BT LPE200 Service Manual Download

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Service Guide

LWE180, LWE200, LPE200, LPE240

Valid from serial number: 723984-

Order number: 225553-040
Issued: 2005-05-11 ITS

Summary of Contents for LPE200

Page 1: ... BT Europe AB Service Guide en LWE180 LWE200 LPE200 LPE240 Valid from serial number 723984 Order number 225553 040 Issued 2005 05 11 ITS ...

Page 2: ...0 LPE200 LPE240 Approved by L G Andersson This manual covers following truck models Issue date Resp Changes 2005 05 11 ITS Completely new issue T code Model Serial number 660 LWE180 723984 661 LWE200 723984 662 LPE200 723984 497 LPE240 723984 ...

Page 3: ...l data M4 LPE 240 3 1 Preventive maintenance P2 LWE 180 200 LPE 200 4 1 Maintenance schedule 1 Lubrication schedule 6 Preventive maintenance P2 LPE 240 5 1 Maintenance schedule 1 Lubrication chart 6 Oil and grease specifica tion P3 LWE 180 200 LPE 200 6 1 Oil and grease specification P3 LPE 240 7 1 Tools P4 LWE 180 200 LPE 200 240 8 1 Super Seal connectors 1 AMP connectors 2 8 2 1 AMP Connectors 0...

Page 4: ...diagram 5 5 14 Operating description 15 9 3 1 Starting truck 15 9 3 2 Driving speed 6 km h 15 9 3 3 Braking in neutral mode 15 9 3 4 Braking in neutral mode on a slope 15 9 3 5 Braking 16 9 3 6 Lifting the forks 16 9 3 7 Lowering the forks 16 9 3 8 Horn 16 Hour meter 16 Error codes 17 Parameters 30 9 6 1 Operator parameters 30 9 6 2 Parameter description 31 Parameter 1 31 Parameter 2 31 Parameter ...

Page 5: ...n on parameter setting for freely ventilated batteries 41 Instructions for verifying parameter setting 42 Recommendation on parameter setting for valve controlled batteries VRLA 43 Instructions for verifying parameter setting 44 Parameter 22 44 Parameter 25 44 Parameter 28 44 Parameter 39 45 Login method and driver parameter access 45 Expanded keypad General 45 Expanded keypad Programming 45 Servi...

Page 6: ...nd gates speed 6 km h 11 10 3 3 Driving from platform without using gates speed 6 km h 11 10 3 4 Driving from platform and using gates speed Š 8 km h 11 10 3 5 Neutral speed reduction 11 10 3 6 Neutral speed reduction on slopes 12 10 3 7 Braking 12 10 3 8 Lifting the forks 12 10 3 9 Lowering the forks 12 10 3 10 Horn 12 Hour meter 13 Error codes 13 Parameters 25 10 6 1 Driver parameters 25 10 6 2 ...

Page 7: ...er setting for freely ventilated batteries 37 Instructions for verifying parameter setting 38 Recommendation on parameter setting for valve controlled batteries VRLA 39 Instructions for verifying parameter setting 40 Parameter 22 40 Parameter 25 40 Parameter 28 40 Parameter 39 41 Login method and driver parameter access 41 Expanded keypad General 41 Expanded keypad Programming 41 Service indicatio...

Page 8: ... symbols 1 11 2 1 List of Symbols 1 Adjustments LWE180 2 11 3 1 Adjusting the pressure limit valve 2 11 3 2 Tools 3 Adjustments LWE200 4 11 4 1 Adjusting the pressure limit valve 4 Hydraulic chart and list of symbols 5 11 5 1 List of Symbols 5 Adjusting the pressure limit valve 6 Hydraulic pneumatic 6000 LPE 240 12 1 General 1 12 1 1 Hydraulic diagram 1 12 1 2 Symbol list 2 Adjustments 3 12 2 1 Ad...

Page 9: ... 55 0 55 0 4498 Resistance armature winding Ω at 24 C 0 0156 0 0156 0 0161 Insulation resistance between the windings and motor casing 1 Mohm 1Mohm 1Mohm Weight kg 14 14 17 Broms Type BFK457 08 BFK457 08 BFK458 12 Braking force Nm 16 16 32 Output W 25 25 40 Resistance coil Ω 23 23 14 4 Nominal play in actuated position mm 0 2 0 4 0 2 0 4 0 3 0 5 Minimum thickness brake disc mm 5 5 5 5 8 8 Thicknes...

Page 10: ...rt castors mm Dia 125x40 Dia 125x40 Dia 125x40 Axle pressure without load 2X70 240 2X75 240 2x75 240 Axle pressure at rated load kg 2x80 240 2x210 240 2x210 240 Hydraulic system Output kW 1 2 2 2 2 2 Duty cycle 10 10 10 Minimum carbon brush length mm 7 5 12 12 Minimum commutator thickness diameter mm 4 75 4 7 4 7 Pressure at rated load bar 110 150 150 Overflow pressure bar 130 170 170 Pump flow li...

Page 11: ...h rated load km t With rated load m s 6 0 1 7 6 0 1 7 7 2 2 0 Lift lowering speed Lift without load s 2 2 1 7 1 7 Lift with rated load s 3 4 2 3 2 3 Lowering without load s 2 6 1 4 1 4 Lowering with rated load s 3 1 1 5 1 75 Power consumption Driving without load A 38 28 46 Driving with rated load A 45 46 65 Lift without load A 39 49 49 Lift with rated load A 80 52 52 Incline climbing ability With...

Page 12: ...ide LWE180 LWE200 LPE200 LPE240 BT Europe AB Technical data M4 LWE 180 200 LPE 200 T code Valid from serial number Date Order number 660 661 662 497 723984 2005 05 11 225553 040 This page is intentionally left blank ...

