BT LWE130 Page 27 Service Manual Download

Page: 27 / 92

Tools - P4

Molex connectors

Order number

Date

Valid from serial number

T-code

226057-040

2005-09-23

914369-

675

Service Manual

LWE130

5- 3

5.2.1 AMP Connectors, 040 series

5.3 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

https://www.besttruckmanuals.com/

Summary of Contents for LWE130

Page 1: ... BT Europe AB Service Manual en LWE130 Valid from serial number 914369 Order number 226057 040 Issued 2005 09 23 ITS https www besttruckmanuals com ...

Page 2: ...ce Manual LWE130 Approved by L G Andersson This manual covers following truck models Issue date Resp Changes 2005 09 23 ITS Completely new issue T code Model Serial number 675 LWE130 914369 https www besttruckmanuals com ...

Page 3: ...aning 3 2 2 2 Cleaning the motor compartment 3 2 2 3 Electrical components 3 Safe lifting 4 Lifting points 5 2 4 1 Using a lifting device 5 2 4 2 Lifting points using another fork lift truck 5 Maintenance Lubrication schedule P2 3 1 Maintenance schedule 1 Lubrication schedule 5 Oil and grease specification P3 4 1 Tools P4 5 1 Super Seal connectors 1 AMP connectors 2 5 2 1 AMP Connectors 040 series...

Page 4: ...00 12 1 General 1 12 1 1 Firmware truck control software 1 Nomenclature 1 Electrical equipment overview 2 12 3 1 Electric component overview 4 Accessing main electrical panel 6 Electrical circuit overview 7 Symbol list 8 Electrical wiring diagram 9 Functional description 14 12 8 1 Theory of operation 14 12 8 2 Transistor regulator 18 General 18 Safety 18 12 8 3 On board battery charger 20 General ...

Page 5: ...Parameters adjustments 37 12 10 1 General 37 12 10 2 Adjusting parameters 37 12 10 3 List of parameters 38 12 10 4 Description of parameters 39 Acceleration ramp time ACC DELAY 39 Deceleration ramp time DECELER DELAY 39 Neutral braking intensity RELEASE BRAKING 39 Reverse braking intensity INVERSION BRAKING 39 Maximum travel speed CUTBACK SPEED 3 39 Reset service counter CHECK UP DONE 39 Select se...

Page 6: ...ure 2 Pressure limit valve 2 Adjustments 3 Adjustment of the pressure limit valve 3 Tools 4 Destruction instructions 14 1 General 1 Procedure 1 Abbreviations 2 Sorting 2 Chassis 0300 3 Hoods hatches 0340 3 Electric Pump Motor 1710 3 Drive assembly drive motor 1760 2550 4 Wheels 3500 5 Tiller arm 4110 5 General electrical equipment 5100 6 Hydraulic unit 6100 7 Hydraulic cables cylinders 6230 6610 7...

Page 7: ...Minimum commutator diameter 40 mm Resistance shunt field winding at 25 C 1 3 Ω Resistance armature winding at 24 C 0 0156 Ω Insulation resistance between the windings and motor casing 1 Mohm Weight 25 kg Brake Type 891 270 0 Braking force 9 Nm Output 28 W Resistance coil 20 8 Ω Minimum thickness brake disc 6 75 mm Thickness of a new brake disc 6 90 mm Transmission drive gear Type 2 stage drive gea...

Page 8: ...g Support castors Ø100x40 mm Axle pressure without load 2x30 kg Axle pressure at rated load 2x24 kg Hydraulic system Output 1 2 kW Duty cycle 10 Minimum carbon brush length 7 5 Minimum commutator thickness diameter 4 75 mm Pressure at rated load 110 bar Overflow pressure 130 bar Pump flow 4 7 litre minute Tank volume 1 0 litre Oil type Hydraulic oil Normal temperature ISO L HM32 Fuses Drive motor ...

Page 9: ...th rated load 4 0 km h 1 1 m s Lift lowering speed Lift without load 1 7 s Lift with rated load 3 0 s Lowering without load 3 0 s Lowering with rated load 3 0 s Power consumption Driving without load 13 A Driving with rated load Lift without load Lift with rated load Incline climbing ability With rated load 5 Without load 10 Measurement L2 420 mm Turning radius WA 1410 mm Lift height 205 mm Weight...

Page 10: ...ical data M4 Tightening torque T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 1 1 Tightening torque Description Amount Tightening torque Procedure Screws 8 20 Nm Wheel bolts 20 Nm https www besttruckmanuals com ...

