BT LWE180 Service Manual
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BT LWE180 Service Manual

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

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Summary of Contents for BT LWE180

  • Page 1 Service Guide LWE180, LWE200, LPE200, LPE240 Valid from serial number: 723984- Order number: 225553-040 Issued: 2005-05-11 ITS © BT Europe AB...
  • Page 2 Issue date Resp. Changes 2005-05-11 Completely new issue This manual covers following truck models: T-code Model Serial number LWE180 723984- LWE200 723984- LPE200 723984- LPE240 723984- © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 Approved by: L-G Andersson...
  • Page 3 LPE 240 Tools – P4 LWE 180/200 LPE 200/240 Super Seal connectors ........AMP connectors ..........8.2.1 AMP Connectors, 040 series ......3 Molex connectors .......... Other tools............. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 1...

  • Page 4: Table Of Contents

    Parameter 17 - Configurable option #2 ..... 33 Parameter 18 - Configurable option #3 ..... 34 Parameter 19 - Configurable option #4 ..... 34 Option parameters ..........34 1- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 5 9.8.1 General ............. 50 Troubleshooting .......... 9.9.1 Error codes and troubleshooting ...... 51 9.9.2 Reset error ............52 9.9.3 Safety ............... 52 Technical specifications – Curtis 1243 ..© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 3...
  • Page 6 Parameter 17 - Configurable option #2 ..... 29 Parameter 18 - Configurable option #3 ..... 29 Parameter 19 - Configurable option #4 ..... 29 Option parameters ..........29 1- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 7 10.8.1 General ............46 Diagnostic and troubleshooting ....10.9.1 Error codes and troubleshooting ...... 47 10.9.2 Resetting errors ..........48 10.9.3 Safety ............... 48 Technical specifications – Curtis 1243 ..© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 5...
  • Page 8 LPE 240 12-1 General ............12.1.1 Hydraulic diagram ..........1 12.1.2 Symbol list ............2 Adjustments ..........12.2.1 Adjustment of the pressure limit valve ....3 Cleaning the filter.......... 1- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 9 Oil volume, litre Oil type Hypoid oil Hypoid oil Hypoid oil at normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90 SAE 75W SAE 75W SAE 75W at temperature < -15 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 2- 1...
  • Page 10 Hydraulic oil Hydraulic oil at normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32 ISO-L-HV32 ISO-L-HV32 ISO-L-HV32 at temperature < -15 Fuses Drive motor circuits, A Pump motor circuits, A Control circuits, A 2- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 11 Lift with rated load, A Incline climbing ability With rated load Measurement, L2 Short 519(LWE200) Medium Lång 1008 1008 Turning radius WA 1466 1960 1960 Lift height Weight Truck without battery, Medium © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 2- 3...
  • Page 12 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 2- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 13 Transmission/drive gear Type 2-stage angle transmission Gear ratio 14.20:1 Oil volume, litre 1.75 Oil type Hypoid oil at normal temperature SAE 80W/90 SAE 75W at temperature < -15 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3- 1...
  • Page 14 Minimum commutator diameter, mm Pressure at rated load, bar Overflow pressure, bar Pump flow, cc/r Tank volume, litre Oil type: at normal temperature ISO-L-HM32 ISO-L-HV32 at temperature < -15 3- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 15 Without load, m/s 3.33 + 5% With rated load, km/h With rated load, m/s 2.63 + 5% Lift/lowering speed Lift to top with load, s Lowering without load, s © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3- 3...
  • Page 16 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 3- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 17 Technical data – M4 LPE 240 Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 800-2350 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3- 5...
  • Page 18 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 3- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 19 Check clearance in connections 1700.2 Check the carbon brushes in the drive motor 1700.3 Clean the drive motor 1700.4 Re-tighten the attachment bolts 1700.5 Check for abnormal noise in bearing © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4- 1...