Page 13: ...mutator diameter mm 68 Resistance shunt field winding Ω at 24 C 0 346 Resistance armature winding Ω at 24 C 0 0098 Insulation resistance between the windings and motor casing 1 Mohm Weight kg 23 Brakes Type 1EB46 11 Braking force Nm 48 Output W 44 Resistance coil Ω 12 Nominal play in actuated position mm 0 25 0 38 Minimum thickness brake disc mm 7 7 Thickness of a new brake disc mm 9 7 Transmissio...

Page 14: ...gie mm 80x74 Axle pressure without load kg 175 320 Axle pressure at rated load kg 1800 2300 Wheel pressure at rated load kg cm2 47 55 Swivel wheel mm 150x50 Axle pressure without load 175 605 Axle pressure at rated load kg 120 790 Wheel pressure at rated load kg cm2 12 37 Hydraulic system Output kW 2 0 Duty cycle 10 Minimum carbon brush length mm 8 Minimum commutator diameter mm 45 Minimum commuta...

Page 15: ...ush length mm Minimum commutator diameter mm Resistance Ω armature 0 27 Fuses Control circuits F50 F51 7 5 A Drive motor 125 A Pump motor 160 A Servo steering Option 20 A Battery compartment Batteries Battery compartment Dimensions LxWxH mm Short Long 212x790x775 296x790x775 Capacity Ah 292 600 Weight kg 240 500 Driving speed Without load km h Without load m s 12 3 33 5 With rated load km h With r...

Page 16: ...ving with rated load A 92 Lift without load A 49 Lift with rated load A 116 Incline climbing ability Without load 15 8 5 With rated load 8 4 5 Measurement L2 Short Long 730 mm 814 mm Wa with 1170 mm forks and lift fork Wa with 1170 mm forks and lift fork fixed side gates Wa with 1170 mm forks and lift fork fixed back rest Lift height 225 mm Weight Truck without battery Max 600 kg Fixed gates kg Fi...

Page 17: ... LPE 240 Order number Date Valid from serial number T code 225553 040 2005 05 11 723984 660 661 662 497 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 3 5 1451 1050 185 422 L2 800 2350 959 85 790 180 450 685 Wa ...

Page 18: ...ice Guide LWE180 LWE200 LPE200 LPE240 BT Europe AB Technical data M4 LPE 240 T code Valid from serial number Date Order number 660 661 662 497 723984 2005 05 11 225553 040 This page is intentionally left blank ...

Page 19: ... pins l 0000 2 Check wear on cover battery locking l 0000 3 Check of cracking and damage l 0000 4 Check the cover locks I 0000 5 Check finger guard I 0000 6 Check signs and stickers I 0000 7 Press grease into grease nipples I L6 0380 Fork carriage 0380 1 Check for crack formation and damage l 0380 2 Check clearance in bushes and links I 0380 3 Press grease into grease nipples Option I L6 0380 4 Ch...

Page 20: ...at the support wheel turns and rotates freely I 3500 4 Check for wear on the support wheel I 4110 Tiller arm 4110 1 Check the mountings I 4110 2 Check the power in the gas damper I 5000 Electrical functions 5000 1 Check the operation of the brake micros witch in the upper and lower brake positions Lubricate the switch head I I L 5000 2 Check the function of the collision safety switch I 5000 3 Che...

Page 21: ...ighten cable connections T1 5400 3 Check the contactor points on K10 and K30 I 5400 4 Check the movement of the contactors I 5400 5 Check the cable insulation I 5700 Electronic circuit board 5700 1 Check connectors and cables T1 I 5700 2 Check all segments on the display I 6100 Hydraulic system 6100 1 Check hoses and connections for wear I 6100 2 Check hoses for wear and damage I 6100 3 Check the ...

Page 22: ...nged 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 envi ronment 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 speci fied above 6680 Power Trak 668...

Page 23: ...nce schedule Order number Date Valid from serial number T code 225553 040 2005 05 11 723984 660 661 662 497 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 4 5 6600 3100 5000 5400 1700 6100 2550 3500 0000 0560 0380 5000 5700 5000 5000 4110 5110 6680 ...

Page 24: ...dule L Lubrication C Check O Oil change 4 The oil is changed for the first time after 80 h 1 month and then eve ry 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 Pos No Service point Interval Operating hours Type of lubricant 80 h 500 1000 h 3000 h 0380 Lubricating nipples Option L E 2550 Drive gear O4 C O C 6100 H...

Page 25: ...6m 12m 36m 0000 Chassis 0000 1 Check all links and spiral pins I 0000 2 Check for damage to the platform I 0000 3 Check the cover locks I 0000 4 Check the finger guard I 0000 5 Check signs and stickers I 0000 6 Push in grease in the grease nipples I L6 0380 Fork carriage 0380 1 Check for crack formation and damage I 0380 2 Check the play in bushings and links I 0380 3 Push in grease in the grease ...

Page 26: ...rake discs M 3100 3 Check for play in released position M 3500 Wheels 3500 1 Remove string and other detritus I 3500 2 Check for wear on the drive wheel I 3500 3 Check that the swivel wheels rotate and swing freely I 3500 4 Check for wear to the swivel wheels I 4110 Tiller arm 4110 1 Check for play on steering joints I 4110 2 Check the steering force I 4110 3 Check the gas cartridge s force I 4110...

Page 27: ...00 8 Check the error code log and operatingtimes I I 5110 Battery 5110 1 Check electrolyte levels 10 15 mm above the cell plates M 5110 2 Check connections on the battery truck and charger I 5110 3 Check that the cell and pole guards are undamaged I 5110 4 Check the fluid density and temperature M 5110 5 Remove overflow fluid from the battery trough C 5110 6 Check the battery lock I 5400 Power sys...

Page 28: ... higher time intervals are addressed the points with shorter time intervals should also be addressed unless otherwise stat ed above 5700 Electronic card 5700 1 Clean the electrical panel C 5700 2 Check the connectors and cables TI I 5700 3 Check all segments on the display I 6100 Hydraulic system 6100 1 Check for leakage from hoses and couplings I 6100 2 Check for wear to the hoses I 6100 3 Check ...