Page 11: ...y 500 driving hours The truck s safety efficiency and service life is depend ent on the service and maintenance it is given Only use BT approved spare parts when service and repair work are carried out 2 1 Safety regulations with maintenance work Only personnel that have been trained in the service and repair of this type of truck are authorised to carry out service and repair work Do not carry ou...

Page 12: ...amaged Always use new and clean oil in the hydraulic system Store and dispose of changed oil in accordance with local directives Do not release solvents and the like which are used for cleaning washing into drains that are not intended for this purpose Follow the local directives that apply for disposal Disconnect the battery when welding on the truck NOTE The battery can be damaged When welding u...

Page 13: ...al components can be damaged After washing the truck should be lubricated as set out in the chapter Maintenance and lubrication chart 2 2 2 Cleaning the motor compartment Cover the electric motors connections and valves before washing NOTE Risk of short circuiting The electrical system can be damaged Electrical components must not be cleaned with a high pressure washing unit Clean the motor compar...

Page 14: ...these can be used to obtain a well balanced lift Ensure that the surface under the jack is clean and free from oil and grease Ensure that your hands and the jack s lever are free from oil and grease Use the lever that belongs to the jack A lever that is too short re quires more force than is necessary If the lever is too long there is a risk of the jack being overloaded Support the truck as close ...

Page 15: ...ce WARNING Risk of overturning The truck can overturn if it is lifted from the wrong lifting points Always lift the truck from the marked lifting points 2 4 2 Lifting points using another fork lift truck WARNING Risk of overturning The truck can overturn if it is lifted incorrectly Always lift the truck secured to and with the centre of gravity between the lifting truck s forks https www besttruck...

Page 16: ...al LWE130 BT Europe AB Introduction Maintenance P1 Lifting points T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 This page is intentionally left blank https www besttruckmanuals com ...

Page 17: ...d damage I 0000 4 Check signs and stickers I 0000 5 Visual inspection of the bolt joint between the chassis and the support arms I 0380 Fork carriage 0380 1 Check for crack formation and damage I 0380 2 Check clearance in bushes and links I 0380 3 Press grease into grease nipples I L 0380 4 Check the lift limit switch I 1700 Drive motor 1700 1 Check clearance in connections I T 1700 2 Check the ca...

Page 18: ...ck the touching protection I 5000 Electrical functions 5000 1 Check the function of the brake microswitch I I 5000 2 Check the function of the collision safety switch I 5000 3 Check the function of the horn I I 5000 4 Check for wear on cabling I 5000 5 Check the function of the driver s control I I 5000 6 Check the emergency switch off I I 5000 7 Check the charging plug and start block I I 5000 8 ...

Page 19: ...ut unless otherwise speci fied above 5400 Power system 5400 1 Cleaning and checking of mounting in chassis C T 5400 2 Re tighten cable connections T 5400 3 Check the cable insulation I 5700 Electronic circuit board 5700 1 Check connectors and cables T 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 oil tank for cracks le...

Page 20: ...AB Maintenance Lubrication schedule P2 Maintenance schedule T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 2550 0380 6600 3500 0000 5400 5700 3100 1700 5000 4110 5000 5000 https www besttruckmanuals com ...

Page 21: ... 2 Lubrication schedule L LubricationC CheckO Oil changeF Grease 4 The grease is changed every 36 months 5 The oil is changed and the filter cleaned for the first time after 12 months and then every 24 months Pos no Service point Interval Running hours Lubricant 12 m 36 m 0380 Lubricating nipples L D 2550 Drive gear C G4 C 6100 Hydraulic system O5 B https www besttruckmanuals com ...

Page 22: ... Manual LWE130 BT Europe AB Maintenance Lubrication schedule P2 Lubrication schedule T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 6100 2550 0380 https www besttruckmanuals com ...

Page 23: ...VG32 Hydraulic system C Grease ESSO UNIREX N2 ESSO UNIREX N2 Gears D Grease 223690 Q8 Rembrandt EP2 223690 Q8 Rembrandt EP2 Grease nipples Ambient temperature Viscosity class Recommended products Similar products from another manufacturer may be used 40 C 30 C VG 15 Klüberoil 4UH 1 15 Klüber Lubrication 30 C 5 C VG 68 Klüberoil 4UH 1 68N Klüber Lubrication Anticorit LBO 160 TT Fuchs DEA 5 C 45 C V...

Page 24: ...4 2 Service Manual LWE130 BT Europe AB Oil and grease specification P3 T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 6100 2550 0380 https www besttruckmanuals com ...

