BT LWE180 LWE200 LPE200-6 8 Service Manual 221609-040 – PDF DOWNLOAD
DESCRIPTION:
BT LWE180 LWE200 LPE200-6 8 Service Manual 221609-040 – PDF DOWNLOAD
Valid from serial number: 723984-
Order number: 221609-040
Introduction, maintenance :
- All points in the service program shall be included to attain the highest safety and a least possible truck downtime. The service intervals are only a guide and do not need to be followed strictly.
- The truck driver must adapt these to local conditions, but it is important that the intervals meet BT’s minimum demands. The service intervals are based on operating times and can be adapted to most normal 8 hour shifts. The following operating hours have be used when calculating the interval.
Day time:08.00-17.00 (20 hours/week)
2-shifts:06.00-14.00, 14.00-22.00 (40 hours/week)
3-shifts:06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)
Ensure the truck is given regular maintenance services according to the maintenance schedule. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.
Only use BT approved spare parts during service and repairs
TABLE OF CONTENTS:
BT LWE180 LWE200 LPE200-6 8 Service Manual 221609-040 – PDF DOWNLOAD
1- Table of contents 3
2- Technical data 7
2 1 General tightening torques 10
2 1 1 Galvanised, non-oiled bolts 10
2 1 2 Untreated, oiled bolts 10
3- Introduction, maintenance 11
3 1 Safety regulations during maintenance work 11
3 2 Cleaning and washing 13
3 2 1 Cleaning the exterior 13
3 2 2 Cleaning the motor compartment 13
3 2 3 Electrical components 13
3 3 Safe lifting 14
3 4 Maintenance schedule 15
3 5 Lubrication schedule 20
3 6 Oil and grease specification 21
4- Tools 23
4 1 Super Seal connectors 23
4 2 AMP connectors 24
4 2 1 AMP Connectors, 040 series 25
4 3 Molex connectors 25
4 4 Grease guns 26
4 5 Other tools 27
5- Fork carriage- 0380 29
5 1 Maintenance 29
5 1 1 Adjusting the play between the fork carriage and body 31
6- Engine suspension- 0450 33
6 1 Component parts 33
6 1 1 Component List 34
7- Electric drive motor – 1760 35
7 1 Component parts 35
7 1 1 Dismantling/assembling of motor from truck 36
7 1 2 Assembling 36
7 2 Service/Repairs 37
7 2 1 Dismantling of motor 37
7 2 2 Assembling of motor 38
7 2 3 Cleaning 38
7 3 Technical data 39
8- Drive unit/gear – 2550 41
8 1 General 41
8 2 Included components 42
8 3 Disassembly of the drive unit from the truck 44
8 4 Assembly of the drive unit in the truck 44
8 5 Oil inspection or changing oil 45
8 5 1 Oil inspection/replenishment 45
8 5 2 Changing oil 45
8 6 Replacing the gasket ring 45
8 6 1 Disassembly 45
8 6 2 Assembly 46
8 7 Leakage from top cover 46
9- Electro magnetic brake – 3370 47
9 1 Brake LWE180, LWE200, LPE200-6 47
9 1 1 Main components 47
9 1 2 Maintenance 48
Exchange of brake disc 48
9 2 Brake LPE200-8 49
9 2 1 Main components 49
9 2 2 Maintenance 50
Exchange of brake disc 50
Adjustment of gap 50
10- Steering system – 4000 51
10 1 Component parts, tiller arm 51
10 2 Adjustments 52
10 2 1 Adjusting of brake microswitch 52
10 3 Tiller arm handle 53
10 3 1 Dismantling/Assembling 54
Change from ignition key to keyboard (2) 55
Change from keyboard to ignition key (2) 55
Changing of signal button/switch (9, 10) 55
Changing of lift/lowering button (13) 56
Changing of pushbutton (16) 56
11- Electrical System – 5000 57
11 1 General 57
11 1 1 Software/hardware order numbers 57
11 1 2 Nomenclature 58
11 2 Electrical equipment overview 59
11 2 1 Electric component overview 61
11 3 Electrical wiring diagram 63
11 3 1 Symbol list 63
11 3 2 Overview 64
11 3 3 Wiring diagram LWE180, LWE 200, LPE200-6 65
11 3 4 Wiring Diagram LPE200-8 71
11 4 Functional description 82
11 4 1 Theory of operation 82
11 4 2 Spider expansion unit (SEU) 87
11 4 3 Hour meter and battery condition 88
11 4 4 TLS – Truck log system (optional) 89
General 89
Registration 89
Logging in/out SD16 89
Logging in/out S16 89
Collision sensor 90
Settings 90
11 4 5 ID unit (optional) 90
11 4 6 Built-in battery charger (optional) 91
Technical data 91
Charging 92
Troubleshooting and service 93
Adjusting the charger 93
11 5 Parameters & adjustments 95
11 5 1 General 95
11 5 2 Displaying parameters – without the CAN service key 95
11 5 3 Adjusting operator parameters – without the CAN service key 96
11 5 4 Displaying & changing parameters – CAN service key connected 96
Changing a parameter 97
11 5 5 List of operator parameters 98
11 5 6 Description of operator parameters 100
# 1 – Travel speed, Turtle button (LWE180, LWE200) 100
# 1 – Creep speed (LPE200-8) 100
# 2 – Maximum travel speed 100
# 3 – Acceleration 100
# 4 – Neutral speed reduction 100
# 5 – Logout 100
11 5 7 List of Service parameters 101
11 5 8 Description of Service parameter 103
# 10 – PIN code 103
To enter a new PIN-code: 103
To remove an existing PIN-code: 104
# 14 – Creep speed 104
#15 – Non-configurable options 104
Setting Non-configurable options 104
#16 – Configurable option #1 105
#17 – Configurable option #2 105
#18 – Configurable option #3 105
#19 – Configurable option #4 105
# 20 – Hour meter selection 106
# 21 – Battery size 107
Instructions for verifying parameter setting 108
Instructions for verifying parameter setting 109
# 22 – Brake switch 109
# 25 – Service interval 109
# 28 – Button selection 109
# 39 – Login method and driver parameter access 110
Expanded keypad – General 110
Expanded keypad – Programming 111
11 5 9 Configurable “Option” parameters 113
General 113
Parameter #16 to #19 configurable options 114
Setting Configurable options 114
11 6 Diagnostic and troubleshooting 125
11 6 1 General 125
11 6 2 Fault code history 126
11 6 3 List of fault codes 126
11 6 4 Transistor regulator troubleshooting and error codes 139
General 139
Transistor regulator errors 140
Resetting errors 141
Safety 141
11 6 5 Built-in Test Function 142
Digital inputs/outputs test mode 143
Transistor regulator inputs 143
Transistor regulator outputs 143
Digital input of logic card [A2] 144
Extra functions 144
11 6 6 Display test mode 145
11 7 Technical specifications – Curtis 1243 146
12- Hydraulic/Pneumatik – 6000 147
12 1 General 147
12 2 Hydraulic chart and list of symbols 147
12 2 1 List of Symbols 147
12 3 Adjustments LWE180 148
12 3 1 Adjusting the pressure limit valve 148
12 3 2 Tools 149
12 4 Adjustments LWE200 150
12 4 1 Adjusting the pressure limit valve 150
12 5 Hydraulic chart and list of symbols 151
12 5 1 List of Symbols 151
12 6 Adjusting the pressure limit valve 152
13- PowerTrak cylinder – 6680 153
13 1 Included components 153
13 2 Disassembling the PowerTrak cylinder and spring guides 154
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V