Service Manual en

LWE180, LWE200, LPE200-6/8

Valid from serial number: 723984-

Order number: 221609-040

Issued: 2006-03-13 ITS

© BT Europe AB
 Issue date Resp. Changes
2004-12-16 ITS Completely new issue (Prel.)
2005-09-01 ITS Updated: P4, 0380 (new) and 5000
2006-03-13 ITS Updated: P2, P3, 0380,5000, 6000, 8340

This manual covers following truck models:

T-code Model Serial number

660 LWE180 723984-
661 LWE200 723984-
662 LPE200 723984-

Some chapters in this manual covers only certain of the T-codes above.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 Approved by: L-G A

 Table of contents
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

1- Table of contents

Technical data – M4 2-1

Introduction Maintenance – P1 3-1

Safety regulations with maintenance work .... 1

Cleaning and washing ................................... 2

3.2.1 External cleaning ................................................ 3
3.2.2 Cleaning the motor compartment ....................... 3
3.2.3 Electrical components ........................................ 3
Safe lifting...................................................... 4

Preventive maintenance – P2 4-1

Maintenance schedule .................................. 1

Lubrication schedule ..................................... 6

Oil and grease specifica tion – P3 5-1

Tools – P4 6-1

Super Seal connectors .................................. 1

AMP connectors ............................................ 2

6.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors .......................................... 3

Grease guns.................................................. 4

Other tools..................................................... 5

Fork carriage- 0380 7-1

Maintenance.................................................. 1
7.1.1 Adjusting the play between the fork carriage and
body 3

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- 1

 Table of contents
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Engine suspension– 0450 8-1

Component parts .......................................... 1

8.1.1 Component List ................................................... 2

Electric drive motor – 1760 9-1

Component parts .......................................... 1

9.1.1 Dismantling/assembling of motor from truck ....... 2
9.1.2 Assembling ......................................................... 2
Service/Repairs ............................................ 3
9.2.1 Dismantling of motor ........................................... 3
9.2.2 Assembling of motor ........................................... 4
9.2.3 Cleaning .............................................................. 4
Technical data .............................................. 5

Mechanical drive gear unit – 2550 10-1

Component parts .......................................... 2

10.1.1 Technical data .................................................... 3
Leakage from top cover ................................ 4
Dismantling ......................................................... 4
Assembling ......................................................... 4
Changing of the drive shaft’s sealing ring ..... 4
Dismantling ......................................................... 4
Assembling ......................................................... 5

Electro magnetic brake – 3370 11-1

Main components ......................................... 1

Maintenance ................................................. 2
11.2.1 Exchange of brake disc ...................................... 2

Electro magnetic brake – 3370 12-1

Main components ......................................... 1

Maintenance ................................................. 2
12.2.1 Basic Adjustment of gap ..................................... 2
Adjustment: ......................................................... 2
12.2.2 Exchange of brake disc ...................................... 2

1- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Table of contents
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Steering system – 4000 13-1

Component parts, tiller arm ........................... 1

Adjustments .................................................. 2
13.2.1 Adjusting of brake microswitch .......................... 2
Tiller arm handle............................................ 3
13.3.1 Dismantling/Assembling ..................................... 4
Change from ignition key to keyboard (2) .......... 5
Change from keyboard to ignition key (2) .......... 5
Changing of signal button/switch (9, 10) ............ 5
Changing of lift/lowering button (13) ................... 6
Changing of pushbutton (16) .............................. 6

Electrical System – 5000 14-1

Electrical components ................................... 1

Symbol List and Wiring Diagram ................... 3

14.2.1 Wiring Diagram LWE180, LWE 200, LPE200-6 . 5
14.2.2 Wiring Diagram LPE200-8 ............................... 11
Operating description .................................. 22
14.3.1 Starting truck .................................................... 22
14.3.2 Driving speed £ 6 km/h .................................... 22
14.3.3 Braking in neutral mode ................................... 22
14.3.4 Braking in neutral mode on a slope ................. 22
14.3.5 Braking ............................................................. 23
14.3.6 Lifting the forks ................................................. 23
14.3.7 Lowering the forks ............................................ 23
14.3.8 Horn ................................................................. 23
Hour meter .................................................. 23

Error codes.................................................. 24

Parameters.................................................. 37
14.6.1 Operator parameters – LWE180, 200 .............. 38
14.6.2 arameter description LWE180, 200 ................. 38
Parameter 1 ...................................................... 38
Parameter 2 ...................................................... 38
Parameter 3 ...................................................... 38
Parameter 4 ...................................................... 38
Parameter 5 ...................................................... 39
14.6.3 Operator parameters – LPE200-6 .................... 39
14.6.4 Parameter description LPE200-6 ..................... 39
Parameter 2 ...................................................... 39
Parameter 3 ...................................................... 39