Page 25: ...Manual LWE130 5 1 5 Tools P4 5 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 https www besttruckmanuals com ...

Page 26: ...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 1 2 https www besttruckmanuals com ...

Page 27: ...T Europe AB Service Manual LWE130 5 3 5 2 1 AMP Connectors 040 series 5 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 https www besttruckmanuals com ...

Page 28: ...se gun with straight discharge pipe and nozzle fif 755142 Two hand grease gun with angled discharge pipe and nozzle 755152 Two hand grease gun with hose and nozzle 755146 Grease hose 450 mm Grease hose 750 mm Grease hose 1500 mm 202154PM Pointed nozzle for grease guns used to apply grease in recessed nipples Fits grease guns with hose and discharge pipe Length 125 mm 755140 Nozzle for neck nipples...

Page 29: ...code 226057 040 2005 09 23 914369 675 BT Europe AB Service Manual LWE130 5 5 5 5 Other tools Figure Number Application 156263 Service instrument CAN 1 163793 2 163792 Service instrument for pro gramme changes 08 13022 Driving gear puller https www besttruckmanuals com ...

Page 30: ...5191 2 3 V10 15191 3 4 V10 15191 4 Oil cleaning 1 Filter for cleaning 2 Filter for removing water 3 Pipe 4 Pipe 207881 Hand terminal for communication with the transistor regulator Needed for the following uses Changing parameters Uploading and downloading parameter settings Display of error messages Calibration Figure Number Application 1 2 3 4 https www besttruckmanuals com ...

Page 31: ...aring 25 Driver 6 Key 26 Screw 7 Axle 27 Connector 8 Venting nipple 28 Guide pin 9 Gear housing 29 Locking ring 10 Screw 8 pcs 30 Stropping 11 Sealing ring 31 Brake complete 12 Gear ring 32 Gear wheel 13 O ring 33 Locking ring 14 Ball bearing 34 Gear wheel 15 Locking ring 35 Sealing ring 16 Drive track 36 Locking ring 17 Screw 8 pcs 20 Nm 37 Washer 18 Locking ring 38 Ball bearing 19 Magnetic coil ...

Page 32: ...ide Loosen the four bolts on the motor s chassis mounting Carefully lift out the motor and place on a clean surface Essential service and repair work can now be carried out on the motor Assembly takes place in the reverse order 6 2 2 Inspection replacement of the carbon brushes Shut down the truck pull out the plug from the start block Remove the hoods from the battery compartment Loosen the batte...

Page 33: ... cleaner with an appropriate nozzle can be used to clean the motor if the motor windings and inner compartment are dry Com pressed air can be used in combination with a vacuum cleaner In which case the compressed air must be clean and dry A cloth of non fluffing material should be used if the windings have a coating The cloth can also be moistened with a grease dissolving organic and volatile dete...

Page 34: ...reventive maintenance it is recommended that the brake discs are regularly inspected with regard to wear 6 2 6 Replacing the brake disc The brake disc should be replaced when its overall thickness has decreased to 5 5 mm Disconnect the electrical cables routed to the brake Loosen and remove the two securing bolts Loosen the brake disc from the hub and check the wear Replace the brake disc if the s...

Page 35: ... number T code 226057 040 2005 09 23 914369 675 BT Europe AB Service Manual LWE130 7 1 7 Steering system 4000 7 1 Components Table 3 Components steering system Pos Name Pos Name 1 Switch 4 Restorer 2 Gas damper 5 Cover 3 Spring 1 2 3 4 5 https www besttruckmanuals com ...

Page 36: ...e Manual LWE130 BT Europe AB Steering system 4000 Components T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 This page is intentionally left blank https www besttruckmanuals com ...

Page 37: ... unit s electric motor is achieved using a contactor A set of parameters used to adjust the truck s performance and brak ing characteristics is stored in the transistor regulator The regulator also monitors error conditions that may occur 12 1 1 Firmware truck control software The current firmware version in the transistor regulator is V1 10 The firmware stored in the transistor regulator cannot b...

Page 38: ...B Electrical system 5000 Electrical equipment overview T code Valid from serial number Date Order number 675 914369 2005 09 23 226057 040 12 3 Electrical equipment overview S20 S18 S15 S16 S34 S41 R1 L1 Fig 1 https www besttruckmanuals com ...