  • Page 20 Check the function of the horn 5000.6 Check for wear on cabling 5000.7 Check the function of the driver’s control 5000.8 Check the error code log and operating times 4- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 21 6100.4 Check that the oil level is correct 6100.5 Change the oil and clean the filter 6600. Lift cylinder 6600.1 Check for leakage 6600.2 Check the mountings © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4- 3...
  • Page 22 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. 4- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 23 Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 5000 5000 6680 4110 5110 5700 5000 6600 5400 3100 1700 6100 0560 0380 0000 2550 5000 3500 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4- 5...
  • Page 24 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. 6100 0000 2550 0380 4- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 25 Check the carbon brushes in the drive motor 1700.3 Clean the drive motor 1700.4 Tighten the mounting bolts 1700.5 Check for abnormal noise in the bearings 1700.6 Check the steering motor carbon brushes (Option) © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 5- 1...
  • Page 26 Tiller arm 4110.1 Check for play on steering joints 4110.2 Check the steering force 4110.3 Check the gas cartridge's force 4110.4 Check the adjustment of the steering chain, lubricate 5- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 27 5400 Power system 5400.1 Clean and check the mountings 5400.2 Tighten the cable connections 5400.3 Check the contactor points on K10 and K30 5400.4 Check the contactor movement © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 5- 3...
  • Page 28 When points with higher time intervals are addressed, the points with shorter time intervals should also be addressed unless otherwise stat- ed above. 5- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 29 225553-040 2005-05-11 723984- 660, 661, 662, 497 5000 5000 5700 4110 4110 6680 5000 5000 5110 6600 0380 5400 3100 2550 1700 3500 0000 0000 6100 3500 5000 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 5- 5...
  • Page 30 5= The oil is changed and the filter cleaned for the first time after 80 hrs/ 1 month and then every 1000 hrs/12 months. 0000 6680 0380 0380 4110 0380 2550 6100 5- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 31 Hypoid oil SAE Gears 80W/90 Grease Staburags Staburags Guide bearing NBU 8EP NBU 8EP Grease BT 73942XX5 BT 73942XX5 Lubricating nipples, TOTAL N3942 TOTAL N3942 Contact pressure spring © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 6- 1...
  • Page 32 Oil and grease specifica tion – P3 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 6- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 33 BT 26778 Chains (Spray) (Spray) Grease Grafloscon Grafloscon Gear ring A-G1 (Klüber) A-G1 (Klüber) Grease BT 73942XX5 BT 73942XX5 Grease nipples, TOTAL N3942 TOTAL N3942 Ground pressure spring © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 7- 1...
  • Page 34 Oil and grease specification – P3 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 7- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 35 Tools for loosening locks (1) 159230 Tool for fitting secondary locks 1-2 poles (2) 159231 Tool for fitting secondary locks 3-6 poles (2) 159228 Tools for removing pins/sleeves (3) © BT Europe AB Service Manual LWE180, LWE200, LPE200, LPE240 8- 1...
  • Page 36 Tools for removing pins/sleeves 213298 (MPT) Tools for removing pins/sleeves 1=163787 Tools for fitting sleeves 2=163788 1=213336 (MPT) 2=213337 (MPT) 1=213336 (JPT) Tools for fitting pins 2=213549 (JPT) For 0,5-2,5 mm 8- 2 Service Manual LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 37 Figure Number Application 213130 Pin removal tool 213129 Tools for fitting pins 8.3 Molex connectors Figure Number Application 156937 Tools for fitting pins/sleeves 156936 Tools for fitting sleeves/pins © BT Europe AB Service Manual LWE180, LWE200, LPE200, LPE240 8- 3...
  • Page 38 660, 661, 662, 497 723984- 2005-05-11 225553-040 8.4 Other tools Figure Number Application 156263 Service instrument (CAN) 1=163793 Service instrument for pro- 2=163792 gramme changes 08-13022 Driving gear puller 8- 4 Service Manual LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 39: Electrical System - 5000 Lwe 180/200 Lpe 200

    Electrical components Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 9- Electrical System – 5000 LWE 180/200 LPE 200 9.1 Electrical components © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 1...
  • Page 40 Electrical System – 5000 LWE 180/200 LPE 200 Electrical components T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 9- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 41: Symbol List And Wiring Diagram