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- 3

 Table of contents
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Parameter 4 ...................................................... 39
Parameter 5 ...................................................... 40
14.6.5 Operator parameters – LPE200-8 .................... 40
14.6.6 Parameter description LPE200-8 ..................... 40
Parameter 1 ...................................................... 40
Max. travel speed in the low-speed range. Gates
are not activated. .............................................. 40
Parameter 2 ...................................................... 40
Parameter 3 ...................................................... 41
Parameter 4 ...................................................... 41
Parameter 5 ...................................................... 41
14.6.7 Service parameters .......................................... 42
14.6.8 Parameter description ...................................... 43
Parameter 10 .................................................... 43
Parameter 14 .................................................... 43
Parameter 15 - Non-configurable option ........... 44
Parameter 16 - Configurable option #1 ............. 44
Parameter 17 - Configurable option #2 ............. 44
Parameter 18 - Configurable option #3 ............. 44
Parameter 19 - Configurable option #4 ............. 44
Option parameters ............................................ 44
General ............................................................. 44
Parameter #15 Non-configurable options ......... 44
Changing non-configurable options .................. 44
Parameter #16 to 19 configurable optional func-
tions .................................................................. 45
Changing configurable optional functions ......... 46
Parameter 20 .................................................... 51
Parameter 21 .................................................... 51
Recommendation on parameter setting for freely
ventilated batteries ............................................ 52
Instructions for verifying parameter setting ....... 53
Recommendation on parameter setting for valve-
controlled batteries (VRLA) ............................... 54
Instructions for verifying parameter setting ....... 55
Parameter 22 .................................................... 55
Parameter 25 .................................................... 55
Parameter 28 .................................................... 55
Parameter 39 .................................................... 56
Login method and driver parameter access ..... 56
Expanded keypad - General ............................. 56
Expanded keypad - Programming .................... 56
Service indication .............................................. 58
Part number ................................................. 62

Transistor panel ........................................... 62

14.8.1 General ............................................................. 62

1- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Table of contents
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Troubleshooting .......................................... 63
14.9.1 Error codes and troubleshooting ...................... 63
14.9.2 Reset error ....................................................... 64
14.9.3 Safety ............................................................... 64
Technical specifications – Curtis 1243 ........ 65

TLS - Truck log system (optional)................ 66

General ............................................................. 66
Registration ...................................................... 66
Logging in/out SD16 ......................................... 66
Logging in/out S16 ........................................... 67
Collision sensor ................................................ 67
Settings ............................................................ 67
14.11.1 ID unit (optional) ............................................. 68
General ............................................................. 68
Installation ........................................................ 68
Settings ............................................................ 69

Hydraulic/Pneumatik – 6000 15-1

General ......................................................... 1

Hydraulic chart and list of symbols ................ 1

15.2.1 List of Symbols ................................................... 1
Adjustments LWE180.................................... 2
15.3.1 Adjusting the pressure limit valve ...................... 2
15.3.2 Tools .................................................................. 3
Adjustments LWE200.................................... 4
15.4.1 Adjusting the pressure limit valve ...................... 4
Hydraulic chart and list of symbols ................ 5
15.5.1 List of Symbols ................................................... 5
Adjusting the pressure limit valve .................. 6

PowerTrak cylinder – 6680 16-1

Component parts........................................... 1

Dismantling of PowerTrak cylinder ................ 2

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- 5

 Table of contents
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Battery charger (built-in) – 8340 17-1

General ......................................................... 1

Technical data – charger .............................. 2

Charging ....................................................... 2
Machine numbers 723984-936512 ..................... 2
Machine numbers 936513- ................................. 3
Troubleshooting and service......................... 3

Setting the charger (applies to machine num-

bers 723984-936512) 4
Freely ventilated batteries ................................... 4
Valve-regulated batteries .................................... 4
17.5.1 Current levels at different charger settings (applies
to machine numbers 936513-) 5
Freely ventilated batteries ................................... 5
Valve-regulated batteries (Evolution type) .......... 6

Control/computer equipment – 8700 18-1

General ......................................................... 1

Connection ................................................... 1
Layout ........................................................... 2
18.3.1 Main program screen ......................................... 2
18.3.2 Nodes ................................................................. 2
18.3.3 Icons ................................................................... 3
18.3.4 Tool buttons and menu bar ................................ 3
18.3.5 Information window ............................................ 4
18.3.6 Status bar ........................................................... 4
Connection function ..................................... 4

Disconnection function.................................. 4

Downloading program function ..................... 5

18.6.1 Normal downloading (truck with key) ................. 5
18.6.2 Normal downloading (truck with keypad) ........... 5
18.6.3 Emergency downloading (truck with keypad) ..... 6
18.6.4 Downloading in old versions of logic card .......... 6
18.6.5 Emergency downloading (truck with keypad) ..... 6
Truck report function ..................................... 7