Page 39: ...rview Order number Date Valid from serial number T code 226057 040 2005 09 23 914369 675 BT Europe AB Service Manual LWE130 12 3 A30 F51 F50 S170 H81 S17 S21 H1 S171 F1 A1 K30 K10 G2 G1 Y41 M3 S10 M1 Y1 PTC CONS Fig 2 https www besttruckmanuals com ...

Page 40: ...ock Auxiliary contactor switch Fig 5 Fig 2 2 PTC Temporary supply PTC resistor Fig 5 Fig 2 Equipment protection F 1 Traction pump motor protection Fuse 100 A Fig 5 Fig 2 F 50 Operating circuit protection A1 Fuse 5 A Fig 5 Fig 2 F 51 Battery charger protection A30 Fuse 10 A Fig 5 Fig 2 Control and Signal processing A1 Traction braking power control Transistor regulator Fig 5 Fig 6 Fig 2 S17 Key swi...

Page 41: ...vel direction selector butterfly Lever Fig 1 1 S15 Travel in forks direction Switch Fig 6 Fig 1 S16 Travel in drive wheel direction Switch Fig 6 Fig 1 R1 Speed control Potentiometer Fig 6 Fig 1 M1 Traction Motor Fig 5 Fig 2 Lifting lowering forks S34 Fork lifting control Switch Fig 6 Fig 1 S41 Fork lowering control Switch Fig 6 Fig 1 Y41 Fork lowering hydraulic control Magnetic valve Fig 5 Fig 2 K...

Page 42: ...l panel ensure the key switch S17 is off and the charger s mains plug is neither plugged into the start inter lock S170 or any mains outlet socket For maximum safety it is ad visable to also remove the negative connection from battery G2 Remove the screws securing the main cover Fig 3 A and lift the cover free of the truck Remove the two securing screws holding the main electrical panel in place F...

Page 43: ...S E1 E2 A2 A1 M A2 A1 INP DRIVE WHEEL DIR INP FORK WHEEL DIR INP BELLY BUTTON INP TILLER SWITCH INP SPEED CONTROL R1 S16 S15 S20 BATT OUT BRAKE OUT FIELD 1 OUT FIELD 2 ARMATURE BATT Y1 M1 S171 K10 OUT NEG K30 Y41 S34 K30 M3 Y41 S41 K10 H81 OUT BATT IND INP KEY SWITCH INP LOWER OUT NEG MAIN CONTACTOR INP SUPPLY MAIN CONTACTOR S10 S17 S18 H1 S21 S170 F50 F1 F51 G2 G1 PTC K10 A1 A30 A C IN INP LIFT S...

Page 44: ... stop switch NC Resistor PTC 1 1 PTC Positive Temperature Coefficient resistance increases as temperature increases Switch key operated NO DC motor2 SEM type 3 2 DC Direct Current 3 SEM Separately Excited Motor Microswitch NO DC motor Microswitch push button NO Contactor Variable resistor potentiometer Brake coil normally applied Coil for hydraulic magnetic valve Multi pin connector NO Normally Op...

Page 45: ... 40 Sh 2 9 Sh 3 1 G2 G1 R2 1 2 LOWER VALVE F1 100A 2 PUMP MOTOR 1 2 8 A2 M3 A1 M FIELD WINDING F2 INP LIFT A10 OUT NEG PUMP CONTACTOR LOWER VALVE A2 IN SUPPLY MAIN CONTACTOR A15 OUT NEGATIVE MAIN CONTACTOR A14 INP TILLER SWITCH A4 OUT NEGATIVE MAGNETIC BRAKE A11 33 Y1 1 2 X31 X31 42 43 23 31 41 INP POWER SUPPLY 24VDC BATT A1 INP POWER SUPPLY 0VDC BATT ELECTRONIC CARD FIELD WINDING F1 ARMATURE WIND...

Page 46: ... INP DRIVE FORK DIRECTION A7 INP TURTLE FUNCTION A8 INP LOWER A13 INP BELLY BUTTON A5 X30 S206 13 14 60 X30 X30 X30 35 S34 COM NO NC S31 COM NC LIFT LIMIT LWE130 S41 COM NO S20 COM NO NC 3K3 FORK LIFT 34 55 OUT GND SUPPLY DRIVE POT A9 OUT BATTERY INDICATOR A12 INP DRIVE STEERED WHEEL DIRECTION A6 INP WIPER DRIVE POT A1 OUT POS SUPPLY DRIVE POT A3 A1 INP 24VDC KEY SWITCH A16 ELECTRONIC CARD X30 X30...