Page 29: ...rder number Date Valid from serial number T code 225553 040 2005 05 11 723984 660 661 662 497 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 5 5 4110 5000 5000 5000 5000 5000 1700 3100 0000 0000 3500 3500 0380 5110 5700 2550 6680 4110 6100 5400 6600 ...

Page 30: ...the first time after 80 hrs 1 month and then every 3000 hrs 36 months 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 Pos no Service point Interval Operating hours Lubrication type 80 hrs 1000 hrs 3000 hrs 0380 Grease nipples Option L F 2550 Drive transmission O4 I O C 2550 Gear ring L E 4110 Steering chain L D 6100 Hydraulic sy...

Page 31: ...ica tion P3 LWE 180 200 LPE 200 Pos Type of lubricant Specification Application 15 C 15o C A Grease BT 26777 Spray BT 26777 Spray Bearings and bushes B Hydraulic oil ISO L HM32 ISO L VG 32 Hydraulic system C Transmission oil Hypoid oil SAE 80W 90 Hypoid oil SAE 75W Gears D Grease Staburags NBU 8EP Staburags NBU 8EP Guide bearing E Grease BT 73942XX5 TOTAL N3942 BT 73942XX5 TOTAL N3942 Lubricating ...

Page 32: ...180 LWE200 LPE200 LPE240 BT Europe AB 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 ...

Page 33: ...0 Pos Lubrication type Specification Use 15 C 15 C A Grease BT 26777 Spray BT 26777 Spray Bearings and bushings B Hydraulic oil ISO L HM32 ISO VG32 Hydraulic system C Transmission oil Hypoid oil SAE 80W 90 Hypoid oil SAE 75W Gears D Grease BT 26778 Spray BT 26778 Spray Chains E Grease Grafloscon A G1 Klüber Grafloscon A G1 Klüber Gear ring F Grease BT 73942XX5 TOTAL N3942 BT 73942XX5 TOTAL N3942 G...

Page 34: ...de LWE180 LWE200 LPE200 LPE240 BT Europe AB 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 ...

Page 35: ...AB Service Manual LWE180 LWE200 LPE200 LPE240 8 1 8 Tools P4 LWE 180 200 LPE 200 240 8 1 Super Seal connectors Figure Number Application 159232 Tools for fitting pins sleeves 159229 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 1 3 2 3 ...

Page 36: ...8 2 AMP connectors PT Power Timer 4 8 5 8 6 3 mm JPT Junior Power Timer 2 8 mm MPT Micro Power Timer 1 5 mm Figure Number Application 151080 PT Tools for removing pins sleeves 213296 JPT Tools for removing pins sleeves 213298 MPT Tools for removing pins sleeves 1 163787 2 163788 1 213336 MPT 2 213337 MPT Tools for fitting sleeves 1 213336 JPT 2 213549 JPT Tools for fitting pins For 0 5 2 5 mm2 1 2...

Page 37: ...23984 660 661 662 497 BT Europe AB Service Manual LWE180 LWE200 LPE200 LPE240 8 3 8 2 1 AMP Connectors 040 series 8 3 Molex connectors Figure Number Application 213130 Pin removal tool 213129 Tools for fitting pins Figure Number Application 156937 Tools for fitting pins sleeves 156936 Tools for fitting sleeves pins 1 8 9 16 ...

Page 38: ...0 LPE 200 240 Other tools T code Valid from serial number Date Order number 660 661 662 497 723984 2005 05 11 225553 040 8 4 Other tools Figure Number Application 156263 Service instrument CAN 1 163793 2 163792 Service instrument for pro gramme changes 08 13022 Driving gear puller ...

Page 39: ...ate Valid from serial number T code 225553 040 2005 05 11 723984 660 661 662 497 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 9 1 9 Electrical System 5000 LWE 180 200 LPE 200 9 1 Electrical components S21 Y1 M3 Y41 M1 S17 F50 F51 F1 K10 F3 K30 A1 H1 X5 X1 S10 S31 X41 R1 ...

Page 40: ...e Guide LWE180 LWE200 LPE200 LPE240 BT Europe AB 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 A17 ...

Page 41: ... A6 Display Display of truck functions A17 Keypad Login with PIN code Option F 1 Fuse Drive motor circuits 130 A F 3 Fuse Pump motor circuits 130 A F 50 Fuse Working circuit A5 7 5 A F 51 Fuse Working circuit A1 7 5 A F 52 Fuse Optional equipment Option G1 Battery 24 V H1 Horn K10 Contactor Main contactor K30 Contactor Pump motor A2 S1 S9 A2 S10 S18 Speed controls Forward backward M1 Motor Drive m...

Page 42: ...tch Man on the platform Applies to LPE200 8 A2 S17 Switch Emergency reversing S21 Switch Emergency switch S31 Switch Lift height limiter A2 S19 Switch Fork lift Standard A2 S20 Switch Fork lowering Standard 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...

Page 43: ...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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 9 5 9 2 1 Wiring diagram 1 5 LWE180 200 LPE200 6 ...

Page 44: ...200 LPE240 BT Europe AB 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 ...

Page 45: ...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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 9 7 9 2 3 Wiring diagram 3 5 LWE180 200 LPE200 6 ...

Page 46: ...200 LPE240 BT Europe AB 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 ...

Page 47: ...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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 9 9 9 2 5 Wiring diagram 5 5 LWE180 200 LPE200 6 ...

Page 48: ...00 LPE200 LPE240 BT Europe AB 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 ...

Page 49: ... 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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 9 11 9 2 7 Wiring diagram 2 5 LPE200 8 ...

Page 50: ...00 LPE200 LPE240 BT Europe AB 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 ...

Page 51: ... 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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 9 13 9 2 9 Wiring diagram 4 5 LPE200 8 ...

Page 52: ...0 LPE200 LPE240 BT Europe AB 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 ...

Page 53: ...and the Speed controls must be activated in any direction 9 3 3 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 c...