    A2:S1-S9 Speed controls Forward/backward A2:S10-S18 Motor Drive motor Motor Pump motor Pressure sensor Load monitoring Digital (Applies to LPE200-8) PTC resistance Power supply 15 Ohm S111 Switch Option © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 3...
  • Page 42 Platform in folded position (Applies to LPE200-8) Electromechanical Mechanical brake brake Solenoid valve Fork lowering Coupling Battery Connection point CAN communication (Extra I/O) Connection point CAN communication (Exter- nal) 9- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 43: Wiring Diagram 1(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 9.2.1 Wiring diagram 1(5) LWE180/200, LPE200-6 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 5...

  • Page 44: Wiring Diagram 2(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 9.2.2 Wiring diagram 2(5) LWE180/200, LPE200-6 9- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 45: Wiring Diagram 3(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 9.2.3 Wiring diagram 3(5) LWE180/200, LPE200-6 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 7...

  • Page 46: Wiring Diagram 4(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 9.2.4 Wiring diagram 4(5) LWE180/200, LPE200-6 9- 8 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 47: Wiring Diagram 5(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 9.2.5 Wiring diagram 5(5) LWE180/200, LPE200-6 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 9...

  • Page 48: Wiring Diagram 1(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 9.2.6 Wiring diagram 1(5) LPE200-8 9- 10 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 49: Wiring Diagram 2(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 9.2.7 Wiring diagram 2(5) LPE200-8 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 11...

  • Page 50: Wiring Diagram 3(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 9.2.8 Wiring diagram 3(5) LPE200-8 9- 12 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 51: Wiring Diagram 4(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 9.2.9 Wiring diagram 4(5) LPE200-8 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 13...

  • Page 52: Wiring Diagram 5(5)

    Electrical System – 5000 LWE 180/200 LPE 200 Symbol List and Wiring Diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 9.2.10 Wiring diagram 5(5) LPE200-8 9- 14 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 53: Operating Description

    If the driver releases the speed control on a slope and the truck does not stop within a certain space of time, the electrical brake is automati- cally engaged. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 15...

  • Page 54: Braking

    • 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 9- 16 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 55: Error Codes

    Truck use can be “blocked” by a TLS command. / cause The truck cannot be used until a new TLS com- mand cancels the blocking of the truck © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 17...
  • Page 56 (tiller arm head) Action 1. Restart with the speed control in neutral position. 2. Replace the electronic card. 9- 18 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 57 Restart. Code Description Service warning Possible error Time for service. cause The service counter has not been reset since the last service. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 19...
  • Page 58 2. Check the battery contact and the pole con- nections 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. 9- 20 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 59 Action 1. Check that the M12 fan is functioning. (Applies to P 24) 2. Check that the travel regulator is installed with good contact with the chassis. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 21...
  • Page 60 Configuration error Extra I/0 (1) Possible error Incorrect setting of options in the extra I/0 box (1) cause Check the outputs’ allocation on the I/0 expansion box (1) 9- 22 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 61 Error in the travel regulator, output. A1/3. cause Incorrect value on parameter 22 Action Check cabling and contacts. Measure Ohms on the magnet coil (Y1) for the brake. Value 13-15 ohm. Check parameter 22 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 23...
  • Page 62 Unfortunately it is not pos- sible to measure ohms for the field winding us- ing a standard universal instrument, since the winding has a value as low as 0.3 ohm. 9- 24 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 63 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. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 25...
  • Page 64 1. Restart the machine. 2. Replace travel regulator. Code E140 Description Error in control total. Possible error Fault on the internal micro-monitoring (tiller arm cause head), incorrect software or circuit board. 9- 26 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 65 CAN bus problem. cause Action 1. Check 119 and 120 cables and the connec- tions on the travel regulator. 2. Replace travel regulator. 3. Replace the electronic card © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 27...
  • Page 66 0.3 ohm. 2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator 9- 28 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 67 Action 1. Check cables 119 and 120 between electronic card and travel regulator. 2. Replace electronic card 3. Replace travel regulator. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 29...