Page 47: ...r T code 226057 040 2005 09 23 914369 675 BT Europe AB Service Manual LWE130 12 11 181444 PROD D 3 5 PLUG B Sh 2 PLUG A Sh 2 40 Sh 2 9 Sh 1 INP GROUND INP MAINS VAC INP MAINS VAC OUT NEGATIVE CHARGER VOLTAGE A30 OUT POSITIVE CHARGER VOLTAGE ONBOARD CHARGER 40 9 https www besttruckmanuals com ...

Page 48: ...E CHARGER VOLTAGE CHARGER BOOSTER ONBOARD LORRIES OUT NEGATIVE CHARGER VOLTAGE INP HOSTING VEHICLE POSITIVE INP HOSTING VEHICLE NEHATIVE OUT 24VDC LED INDICATOR BK RD INP TRUCK DISABLE RELAY CONTACT OUT GND LED INDICATOR 1 2 1 2 OUT TRUCK DISABLE RELAY CONTACT H80 23 A Sh 2 23 B Sh 2 F52 20A BK BK BK RD BU RD 181444 PROD D 4 5 OPTION POWER INP CONNECTOR Fig 8 Sheet 4 of 5 https www besttruckmanual...

Page 49: ...3 F E D 2 3 4 C B A 1 2 3 4 6 7 8 F E D 6 5 7 C B 8 A 1 181444 PROD E 5 5 Option Battery Indicator OPTION A1 PCLRXD B1 ELECTRONIC CARD GND B5 12VDC SUPPLY VOLTAGE B6 NCLTXD B4 PCLTXD B3 NCLRXD B2 A6 DISPLAY MDI PCLRXD 1 2 GND 3 12VDC SUPPLY VOLTAGE 4 NCLTXD 5 PCLTXD 6 NCLRXD 101 102 103 104 105 106 101 102 103 104 105 106 Fig 9 Sheet 5 of 5 https www besttruckmanuals com ...

Page 50: ...equired action from the operator for the event to occur Influencing elements conditions which must be fulfilled in order for the event to occur Certain parameter settings may also affect the outcome of the event Resulting conditions Describes key occurrences which can be checked to confirm that a function operates correctly Logic Shows the logic relationship between inputs and outputs re lating to...

Page 51: ...ower tiller handle Influencing elements Tiller switch S10 Main contactor K10 Secondary interlock S171 Resulting conditions Tiller switch S10 activated Input A1 INP TILLER SWITCH is high Output A1 OUT NEG MAIN CONTACTOR goes low Main contactor closes K10 auxiliary switch S171 closes Event 4 Traction forks first Preceding event 3 Action s Move butterfly L1 in forks drive direction Influencing elemen...

Page 52: ...ent 4 or 5 Action s Let butterfly L1 return to neutral position while truck is in motion Influencing elements Parameter settings RELEASE BRAKING Resulting conditions Traction motor M1 acts as generator and via transistor regulator A1 con verts the truck s energy of motion into electrical energy thus reducing the truck s speed The braking intensity is dependant on a parameter setting The mechanical...

Page 53: ...lied Event 9 Fork lifting Preceding event 2 Action s Depress the fork lift button S34 Influencing elements Fuse F1 Main contactor K10 Forks lift button S34 Secondary interlock S171 Battery charge status Lift limit S31 Resulting conditions A1 INP LIFT goes high Pump contactor K30 activates Pump motor M3 starts Event 10 Fork lowering Preceding event 9 Action s Depress the fork lowering button S41 In...

Page 54: ...ED Fig 10 AL displays eventual error conditions which may be present Fig 10 B shows the connector for the hand terminal NOTE In order to see the alarm status LED or gain access to the connector for the hand terminal it is necessary to fold out the main electrical panel See section 12 4 Accessing main electrical panel Safety The regulator is a high power component When working on a battery operated...

Page 55: ...6 active high B A7 REV Input from travel in forks direction switch S15 active high B A8 H S Reserved for future use A9 NPOT Provides ve supply connection to potentiometer R1 A10 PLIFT Input from fork lift control switch S34 A11 NEB Output for electromagnetic brake coil Y1 1 5A continuous protected against short circuit A12 NLED Output to drive Battery status indication LED H81 100mA max A13 PEVD I...

Page 56: ...ery is fully charged maintenance charging starts yellow and green LED Fig 11 B C and 27 6 V This continues until the charger switches off If a fully charged battery is connected to the charger or if the charger does not find a connected battery the maintenance charge is started yellow and green LED 27 6 V The charger starts with the main charge yellow LED and 28 8 V after a power failure if a disc...