Page 54: ... fulfilled and the truck begins to move Requirements for the truck to be able to brake S10 open 9 3 6 Lifting the forks S34 S31 closed Battery status OK if battery capacity remaining is 20 9 3 7 Lowering the forks S41 activated 9 3 8 Horn S18 activated 9 4 Hour meter 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 ...

Page 55: ... 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 Code C3 Description TLS Shock sensors registered values outside the limits Possible error cause A shock sensor has reported values that exceed the truck s tole...

Page 56: ...tically 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 Code C20 Description Speed control caution Possible error cause Problem with the speed control sensors The toggle switch may have been ...

Page 57: ...ossible error cause The emergency switch has been activated No current to the travel regulator input A1 16 Action 1 Check fuse F51 2 Check the emergency switch 3 Check the cables from the battery and the bat tery contacts 4 If PTC resistor R1 is very hot remove the bat tery contact and allow the resistor to cool Restart Code C29 Description Service warning Possible error cause Time for service The...

Page 58: ...ted to the pressure sensor Check the voltage between cable 40 and 63 con nected to the pressure sensor The output voltage should be 0 5 Volt unloaded machine 5 Volt max load Code C41 Description Warning of low battery voltage Possible error cause Battery voltage 17 volt The battery parameters are not correctly set Time to charge up the battery Action 1 Check parameter 21 battery size and type 2 Ch...

Page 59: ...y 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 Code C43 Description The travel regulator shuts off due to excess or subnormal temperature Possible error cause Too intensive operation or ambient temperature too cold Error in the travel regulator Temperature levels belo...

Page 60: ...estart the truck Code C91 Option Description Extra I 0 1 CAN communication error Possible error cause Data from extra I 0 box 1 not being received by A2 Check the CAN bus cable and the connections A2 Restart the truck Code C92 Option Description Configuration error Extra I 0 0 Possible error cause Incorrect setting of options in the extra I 0 box 0 Check the outputs allocation on the I 0 expansion...

Page 61: ...l regulator or electronic card has been installed 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 Code E104 Description Switch transistor to brake is short circuited Possible error cause Error in the travel regulator output A1 3 Incorrect value on ...

Page 62: ...Internal monitoring error Action 1 Check the output for main contactor K10 A1 4 check cabling and contacts and measure ohms for the coil Value 25 30 ohm Check the output for the brake coil K10 A1 3 check ca bling and contacts and measure ohms for the coil Value 13 15 ohm 2 Check the output for horn A1 7 check ca bling and contacts 3 Check the drive motor s shunt winding and ca bling and contacts U...

Page 63: ...t close Possible error cause 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 Valu...

Page 64: ...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 regu lator s output A1 4 Code E110 Description System error Possible error cause Temporary error error in the travel regulator Action 1 Restart the machine 2 Replace travel regulato...

Page 65: ...ce the electronic card Code E150 Description Fault in the data communication Possible error cause Break on the CAN cable Action 1 Check the 119 and 120 cables and their contacts 2 Replace travel regulator Code E151 Description Tx error in data communication Possible error cause Travel regulator not responding Action 1 Check 119 and 120 cables and the connec tions on the travel regulator 2 Replace ...

Page 66: ... 2 Replace travel regulator 3 Replace the electronic card Code E160 Description Error in safety reversing function Possible error cause Error in important sensor part Action 1 Replace the electronic card Code E200 Description Open field Possible error cause Shunt field s circuit open Action 1 Check the field winding connections E1 and E2 Unfortunately it is not possible to measure ohms for the fie...

Page 67: ...nnections between A1 M on the travel regulator and connection A2 on drive motor 2 Replace travel regulator Code E202 Description Fault on sensor in travel regulator Possible error cause Fault on armature current sensor in travel regulator Action Replace travel regulator Code E214 Description CAN timeout in power amplifier Possible error cause The motor monitor is reporting an unexpected data loss ...

Page 68: ...ing will come into force the next time you start the machine NOTE 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 9 6 1 Operator parameters Parameter Description Unit Min Max Step Std Description 01 Speed Turtle button 40 100 5 100 Speed Turtle button 10 slow speed ...

Page 69: ...n can be adjusted Parameter 2 The maximum speed can be adjusted Parameter 3 The lower the parameter value the longer it takes for the truck to achieve maximum speed Parameter 4 Specifies the motor braking power when the lever L1 is put into neu tral The lower the parameter value the longer the braking time Parameter 5 The time it takes for the truck to switch off when the keypad is used The time c...

Page 70: ... new setting will come into force the next time you start the machine NOTE 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 10 PIN code 0 9999 1 1 Facility for specifying up to 10 PIN codes 10 different drivers ...

Page 71: ...ered 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 Parameter 14 Specifies the speed you will have when you reach the first speed sensor Parameter 15 Non configurable option See Option parameters on page 34 Servicemanual Para...

Page 72: ...ons These parame ters are normally configured by the manufacturer on modification or customisation of the truck It is recommended that the parameter set tings be loaded up from the truck when carrying out any modification If for example the main electronic card A2 must be replaced the origi nal parameter settings can then be simply transferred to the new card which ensures that all the special opt...

Page 73: ...ctly before the truck is put back in operation P Parameter 16 to 19 configurable optional functions Parameter no 16 17 18 19 can be adjusted to activate up to a maximum of 4 pre programmed functions and configure these to suit optional equipment or customisation of the truck See Table 2 List of configurable optional functions on page 37 These are thus called the configurable optional functions Eac...

Page 74: ...isplayed 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 Press the horn button S18 The parameter symbol flashes Enter the independent variable value 0 by repeatedly operating the speed control L1 in either direction See Table 2 Press the S18 horn butto...

Page 75: ...l 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 1 Independent vari able 2 Independent var iable 3 Independent varia ble 4 Independent variable 0 1 The option button controls the spider output 0 Spider 0 1 Spider 1 0 Digital output 1 1 Digital output 2 2 Digita...