  • Page 68: Parameters

    The time counts down from the moment the last power-consuming unit is used. Value = 0 gives 4 hours. In steps of 1 9- 30 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 69: Parameter Description

    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. Value = 0 gives 4 hours. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 31...

  • Page 70: Service Parameters

    See “Option parameters” on page 34, Servicemanual option #1 Configurable option #2 Configurable option #3 Configurable option #4 Hour meter Select hour meter. option Battery size Selection of battery size. 9- 32 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 71: Parameter Description

    See “Option parameters” on page 34, Servicemanual - Configurable option #1 Parameter 16 See “Option parameters” on page 34, Servicemanual - Configurable option #2 Parameter 17 See “Option parameters” on page 34, Servicemanual © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 33...

  • Page 72: Option Parameters

    L1. Ensure that only the relevant sub-parame- ters are displayed. The value of the sub-parameters is displayed after 1 second. • Press the horn button S18. 9- 34 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 73: Parameter #16 To 19 Configurable Optional

    • Each optional function can have up to 4 independent variables asso- ciated with it. • Each independent variable has a value you can change to configure the function. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 35...

  • Page 74: Changing Configurable Optional Functions

    • Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 2: • Press the S18 horn button once to confirm the new setting. 9- 36 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 75 Initial position: 1:Spider 1 1:Digital output 2 See Table 3: 0: shines constantly 2: :Digital output 3 1: flashes 1 Hz 3: :Digital output 4 2: flashes 2 Hz © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 37...
  • Page 76 8 Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 0-7: Limit 1-6: By-pass, Not used 1:Spider 1 switch for option switch 1-6 digital input 1-8 9- 38 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 77 Fork lift or driving backward or AOM Fork lift or driving forward or driving back- ward or AOM Fork lowering or AOM Fork lowering or driving forward or AOM © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 39...

  • Page 78: Parameter 20

    • 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. 9- 40 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 79: Recommendation On Parameter Setting For Freely

    Other applications may require a differ- ent setting of parameter 21. Check that the parameter setting is the correct one using the instructions below. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 41...

  • Page 80: Instructions For Verifying Parameter Setting

    If a longer operating time is required, the parameter value can be increased. Maximum one unit. • Each change must be accompanied by a new verification of the pa- rameter setting. 9- 42 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 81: Recommendation On Parameter Setting For Valve-Controlled Batteries (Vrla)

    Other applications may require a differ- ent setting of parameter 21. Check that the parameter setting is the correct one using the instructions below. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 43...

  • Page 82: Instructions For Verifying Parameter Setting

    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 9- 44 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 83: Parameter 39

    The truck program stores a standard list of PIN codes as per Table 5: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 45...
  • Page 84 Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles. NOTE! Resetting the expanded keypad does NOT affect the driver profile set- tings. 9- 46 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 85: Service Indication

    Armature voltage (A) Field current (A) PWM (pulse width modulation) armature in percentage Status of Curtis *These are displayed by segments of three of the figures being marked (A). © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 47...
  • Page 86 • The figure with the second highest value is active (marked with an arrow). • Power amplifier, inputs Segment Function Y41, output A1:2 Y1, output A1:3 K10, output A1:4 H1, output A1:7 Y1, output A1:5 K30, output A1:6 9- 48 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 87 • The figure with the fourth highest value is active (marked with an arrow). Segment Function Extra function 6 Extra function 5 Extra function 4 Extra function 3 Extra function 2 Extra function 1 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 49...

  • Page 88: Part Number

    The rotation direction is changed by changing the polarity in the field winding (S1-S2). The regulator is equipped with a transistor-fitted four- quadrant bridge for the field winding and a single-quadrant bridge for the rotor winding. 9- 50 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 89: Troubleshooting

    Too high/too low 1. Temp. > 85 C or < -25 BACK temperature reduc- 2. The truck is overloaded. tion. 3. Incorrectly installed transistor regulator. 4. Operation under extreme conditions. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 51...