Page 57: ...d 1 red LED which indicate the battery charge status according to the following table NOTE The battery display is only updated when the drive motor is active That means if only the lift motor is used for some time and the truck is not moved the display may show a too large remaining charge Table 8 Battery charge status LED Status H81 Remaining battery charge Off 60 charge remaining Blinking 60 cha...

Page 58: ...hen driving The charger is equipped with an ignition lock that prevents the truck being driven during charging To prevent the batteries overheating and to optimise charging at different ambient temperatures the charger is also equipped with temperature compensation The option includes a connection cable that can be connected to the truck s rear lift Please note that it is particularly important fo...

Page 59: ... T code 226057 040 2005 09 23 914369 675 BT Europe AB Service Manual LWE130 12 23 Installation in truck Install the truck charger as per instruction drawing 219205 See pic tures below 23112 2x 218353 218856 29918 2x 218068 42322 4x 22006 4x 20235 4x 21307 8x https www besttruckmanuals com ...

Page 60: ...onnect it to the con tact housing for cabling from the truck charger Connect cable using 4 8 bushing from the truck charger to the igni tion lock Strap the cabling to the standard cabling Note 2 Remove rubber plug on electrical panel Install yellow indication lamp on electrical panel and connect the red cable from the truck charger to the brass coloured pin on the indica tion lamp Not 2 Not 1 http...

Page 61: ...lly once the truck s voltage reaches 25 5 V Troubleshooting Check that the charger is connected to mains voltage Check the fuse for the charger s battery cable Check that the charger is not overheating If the charger is still not working replace the charger Technical data Charging voltage 28 4 V Charging current 8 15 A Temperature compensation YES Ignition lock YES Charging starts 25 5 V Charging ...

Page 62: ...l be active 12 8 7 Hour meter The truck s control system stores the elapsed activity time drive motor in units of hours A time to next service counter can optionally be acti vated When this service counter time reaches the time to next serv ice value the transistor regulator emits an audible signal and the Bat tery charge status H81 LED flashes continuously To check the present activity time value...

Page 63: ...o from the transistor regula tor Display error and diagnostic information Perform calibration Connecting the hand terminal To connect the hand terminal Ensure the key switch is off S17 Fold out the main electrical panel See section 12 4 Accessing main electrical panel Connect the hand terminal s connector Fig 14 A to the transistor regulator s diagnostic connector Fig 10 B Turn on the key switch S...

Page 64: ... Confirmation of connection to a SEM X transistor regulator and firmware version A Transistor regulator s firmware version B Supply voltage C Transistor regulator s rated current D Present hour meter value Press ENTER Fig 15 C to display the first menu Cycle through the menus by repeatedly pressing the ROLL buttons Fig 15 B Press OUT Fig 15 D to leave the present menu Buttons PARAM SET Fig 15 E ar...

Page 65: ...5A 00000 MAIN MENU PARAMETER CHANGE MAIN MENU STEER TABLE MAIN MENU PROGRAM VACC MAIN MENU ALARMS MAIN MENU RESTOR PARAM MAIN MENU SAVE PARAM MAIN MENU TESTER ENTER ROLL ROLL ROLL ROLL ROLL ROLL ROLL OUT Normal hand terminal display Menu for changing or setting parameters This is menu is not applicable Menu for calibration of speed control potentiometer R1 Menu for displaying error history Menu fo...

Page 66: ...hing back on again Check to see if the error code is displayed again Use the hand terminal s TESTER function to test basic truck character istics 12 9 2 Display of error codes Direct display of error codes To check for an eventual error condition by directly inspecting the status LED carry out the following Fold out the main electrical panel See section 12 4 Accessing main electrical panel Under n...

Page 67: ...he log will display up to 5 most recent error types with the following information for each error A Error code description B Hour meter value when fault occurred C Number of occurrences of specific error D Transistor regulator temperature when fault occurred The error code history log can be optionally cleared when exiting the ALARM menu MAIN MENU PARAMETER CHANGE MAIN MENU STEER TABLE MAIN MENU P...

Page 68: ... KO Output for electromagnetic brake coil Y1 not functioning Replace transistor regulator 1 2 CONTACTOR DRIVER Main contactor K10 not responding when driven Check Main contactor coil and wiring DRIVER SHORTED The main contactor coil is either s c o c or not connected Main contactor o p s c to BATT Check Main contactor coil and wiring CONTACTOR CLOSED Main contactor tips K10 are fused Field circuit...