Page 76: ... Lowering digital input 3 Blocking of lower ing input 4 2 Lift digital input 3 Lowering digital input 4 Blocking of lower ing input 5 3 Lift digital input 4 Lowering digital input 5 Blocking of lower ing input 6 4 Lift digital input 5 Lowering digital input 6 Blocking of lower ing input 7 5 Lift digital input 6 Lowering digital input 7 Blocking of lower ing input 8 0 Blocking of lower ing disconne...

Page 77: ...lowering 8 Fork lowering or driving forward 9 Fork lowering or driving backward 10 Fork lowering or driving forward or driving backward 11 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 15 All other movements AOM 16 Driving forward or AOM 17 Driving ba...

Page 78: ...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 drivi...

Page 79: ... if the value of parameter 21 is set at too high a value The standard setting of parameter 21 is set for normal truck handling Other applications may require a differ ent setting of parameter 21 Check that the parameter setting is the correct one using the instructions below Parameter 21 Battery size LWE180 LWE200 LPE200 6 Battery size LPE200 8 Less dis charge Greater dis charge 1 2 3 4 5 260Ah 32...

Page 80: ...Remove the battery from the truck and allow to rest for at least two hours NB No charging or discharging during this period Measure the acid weight of the battery at room temperature If the acid weight is less than 1 15 g cm3 the parameter value must be reduced If the value significantly exceeds 1 15 g cm3 the risk of damage to the battery is reduced At the same time the operating time of the truc...

Page 81: ...y will be reduced if the value of parameter 21 is set at too high a value The standard setting of parameter 21 is set for normal truck handling Other applications may require a differ ent setting of parameter 21 Check that the parameter setting is the correct one using the instructions below Parameter 21 Battery size LWE180 LWE200 LPE200 6 Battery size LPE200 8 Less discharge Greater dis charge 1 ...

Page 82: ...ceeds Uend the risk of damage to the battery is reduced At the same time the operating time of the truck is reduced 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 Parameter 22 You must specify the type of brake switch the truck is equipped with Mechanical switch 0 Inductive...

Page 83: ...7 Expanded keypad 100 PIN code TLS Driver parame ters accessible without CAN service key Value 8 Expanded keypad 100 PIN code TLS Driver parame ters NOT accessible without CAN service key Expanded keypad General The truck can contain a maximum of 10 individual driver profiles The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles This allow...

Page 84: ...ver profile has been set for a specific application goods han dling Table 5 shows the PIN codes available as standard in the program These can be activated for use or changed according to the driver s wishes One or more of these blocks can be activated A driver profile is activated on normal login by all PIN codes whose block no is activated The truck program does not approve login using the PIN c...

Page 85: ...ock 1 5421 7901 1437 3731 1049 9439 7265 1322 2869 1574 Block 2 1787 4854 2907 9175 5799 1490 3031 7392 5622 5023 Block 3 4659 3174 1026 3815 6703 1179 5152 7514 5668 3215 Block 4 9197 7110 5477 3846 9491 5918 8222 6923 8139 7025 Block 5 2549 6276 9879 9658 1690 4042 5201 9807 4332 9715 Block 6 7474 4142 8620 3754 8432 8788 7430 1948 2595 8527 Block 7 1930 1482 7135 2395 7365 7092 4611 2831 4185 6...

Page 86: ...e highest value is active marked with an arrow Power amplifier inputs T The figure with the second highest value is active marked with an arrow Power amplifier inputs Segment Function A B C S31 input A1 15 D S10 input A1 12 E F G S10 input A1 5 DP Segment Function A B C Y41 output A1 2 D Y1 output A1 3 E K10 output A1 4 F H1 output A1 7 G Y1 output A1 5 DP K30 output A1 6 A B C D E A D B C E F G D...

Page 87: ... the third highest value is active marked with an arrow Digital input from control sensors The figure with the fourth highest value is active marked with an arrow Segment Function A B C D Forks up E Forks down F Support arm up G Support arm down DP Horn Segment Function A Extra function 6 B Extra function 5 C Extra function 4 D Extra function 3 E Extra function 2 F Extra function 1 G DP A B C D E ...

Page 88: ...the following information SPn Part number for software HPn Part number for hardware HSn Serial number for hardware 9 8 Transistor panel 9 8 1 General Curtis 1243 is a regulator that controls shunt motors What primarily controls the speed is the variation in the voltage in the rotor The volt age is varied by means of pulse width modulation PWM This also includes variation in on time for the MOS tra...

Page 89: ...plifier The motor monitor is reporting an unexpected data loss from the tiller arm head 1 3 M SHORTED Internal M short circuited to B Problem with switch transistor in the rotor circuit inside the motor monitor 3 1 CONT COIL FLD SHORT Voltage too high for contactor feed or short circuited field winding Attempt to extract more current than the output device can manage Problem regulating the field c...

Page 90: ...powered vehicle all necessary safety measures must be taken This means among other things that the driver must have suitable training use goggles avoid loose clothing take off watches and jewel lery and only use insulated tools It may also be necessary to take other measures WARNING Risk of short circuiting Remove watches jewellery and always use insulated tools only Error Reset when OVERVOLTAGE T...

Page 91: ...inimum operating voltage Electrical insulation against cold chassis 500 V AC Minimum PWM frequency 16 kHz Maximum current in rotor winding 150 Ampere for 2 minutes 100 Ampere for 1 hour Maximum current in field winding 20 Ampere for 2 minutes 20 for 1 hour Contactor voltage 24 Volt The same as for the battery Contactor current 2 Ampere Max valid limit for 2 5 ampere KSI input voltage min 16 8 Volt...

Page 92: ...E200 LPE240 BT Europe AB 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 ...

Page 93: ...id from serial number T code 225553 040 2005 05 11 723984 660 661 662 497 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 10 1 10 Electrical systems 5000 LPE 240 10 1 Electrical parts S10 S53 S17 S21 Y1 M1 X41 A1 F1 K10 F3 K30 H1 S19 S59 P1 Y41 M3 X1 F50 F51 R1 M6 ...

Page 94: ... 2 Service Guide LWE180 LWE200 LPE200 LPE240 BT Europe AB 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 A7 ...

