (the battery is 80 % dis- charged), the value must be close to, but not below, 1.14.

The acid concentration can vary depending on the battery make.

Fork lowering or driving backward or AOM 26

Fork lowering or driving forward or driving backward or AOM

Fork lift or fork lowering or AOM 28

Fork lift or fork lowering or driving forward or AOM

Fork lift or fork lowering or driving backward or AOM

Fork lift or fork lowering or driving forward or driving backward or AOM

Table 3: Option 3 – Choice of movement

Recommendation on parameter setting for freely ventilated batteries

Instructions for verifying parameter setting

• Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Remove the battery from the truck and allow to rest for at least two hours NB! No charging or discharging during this period.

To ensure optimal battery performance, measure the acid weight at room temperature A value below 1.15 g/cm³ indicates that the parameter should be decreased, while a significantly higher value reduces the risk of battery damage but also shortens the truck's operating time For longer operating durations, the parameter can be increased by up to one unit.

• Each change must be accompanied by a new verification of the parameter setting.

Recommendation on parameter setting for valve- controlled batteries (VRLA)

Instructions for verifying parameter setting

• Use the truck in its normal application until the battery indicator shows an empty battery (0% on the display).

• Disconnect the battery from the truck and allow the battery to rest for at least two hours NB! No charging or discharging during this period.

Measure the battery voltage at room temperature to determine proper parameter settings If the voltage is below U end, adjust the parameter value downward according to the provided table Conversely, if the voltage significantly exceeds U end, the risk of battery damage decreases, but the truck’s operating time also shortens To extend operating time, you may increase the parameter value by up to one unit.

• Each change must be accompanied by a new verification of the parameter setting.

You must specify the type of brake switch the truck is equipped with. Mechanical switch = 0

You can set a service reminder using this parameter, allowing you to specify a time limit from 0 to 2000 hours in 50-hour increments When the scheduled service time arrives, warning 29 (C29) will appear on the display to alert you This feature helps ensure timely maintenance and optimal performance of your equipment.

Using this parameter you can select which button is to be used for lift/ lower.

1 = Bottom lift/lower button activated (default)

2 = Top lift/lower button activated

3 = Both lift/lower buttons are activated

Battery type Battery voltage at rest, U end

Login method and driver parameter access

This parameter determines which function is to be used for login and whether the operator can adjust the driver parameter settings.

• Value 1 – Key switch fitted – Driver parameters accessible (without CAN service key).

• Value 2 – Key switch fitted – Driver parameters NOT accessible (without CAN service key).

• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters accessible (without CAN service key) NB! this is the original setting.

• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT accessible (without CAN service key).

• Value 5 – Expanded keypad (100 PIN code)- Driver parameters accessible (without CAN service key)

• Value 6 – Expanded keypad (100 PIN code)- Driver parameters NOT accessible (without CAN service key)

• Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parameters accessible (without CAN service key)

• Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parameters NOT accessible (without CAN service key)

Tiêu đề	BT LPE Forklift Pallet Mode LWE 180 200 LPE 200 Service Manual PDF
Trường học	BT Europe AB
Chuyên ngành	Service Manual
Thể loại	manual
Năm xuất bản	2004

Định dạng
Số trang	142
Dung lượng	6,38 MB