Page 69: ...re correct and no motor s c exists If above is ok replace transistor regulator FW HIGH FIELD CURR Field current abnormally high in drive wheel direction Trac tion motor s M1 field winding s c or o c Field winding incorrectly connected to the transistor regula tor Transistor regulator defect Check field connections M1 are correct and no motor s c exists If above is ok replace transistor regulator B...

Page 70: ...r on page 42 3 5 INCORRECT START Starting sequence incorrect for travel Emergency reverse switch S20 operated during start o c in main contactor coil circuit K10 Tiller switch S10 operated during start Check wiring to S10 S20 Adjust or replace these switches Check wiring to K10 coil check or replace K10 3 6 FORW BACK Conflicting travel direction order Check wiring to S15 S16 check operation of S15...

Page 71: ...nal See Connecting the hand terminal on page 27 Select TESTER from the menu and press ENTER Scroll through the various available test functions by pressing ROLL buttons MAIN MENU PARAMETER CHANGE MAIN MENU STEER TABLE MAIN MENU PROGRAM VACC MAIN MENU ALARMS MAIN MENU RESTOR PARAM MAIN MENU SAVE PARAM SEM X V 24v 75A 00000 MAIN MENU TESTER ENTER ENTER ROLL BATTERY VOLTAGE VMN MOTOR CURRENT FIELD CU...

Page 72: ...vel on digital input pin A4 for tiller switch S10 ON VB active input switch closed OFF GND inactive input switch open Tiller upright OFF Tiller in drive pos ON FORWARD SWITCH TRAVEL IN DRIVE WHEEL DIR SWITCH Level on digital input pin A6 for travel in drive wheel direction switch S16 ON VB active input switch closed OFF GND inactive input switch open L1 in neutral OFF L1 in drive wheel dir ON BACK...

Page 73: ... the menu and press ENTER Press ROLL buttons to display the required parameter Adjust the setting of the parameter with the PARAM SET buttons Press OUT followed by ENTER to store the new parameter setting or Press OUT followed by OUT to return to the main menu without changing the existing parameter setting NOTE Truck handling Modifying specific truck parameters will change the driving charac teri...

Page 74: ...erview of parameters Parameter name display Function Min Max Std Note ACC DELAY Determines accelera tion ramp time 0 9 6 A acceleration DECELER DELAY Determines decelera tion ramp when speed control is reduced 0 9 5 D deceleration RELEASE BRAK ING Determines neutral braking intensity 0 9 5 B braking intensity INVERSION BRAK ING Determines reverse braking intensity 0 9 9 B braking intensity CUTBACK...

Page 75: ...ition Reverse braking intensity INVERSION BRAKING Increasing the parameter value will result in harder braking Reverse braking is defined as the reduction of a truck s speed through motor braking by moving the speed control L1 in the opposite direction to the direction of travel Maximum travel speed CUTBACK SPEED 3 Determines the truck s maximum speed Increasing the parameter will result in an inc...

Page 76: ...tus H81 LED flashes continuously Time to next service CHECK UP HOURS Set this value to correspond with number of hours truck activity must increase by when the next service warning must be given Time to next service 200 p X 50 hours where p parameter value 12 10 5 Transferring parameter sets General The Hand terminal can be used to save a parameter set and configura tion from a truck This is usefu...

Page 77: ...emory slots will display FREE Memory slots which contain a parameter set will display SEM X V Press ENTER to save the truck s parameter set NOTE It is advisable to keep a record of trucks and stored parameter sets This will help to ensure that saved parameter sets are restored to the correct truck MAIN MENU PARAMETER CHANGE MAIN MENU STEER TABLE MAIN MENU PROGRAM VACC MAIN MENU ALARMS MAIN MENU RE...

Page 78: ... 31 Press ENTER The parameter set will be restored to the transistor regulator s memory 12 10 6 Calibrating the speed potentiometer General The transistor regulator A1 can be calibrated to allow the speed potentiometer R1 to give a smooth and symmetrical response over the whole operating range Perform a calibration in the following cir cumstances MAIN MENU PARAMETER CHANGE MAIN MENU STEER TABLE MA...

Page 79: ...See Connecting the hand terminal on page 27 Select PROGRAM VACC from the menu and press ENTER then ENTER Move tiller arm to drive position Slowly move the speed control L1 from neutral to full deflection first in one direction then the other direction Press OUT followed by ENTER The transistor regulator and potentiometer have now been calibrated MAIN MENU PARAMETER CHANGE MAIN MENU STEER TABLE SEM...