Page 95: ...A5 Electronic card A6 Display A7 Keypad PIN number login Option F 1 Fuse Drive motor circuit 175 A F 3 Fuse Pump motor circuit 130 A F 50 Fuse Operating circuit A5 7 5A F 51 Fuse Operating circuit A1 7 5 A F 52 Fuse Optional equipment Option F64 Fuse Steering motor 20 A Option G1 Battery 24 V H1 Horn K10 Contactor Main contactor K30 Contactor Pump motor M1 Motor Drive motor M3 Motor Pump motor M6 ...

Page 96: ... Option S5 Switch Option S6 Switch Option S10 Switch Travel brake Brake lever S17 Switch Key S18 Switch Horn button S19 Switch Man on platform S20 Switch Switch for safety reversing S21 Switch Emergency switch off S31 Switch Lift height limiter S34 Switch Fork lifting S41 Switch Fork lowering S53 Switch Gates S59 Switch Platform in upper position Y1 Brake Y41 Magnetic valve Fork lowering X1 Connec...

Page 97: ...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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 10 5 10 2 1 Electrical wiring diagram 1 5 ...

Page 98: ...E200 LPE200 LPE240 BT Europe AB 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 ...

Page 99: ...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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 10 7 10 2 3 Electrical wiring diagram 3 5 ...

Page 100: ...E200 LPE200 LPE240 BT Europe AB 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 ...

Page 101: ...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 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 10 9 10 2 5 Electrical wiring diagram 5 5 ...

Page 102: ... LPE200 LPE240 BT Europe AB 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 ...

Page 103: ... gates speed 6 km h S 19 closed S10 closed L1 activated in any direction 10 3 4 Driving from platform and using gates speed 8 km h S 19 closed S 53 closed S10 closed L1 activated in any direction 10 3 5 Neutral speed reduction L1 to neutral position motor starts to work as generator Brake ener gy comes back to battery Load sensor P1 determines speed reduction force Y1 will be applied when the truc...

Page 104: ...ome to a stop within a certain time the electrical brake will be applied 10 3 7 Braking The brake is always applied when the truck is started with the tiller arm in it s upper or lower position S10 open The brake is released in the same moment as the conditions for driving are fulfilled and the truck starts to move Conditions to brake the truck S10 open or S19 open 10 3 8 Lifting the forks S34 act...

Page 105: ...s an indication of what is shown in the display The 50 most recent error codes are stored The latest error is dis played 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 o...

Page 106: ...rameters have probably been changed When changing updating the program the param eters 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 Code C20 Description Speed control ca...

Page 107: ...le error cause The emergency switch has been activated No current to the travel regulator input A1 16 Action 1 Check fuse F51 2 Check the emergency switch 3 Check the cables from the battery and the bat tery contacts 4 If PTC resistor R1 is very hot remove the bat tery contact and allow the resistor to cool Restart Code C29 Description Service warning Possible error cause Time for service The serv...

Page 108: ...ssure sensor Check the voltage between cable 40 and 63 con nected to the pressure sensor The output voltage should be 0 5 Volt unloaded machine 5 Volt max load Code C41 Description Warning of low battery voltage Possible error cause Battery voltage 17 volt 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 batter...

Page 109: ...ion 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 Code C43 Description The travel regulator shuts off due to excess or subnormal temperature Possible error cause Too intensive operation or ambient temperature too cold Error in the travel regulator Temperature levels below 25o...

Page 110: ...ections A2 Restart the truck Code C92 Option Description Configuration error Extra I 0 0 Possible error cause Incorrect setting of options in the extra I 0 box 0 Check the outputs allocation on the I 0 expansion box 0 Code C93 Option Description Configuration error Extra I 0 1 Possible error cause Incorrect setting of options in the extra I 0 box 1 Check the outputs allocation on the I 0 expansion...

Page 111: ... Description Digital outputs short circuited or exceeding field current limit Possible error cause Problem regulating the field current Internal monitoring error Action 1 Check the output for main contactor K10 A1 4 check cabling and contacts and measure ohms for the coil Value 25 30 ohm Check the output for the brake coil K10 A1 3 check cabling and contacts and measure ohms for the coil Value 13 ...

Page 112: ...se Possible error cause 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 ...

Page 113: ...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 regu lator s output A1 4 Code E110 Description System error Possible error cause Temporary error error in the travel regulator Action 1 Restart the machine 2 Replace travel regulator Cod...

Page 114: ...e electronic card Code E150 Description Fault in the data communication Possible error cause Break on the CAN cable Action 1 Check the 119 and 120 cables and their contacts 2 Replace travel regulator Code E151 Description Tx error in data communication Possible error cause Travel regulator not responding Action 1 Check 119 and 120 cables and the connec tions on the travel regulator 2 Replace trave...

Page 115: ...place travel regulator 3 Replace the electronic card Code E160 Description Error in safety reversing function Possible error cause Error in important sensor part Action 1 Replace the electronic card Code E200 Description Open field Possible error cause Shunt field s circuit open Action 1 Check the field winding connections E1 and E2 Unfortunately it is not possible to measure ohms for the field wi...

Page 116: ...ions between A1 M on the travel regulator and connection A2 on drive motor 2 Replace travel regulator Code E202 Description Fault on sensor in travel regulator Possible error cause Fault on armature current sensor in travel regula tor Action Replace travel regulator Code E214 Description CAN timeout in power amplifier Possible error cause The motor monitor is reporting an unexpected data loss from...

Page 117: ... and the next time you start the truck the new parameter setting will be valid NOTE Truck handling Modifying specific truck parameters will change the driving charac teristics of the truck Do not change any parameters without the necesarry know how 10 6 1 Driver parameters Parameter Name Unit Min Max Step Std Description 1 Speed low Speed 10 100 5 100 10 low Speed 100 highest Speed 02 Speed high s...