  • Page 90: Reset Error

    It may also be necessary to take other measures. WARNING ! Risk of short circuiting Remove watches, jewellery and always use insulated tools only. 9- 52 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 91: Technical Specifications - Curtis 1243

    < 1; Low Logical input current value Operating temperature -40 to +50 °C Upper temperature limit, reduction °C Lower temperature limit, reduction °C * Under special test conditions. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 9- 53...
  • Page 92 Electrical System – 5000 LWE 180/200 LPE 200 Technical specifications – Curtis 1243 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 9- 54 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 93: Electrical Systems - 5000 Lpe 240

    Electrical systems – 5000 LPE 240 Electrical parts Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 10- Electrical systems – 5000 LPE 240 10.1 Electrical parts © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 1...
  • Page 94 Electrical systems – 5000 LPE 240 Electrical parts T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 10- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 95: Symbol List And Electrical Diagram

    Contactor Main contactor Contactor Pump motor Motor Drive motor Motor Pump motor Motor Steering motor option Motor Not cold store Potentiometer Load sensor PTC-resistor Power supply 15 Ohm © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 3...
  • Page 96 Switch Lift height limiter Switch Fork lifting Switch Fork lowering Switch Gates Switch Platform in upper position Brake Magnetic valve Fork lowering Connector Battery Connection point CAN communication 10- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 97: Electrical Wiring Diagram 1(5)

    Electrical systems – 5000 LPE 240 Symbol list and electrical diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 10.2.1 Electrical wiring diagram 1(5) © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 5...
  • Page 98 Electrical systems – 5000 LPE 240 Symbol list and electrical diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 10.2.2 Electrical wiring diagram 2(5) 10- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 99 Electrical systems – 5000 LPE 240 Symbol list and electrical diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 10.2.3 Electrical wiring diagram 3(5) © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 7...
  • Page 100 Electrical systems – 5000 LPE 240 Symbol list and electrical diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 10.2.4 Electrical wiring diagram 4(5) 10- 8 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 101 Electrical systems – 5000 LPE 240 Symbol list and electrical diagram Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 10.2.5 Electrical wiring diagram 5(5) © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 9...

  • Page 102: Electrical Wiring Diagram Servo (Option)

    Electrical systems – 5000 LPE 240 Symbol list and electrical diagram T-code Valid from serial number Date Order number 660, 661, 662, 497 723984- 2005-05-11 225553-040 10.2.6 Electrical wiring diagram Servo (Option) 10- 10 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 103: Functional Description

    • Y1 will be applied when the truck comes to a stand still even if the till- er arm is in drive position. • Energy back to the battery, see picture. • The transistors (T2) for the generated brake current are not live. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 11...

  • Page 104: Neutral Speed Reduction On Slopes

    10.3.8 Lifting the forks • S34 activated. • S31 closed. • Battery status ok (if battery capacity >20% left). 10.3.9 Lowering the forks • S41activated. 10.3.10 Horn • S18 activated. 10- 12 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 105: Hour Meter

    Check that the shock sensor’s limit values are correctly set. Check that the shock sensor is correctly posi- tioned./The brake engages and stops the truck. The TLS reset command activates the truck © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 13...
  • Page 106 (tiller arm head) Action 1. Restart with the speed control in neutral position. 2. Replace the electronic card. 10- 14 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 107 Restart. Code Description Service warning Possible error Time for service. cause The service counter has not been reset since the last service. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 15...
  • Page 108 2. Check the battery contact and the pole con- nections 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. 10- 16 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 109 Action 1. Check that the M12 fan is functioning. (Applies to P 24) 2. Check that the travel regulator is installed with good contact with the chassis. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 17...
  • Page 110 The truck has a built-in control function that checks to ensure the wrong combina- tion of travel regulator and electronic card has not been installed. Action Check travel regulator and electronic card. 10- 18 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 111 Unfortunately it is not possi- ble to measure ohms for the field winding using a standard universal instrument, since the winding has a value as low as 0.3 ohm. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 19...
  • Page 112 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. 10- 20 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 113 1. Restart the machine. 2. Replace travel regulator. Code E140 Description Error in control total. Possible error Fault on the internal micro-monitoring (tiller arm cause head), incorrect software or circuit board. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 21...
  • Page 114 CAN bus problem. cause Action 1. Check 119 and 120 cables and the connec- tions on the travel regulator. 2. Replace travel regulator. 3. Replace the electronic card 10- 22 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 115 0.3 ohm. 2. Check cables 4 and 5 and outputs S1 and S2 3. Replace travel regulator © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 23...
  • Page 116 Action 1. Check cables 119 and 120 between electronic card and travel regulator. 2. Replace electronic card 3. Replace travel regulator. 10- 24 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 117: Parameters