Page 80: ... 8 Volts Minimum operating voltage Electrical insulation towards cold body 500 V AC Minimum PWM frequency 16 kHz Max current of armature winding 75 Amps for 2 minutes 40 Amps for 1 hour Max current of field winding 12 Amps for 2 minutes 6 6 for 1 hour Contactor voltage 24 Volts Same as battery voltage Contactor current 3 Amps Max KSI input voltage Min 16 8 Volts Logic input voltage 9 4 High 9 2 Lo...

Page 81: ...Manual LWE130 13 1 13 Hydraulic system 6000 13 1 Hydraulic chart and 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 Pump T Tank 1 2 litre Y41 Valve Lowering valve for the forks Y41 A 4 3 5 P T 2 1 M3 https www besttruckmanuals com ...

Page 82: ...return valve and the closed electric lowering valve Y41 Lower By opening the electric lowering valve Y41 the load is lowered and the maximum lowering speed of the forks is regulated by the flow con trol valve A pressure limit valve overflow valve prevents overload and protects the pump motor from overpressure A hose rupture valve is located at the cylinder to prevent the load from falling uncontro...

Page 83: ...essure decreases Place a load of 1300 kg on the forks and check that the truck can lift it If the truck cannot lift 1300 kg Loosen the lock nut 1 by turning it counter clockwise Turn the adjuster screw 2 clockwise until the truck is able to lift the load without problems Tighten the lock nut 1 by turning it clockwise If the truck can lift 1300 kg place a further 100 kg on the forks Check that the ...

Page 84: ... 23 226057 040 13 4 Tools Two special tools are required to adjust the pressure limit valve of the hydraulic system A Socket for loosening or tightening the adjuster screw for pres sure limitation part number 0816530 B Socket for loosening or tightening the lock nut part number 0816530 1 26 5 12 A 13 5 8 B https www besttruckmanuals com ...

Page 85: ...ent C codes parts and functions on the truck These C codes are 0000 Chassis 1000 Motors 2000 Transmission drive transmission 3000 Brakes belt wheel system 4000 Steering system 5000 Electrical system 6000 Hydraulics pneumatics 7000 Working function lift mast 8000 Auxiliary installation equipment 9000 Accessories extra equipment The instructions do not tell you the type of material the parts are mad...

Page 86: ...hose cases where the container is indicated the type of plastic is shown by an abbreviation Sorting is not necessary for non recycla ble plastics These are placed in containers intended for combusti ble material Small plastic and rubber items are placed in the container intended for combustible material Iron and steel scrap are sorted separately Composite scrap that is difficult to dismantle and w...

Page 87: ...s hatches 0340 Disassembly Remove the hood Material handling The hood is to be placed in a container intended for ABS 14 7 Electric Pump Motor 1710 Disassembly Remove the hydraulic unit Remove hydraulic cables Remove the pump motor including the pump Material handling Oil should be treated as dangerous waste Hydraulic cables should be placed in a container for oil contaminated components The motor...

Page 88: ...Remove the drive motor including the electric parking brake 1 from the gearbox Empty the oil from the gearbox Remove the drive wheel 2 Material handling Cables are to be placed in a container intended for cables The motor and electric parking brake should be placed in a container for danger ous waste The oil should be treated as dangerous waste The gearbox is to be placed in a container intended f...

Page 89: ... placed in a container for vulcanised wheels 14 10 Tiller arm 4110 Disassembly Remove the cables Remove the gas dashpot 1 and cut it in half Remove the switch 2 Remove the potentiometer 3 Remove the sensor 4 Material handling Cables are to be placed in a container intended for cables Metal parts and gas dashpots should be placed in a container for metal The switch potentiometer and sensor should b...

Page 90: ...andling Cables are to be placed in a container intended for cables The battery classified as hazardous waste within the EU should be returned to the battery manufacturer or the manufacturer s representa tive see the rating plate on the battery The batteries can also be handed in to a representative of the truck manufacturer who bears responsibility for returning it to the battery manufacturer The ...

Page 91: ...aced in a container for oil contaminated components The tank should be placed in a container for PP The motor together with the pump should be placed in a container for dangerous waste 14 13 Hydraulic cables cylinders 6230 6610 Disassembly Remove the cylinder 1 Empty the oil from the cylinder Cut the cylinder in half Remove the hydraulic cables 2 Remove the hydraulic hoses Material handling The oi...

Page 92: ... BT Europe AB SE 595 81 Mjölby Sweden www bt industries com https www besttruckmanuals com ...

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BT LWE130, Service Manual

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