Page 118: ...are not used Parameter 2 Possibility to adjust the speed in the high speed range when the safety gates are used Parameter 3 The lower value of the parameter the longer time it takes to accelerate the truck to top speed Parameter 4 Defines motor brake force when lever L1 goes to neutral position The lower value of parameter the longer time to reduce speed Parameter 5 The time until the truck will b...

Page 119: ...parameter change and the next time you start the truck the new parameter setting will be valid NOTE Truck handling Modifying specific truck parameters will change the driving charac teristics of the truck Do not change any parameters without the necesarry know how Parameter Description Unit Min Max Step Std Description 10 PIN code 0 9999 1 1 Facility for specifying up to 10 PIN codes 10 different ...

Page 120: ...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 Parameter 14 Specifies the speed you will have when you reach the first speed sensor Parameter 15 Non configurable option See Option parameters on page 29 Service...

Page 121: ...ave access to particular service informa tion Incorrect adjustment of option parameters may result in incor rect function General Parameters 15 to 19 have been reserved in the truck control system for extra options and or specific product modifications These parame ters are normally configured by the manufacturer on modification or customisation of the truck It is recommended that the parameter se...

Page 122: ...is displayed The next set up of sub parameters is displayed if you continue to acti vate the speed control 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 The parameter symbol flashes Enter the sub parameter value by repeatedly operating the speed control L1 in either direction See Table 6 for more...

Page 123: ... maximum of 4 pre programmed functions and configure these to suit optional equipment or customisation of the truck See Table 7 List of configurable optional functions on page 33 These are thus called the configurable optional functions Each parameter can be programmed to cover a specific optional function Each optional function can have up to 4 independent variables asso ciated with it Each indep...

Page 124: ...yed 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 Press the horn button S18 The parameter symbol flashes Enter the independent variable value 0 by repeatedly operating the speed control L1 in either direction See Table 7 Press the S18 horn button onc...

Page 125: ...unction is now activated Check that the optional function works correctly before the truck is put back in operation Table 7 List of configurable optional functions Independent variable 1 Independent variable 2 Independent variable 3 Independent variable 4 Independent variable 0 1 The option button controls the spider output 0 Spider 0 1 Spider 1 0 Digital output 1 1 Digital output 2 2 Digital outp...

Page 126: ...owering digital input 3 Blocking of lowering input 4 2 Lift digital input 3 Lowering digital input 4 Blocking of lowering input 5 3 Lift digital input 4 Lowering digital input 5 Blocking of lowering input 6 4 Lift digital input 5 Lowering digital input 6 Blocking of lowering input 7 5 Lift digital input 6 Lowering digital input 7 Blocking of lowering input 8 0 Blocking of lower ing disconnected 1 ...

Page 127: ...ing 8 Fork lowering or driving forward 9 Fork lowering or driving backward 10 Fork lowering or driving forward or driving backward 11 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 15 All other movements AOM 16 Driving forward or AOM 17 Driving backwar...

Page 128: ...ken 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 ba...

Page 129: ...the battery will be reduced if the value of parameter 21 is set at too high a value The standard setting of parameter 21 is set for normal truck handling Other applications may require a differ ent setting of parameter 21 Check that the parameter setting is the correct one using the instructions below Parameter 21 Battery size LPE240 Less dis charge Greater dis charge 1 2 3 4 5 6 7 8 570Ah 640Ah S...

Page 130: ...e the battery from the truck and allow to rest for at least two hours NB No charging or discharging during this period Measure the acid weight of the battery at room temperature If the acid weight is less than 1 15 g cm3 the parameter value must be reduced If the value significantly exceeds 1 15 g cm3 the risk of damage to the battery is reduced At the same time the operating time of the truck is ...

Page 131: ...e life of the battery will be reduced if the value of parameter 21 is set at too high a value The standard setting of parameter 21 is set for normal truck handling Other applications may require a differ ent setting of parameter 21 Check that the parameter setting is the correct one using the instructions below Parameter 21 Battery size LPE200 8 Less discharge Greater discharge 1 2 3 4 5 570Ah 640...

Page 132: ... Uend the risk of damage to the battery is reduced At the same time the operating time of the truck is reduced 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 Parameter 22 You must specify the type of brake switch the truck is equipped with Mechanical switch 0 Inductive sens...

Page 133: ...nded keypad 100 PIN code TLS Driver parame ters accessible without CAN service key Value 8 Expanded keypad 100 PIN code TLS Driver parame ters NOT accessible without CAN service key Expanded keypad General The truck can contain a maximum of 10 individual driver profiles The expanded keypad function thus allows you to assign a maximum of 10 PIN codes for each of the driver profiles This allows you ...

Page 134: ...ofile has been set for a specific application goods han dling Table 10 shows the PIN codes available as standard in the program These can be activated for use or changed according to the driver s wishes One or more of these blocks can be activated A driver profile is activated on normal login by all PIN codes whose block no is activated The truck program does not approve login using the PIN code 0...

Page 135: ...1 5421 7901 1437 3731 1049 9439 7265 1322 2869 1574 Block 2 1787 4854 2907 9175 5799 1490 3031 7392 5622 5023 Block 3 4659 3174 1026 3815 6703 1179 5152 7514 5668 3215 Block 4 9197 7110 5477 3846 9491 5918 8222 6923 8139 7025 Block 5 2549 6276 9879 9658 1690 4042 5201 9807 4332 9715 Block 6 7474 4142 8620 3754 8432 8788 7430 1948 2595 8527 Block 7 1930 1482 7135 2395 7365 7092 4611 2831 4185 6067 ...

Page 136: ...hest value is active marked with an arrow Power amplifier inputs T The figure with the second highest value is active marked with an arrow Power amplifier inputs Segment Function A B C S31 input A1 15 D S10 input A1 12 E F G S10 input A1 5 DP Segment Function A B C Y41 output A1 2 D Y1 output A1 3 E K10 output A1 4 F H1 output A1 7 G Y1 output A1 5 DP K30 output A1 6 A B C D E A D B C E F G DP A B...