    The time counts down from the moment the last power-consuming unit is used. Value = 0 gives 4 hours. In steps of 1 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 25...

  • Page 118: Parameter Description

    The time until the truck will be switched off when a key pad is used. Time is counted from when the latest power consumer is used. Value = 0 gives 4 hours. 10- 26 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 119: Service Parameters

    0 to 9 Configurable See “Option parameters” on page 29, Servicemanual option #1 Configurable option #2 Configurable option #3 Configurable option #4 Hour meter Select hour meter. option © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 27...

  • Page 120: Parameter Description

    Specifies the speed you will have when you reach the first speed sensor. - Non-configurable option Parameter 15 See “Option parameters” on page 29, Servicemanual - Configurable option #1 Parameter 16 See “Option parameters” on page 29, Servicemanual 10- 28 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 121: Option Parameters

    Up to 16 so-called sub-parameters are stored under parameter #15. Their status is either ON or OFF and they do not require any other adjustments. They are therefore called non-configurable options. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 29...

  • Page 122: Changing Non-Configurable Options

    • 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. 10- 30 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 123: Parameter #16 To 19 Configurable Optional Functions

    • Each optional function can have up to 4 independent variables asso- ciated with it. • Each independent variable has a value you can change to configure the function. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 31...

  • Page 124: Changing Configurable Optional Functions

    • Enter the independent variable value #0 by repeatedly operating the speed control L1 in either direction. See Table 7: • Press the S18 horn button once to confirm the new setting. 10- 32 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 125 Initial position: 1:Spider 1 1:Digital output 2 See Table 8: 0: shines constantly 2: :Digital output 3 1: flashes 1 Hz 3: :Digital output 4 2: flashes 2 Hz © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 33...
  • Page 126 8 Independent variable #0 = 6:Lift height limitation with by-pass 0:Spider 0 0-7: Limit 1-6: By-pass, Not used 1:Spider 1 switch for option switch 1-6 digital input 1-8 10- 34 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 127 Fork lift or driving backward or AOM Fork lift or driving forward or driving backward or AOM Fork lowering or AOM Fork lowering or driving forward or AOM © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 35...

  • Page 128: Parameter 21

    • 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. 10- 36 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 129: Recommendation On Parameter Setting For Freely

    Other applications may require a differ- ent setting of parameter 21. Check that the parameter setting is the correct one using the instructions below. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 37...

  • Page 130: Instructions For Verifying Parameter Setting

    If a longer operating time is required, the parameter value can be increased. Maximum one unit. • Each change must be accompanied by a new verification of the pa- rameter setting. 10- 38 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 131: Recommendation On Parameter Setting For Valve-Controlled Batteries (Vrla)

    Other applications may require a differ- ent setting of parameter 21. Check that the parameter setting is the correct one using the instructions below. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 39...

  • Page 132: Instructions For Verifying Parameter Setting

    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 10- 40 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 133: Parameter 39

    The truck program stores a standard list of PIN codes as per Table 10: These PIN codes can be changed to any value, but you should avoid the same PIN code in different driver profiles. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 41...
  • Page 134 Service personnel should keep notes on activated blocks, changed PIN codes and specially-set driver profiles. NOTE! Resetting the expanded keypad does NOT affect the driver profile set- tings. 10- 42 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 135: Service Indication

    Armature voltage (A) Field current (A) PWM (pulse width modulation) armature in percentage Status of Curtis *These are displayed by segments of three of the figures being marked (A). © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 43...
  • Page 136 • The figure with the second highest value is active (marked with an arrow). • Power amplifier, inputs Segment Function Y41, output A1:2 Y1, output A1:3 K10, output A1:4 H1, output A1:7 Y1, output A1:5 K30, output A1:6 10- 44 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 137 • The figure with the fourth highest value is active (marked with an arrow). Segment Function Extra function 6 Extra function 5 Extra function 4 Extra function 3 Extra function 2 Extra function 1 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 45...