Page 137: ...third highest value is active marked with an arrow Digital input from control sensors The figure with the fourth highest value is active marked with an arrow Segment Function A B C D Forks up E Forks down F Support arm up G Support arm down DP Horn Segment Function A Extra function 6 B Extra function 5 C Extra function 4 D Extra function 3 E Extra function 2 F Extra function 1 G DP A B C D E A D B...

Page 138: ...ing information SPn Software part number HPn Hardware part number HSn Hardware serial number 10 8 Transistor panel 10 8 1 General Curtis 1243 is a regulator for controlling shunt motors Varying the volt age applied through the armature primarily controls the speed The voltage is varied through use of pulse width modulation PWM This involves varying the on time of the MOS FET transistors regulating...

Page 139: ...2 HW FAILSAFE Power amplifier CAN timeout Motor controller reports unexpected loss of data flow from tiller head 1 3 M SHORTED Internal M short to B Problem with switch transistor in arma ture circuit inside motor controller 3 1 CONT COIL FLD SHORT Too high current for contactor feeding or shorted field winding Attempt to drive more current than specified from outputs Problem to regulate field cur...

Page 140: ...king on a battery operated vehicle necessary precautions should be taken This includes but is not limited to correct training use of eye protectors avoiding use of lose fitting clothes removal of watches and jewellery and use of insulated tools only WARNING Risk of short circuiting Remove all watches jewellery and always use insulated tools only Error Reset when OVERVOLTAGE Battery voltage falls b...

Page 141: ...oltage limit 16 Volts Minimum operating voltage Electrical insulation towards cold body 500 V AC Minimum PWM frequency 16 kHz Max current of armature winding 300 Amps for 2 minutes 100 Amps for 1 hour Max current of field winding 35 Amps for 2 minutes 20 for 1 hour Contactor voltage 24 Volts Same as battery voltage Contactor current 2 Amps Max current limit at 2 5 amps KSI input voltage Min 16 8 V...

Page 142: ...200 LPE200 LPE240 BT Europe AB 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 ...

Page 143: ...lems 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 11 2 Hydraulic chart and list of symbols LWE180 LWE200 n 11 2 1 List of Symbols Pos No Description Function Remarks 1 Lift cylinder Lifting the forks 2 Preasure relief valve 3 Flow control valve 4 Non return valve 5 Filter M3 Motor Pump motor P Pum...

Page 144: ...tween 1850 1900 kg 1 Locking nut Use special tool see drawing in chapter Tools 2 Adjuster screw pressure limit Adjusting clockwise results in increased pressure Adjusting anticlockwise results in decreased pressure 3 Pressure limit valve Use special tool see drawing in chapter Tools Loosen the locking nut 1 using a special tool see drawing 3 2 Place a load of 1800 kg on the forks and check that th...

Page 145: ...rope AB Service Guide LWE180 LWE200 LPE200 LPE240 11 3 11 3 2 Tools Use a 22 mm standard socket and turn it down to the values shown below in drawing A when you wish to loosen or tighten the pressure limit valve 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 26 5 12 A 13 5 8 B ...

Page 146: ...unit is replaced The truck should be capable of lifting a load of between 2050 2100 kg 1 Locking nut 2 Adjuster screw pressure limit Adjusting clockwise results in increased pressure Adjusting anticlockwise results in decreased pressure Loosen the locking nut 1 using a 13 mm spanner Place a load of 2000 kg on the forks and check that the truck can lift it If the truck lifts 2000 kg place a further...

Page 147: ...200 LPE240 11 5 11 5 Hydraulic chart and list of symbols LPE200 6 LPE200 8 n 11 5 1 List of Symbols Pos No Description Function Remarks 1 Lift cylinders Lifting the forks 2 pieces 2 Powertrakcylinder Increase the pulling quality when loaded 3 Preasure relief valve 4 Flow control valve 5 Non return valve 6 Filter M3 Motor Pump motor P Pump T Tank 1 2 litre Y41 Valve Lowering valve for the forks Y41...

Page 148: ...is replaced The truck should be capable of lifting a load of between 2050 2100 kg 1 Locking nut 2 Adjuster screw pressure limit Adjusting clockwise results in increased pressure Adjusting anticlockwise results in decreased pressure Loosen the locking nut 1 using a 13 mm spanner Place a load of 2000 kg on the forks and check that the truck can lift it If the truck lifts 2000 kg place a further 100 ...

Page 149: ... BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 12 1 12 Hydraulic pneumatic 6000 LPE 240 12 1 General 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 1 2 3 Y41 4 5 5 P M3 7 6 T ...

Page 150: ...nction Notes 1 Lift cylin ders Fork lift 2 PowerTrak cylinder Increases the pulling capacity with a loaded machine 3 Pressure sensor Input signal to transistor panel that a flow limit change is to be made 4 Flow valve 5 Filter One filter on the pump s suc tion side and one on the return 6 Pressure relief valve 7 Non return valve M3 Motor Pump motor P Pump 2 5 ccpr T Tank 1 2 litre Y41 Valve Loweri...

Page 151: ... should be able to lift a load of between 2250 2300 kg Unscrew the cover nut 1 with a spanner 13 mm Place a load 2200 kg on the forks and check that the machine lifts this If the machine can lift 2200 kg place a further 100 kg on the forks Check whether machine can lift the load If the machine can lift 2300 kg adjust the pressure limit valve by screwing the adjuster screw 2 anticlockwise using a 4...

Page 152: ...0 661 662 497 723984 2005 05 11 225553 040 12 3 Cleaning the filter Dismantle the hydraulic unit from the machine Empty the oil from the tank Loosen and remove the hose clip 1 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 2 1 3 4 5 ...

Page 153: ...00 LPE 240 Cleaning the filter Order number Date Valid from serial number T code 225553 040 2005 05 11 723984 660 661 662 497 BT Europe AB Service Guide LWE180 LWE200 LPE200 LPE240 12 5 This page is intentionally left blank ...

Page 154: ... BT Europe AB SE 595 81 Mjölby Sweden www bt industries com ...

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