  • Page 138: Part Numbers

    (S1-S2). The regulator is fitted with a four-quad- rant transistor bridge for the field winding and a single-quadrant transis- tor bridge for the armature winding. 10- 46 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 139: Diagnostic And Troubleshooting

    ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85 C or < - 25 CUTBACK perature reduction 2. Truck overloaded 3. Wrong installation of transistor regulator 4. Operation under extreme conditions © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 47...

  • Page 140: Resetting Errors

    WARNING! Risk of short-circuiting. Remove all watches, jewellery and always use insulated tools only. 10- 48 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 141: Technical Specifications - Curtis 1243

    Logic input voltage >7.5; High Volts <1; Low Logic input current Operating temperature -40 to +50 °C Overtemperature, reduction °C Undertemperature, reduction °C * During specific test conditions. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 10- 49...
  • Page 142 Electrical systems – 5000 LPE 240 Technical specifications – Curtis 1243 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 10- 50 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 143 Lifting the forks Preasure relief valve Flow control valve Non-return valve Filter Motor Pump motor Pump Tank 1,2 litre (B20 0,5 litre) Valve Lowering valve for the forks © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 11- 1...

  • Page 144: Adjusting The Pressure Limit Valve

    • If the truck lifts 1900 kg, adjust the pressure limit by turning the ad- juster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load. 11- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 145: Tools

    • Use a 10 mm standard socket and turn it down to the values shown below in drawing B, when you wish to loosen or tighten the locking nuts. 13,5 26,5 © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 11- 3...

  • Page 146: Adjustments Lwe200

    • If the truck lifts 2100 kg, adjust the pressure limit by turning the ad- juster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load. 11- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 147: Hydraulic Chart And List Of Symbols

    Increase the pulling quality when loaded Preasure relief valve Flow control valve Non-return valve Filter Motor Pump motor Pump Tank 1.2 litre Valve Lowering valve for the forks © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 11- 5...

  • Page 148: Adjusting The Pressure Limit Valve

    • If the truck lifts 2100 kg, adjust the pressure limit by turning the ad- juster screw (2) anticlockwise using a 4 mm allen key until the truck cannot lift the load. 11- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 149: Hydraulic, Pneumatic - 6000 Lpe 240

    To avoid functional problems with the lowering valve (Y41), such as unintentional lowering of forks, the valve must be cleaned and the func- tion checked before replacing the valve. 12.1.1 Hydraulic diagram © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 12- 1...

  • Page 150: Symbol List

    One filter on the pump's suc- tion side and one on the return Pressure relief valve Non-return valve Motor Pump motor Pump 2.5 ccpr Tank 1.2 litre Valve Lowering valve for forks 12- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...

  • Page 151: Adjustments

    • If the machine can lift 2300 kg, adjust the pressure limit valve by screwing the adjuster screw (2) anticlockwise using a 4 mm allen key until the machine cannot lift the load. © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 12- 3...

  • Page 152: Cleaning The Filter

    • Loosen and remove the two tank holders (2). • Loosen the suction filter (5) and the return filter (3). • Clean the filter in an environment friendly cleaning agent. Assemble in the reverse order. 12- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB...
  • Page 153 Hydraulic, pneumatic – 6000 LPE 240 Cleaning the filter Order number Date Valid from serial number T-code 225553-040 2005-05-11 723984- 660, 661, 662, 497 This page is intentionally left blank © BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 12- 5...
  • Page 154 © BT Europe AB SE-595 81 Mjölby Sweden www.bt-industries.com...

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