Parameters function...................................... 8

1- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Table of contents
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Diagnostics function ...................................... 8

18.9.1 Representation of signal colours ........................ 9
18.9.2 “Tiller arm” tab .................................................... 9
18.9.3 “Drive Controller” tab (transistor regulator -
travel) 10
18.9.4 “Pump controller” tab (transistor regulator -
pump) ............................................................... 11
18.9.5 “EPS” steering servo tab .................................. 12
Other menu functions .................................. 13
18.10.1 Save to file ..................................................... 13
18.10.2 Download from file ......................................... 13
18.10.3 Reset CAN adapter ........................................ 13
18.10.4 Delete error code log ..................................... 13
18.10.5 Reset hour meter ........................................... 13
18.10.6 Read error code log ....................................... 13
18.10.7 Adjust date and time ...................................... 14
18.10.8 Adjusting the hour meter on older cards ........ 14
18.10.9 Help ................................................................ 14
About the TruckCom application ...................... 14
18.10.10 Exit ............................................................... 14
Specifications .............................................. 14

Installation ................................................... 15
18.12.1 Installation on a PC with Windows® 95/98 .... 15
18.12.2 Installation on a PC with Windows XP/2000 .. 16
18.12.3 Installation on a PC with Windows NT ........... 21
18.12.4 In case of communication problems with CAN 21
18.12.5 To uninstall ..................................................... 21

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- 7

 Table of contents
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

1- 8 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Technical data – M4
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

2- Technical data – M4
Model LWE180 LWE200, LPE200-8
LPE200-6
Drive motor
Type TSL140S-DS20 TSL140S-DS30 TSL140S-DS40
Output, kW 1.0 1.2 1,7
Duty cycle S2, 60 min S2,60 min S2,60 min
Minimum carbon brush length, mm 13 13 13
Nominal commutator diameter, mm 47 47 60
Minimum commutator diameter, mm 47 47 60
Resistance, shunt field winding, Ω at 25 C° 0,55 0,55 0,4498
Resistance armature winding, Ω at 24 °C 0.0156 0,0156 0,0161
Insulation resistance between the wind- >=1 Mohm >= 1Mohm >= 1Mohm
ings and motor casing
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
Thickness of a new brake disc, mm 7.0 7.0 10.0
Transmission/drive gear
Type 2-stage angle 2-stage angle 2-stage angle
transmission transmission transmission
Gear ratio 19,14:1 19,14:1 16,29:1
Oil volume, litre 1.0 1.0 1.0
Oil type Hypoid oil Hypoid oil Hypoid oil
at normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90
at temperature < -15oC SAE 75W SAE 75W SAE 75W

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 2- 1

 Technical data – M4
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Model LWE180 LWE200, LPE200-8

LPE200-6
Wheels
Drive wheel, mm Dia 215x70 Dia 215x70 Dia 215x70
Axle pressure without load, kg 200 374 374
Axle pressure at rated load, kg 650 565 565
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm 65 Nm
Fork wheel, mm Dia 85x75 Dia 85x75 Dia 85x75
Axle pressure without load, kg 2x40 (240) 2x65 (240) 2x65 (240)
Axle pressure at rated load, kg 2x710 (240) 2x790 (240) 2x790 (240)
Support 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/diame- 4.75 4.7 4.7
ter, mm
Pressure at rated load, bar 110 150 150
Overflow pressure, bar 130 170 170
Pump flow, litre/minute 4.7 4.6 4,6
Tank volume, litre 0,5 1,0 1,0
Oil type: Hydraulic oil Hydraulic oil Hydraulic oil
at normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
at temperature < -15oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32

Fuses
Drive motor circuits, A 125 125 125
Pump motor circuits, A 125 125 125
Control circuits, A 7,5 7,5 7,5

2- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Technical data – M4
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Model LWE180 LWE200, LPE200-8

LPE200-6
Battery compartment, Batteries
Dimensions LxWxH, mm 193x642x450 193x642x450-510 193x642x450-510
Capacity, Ah 160-320 240-320 240-320
Weigh, kg 165-250 210-250 210-250
Driving speed
Without load, km/t 6,0 6,0 8,0
Without load, m/s 1.7 1.7 2.22
With rated load, km/t 6,0 6,0 7.2
With rated load, m/s 1,7 1,7 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 rated load 8% 9% 9%
Measurement, L2
Short 519 519(LWE200)
Medium 565 660 660
Lång 613 1008 1008
Turning radius WA 1466 1960 1960
Lift height 205 205 205
Weight
Truck without battery, Medium 295 420 440

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 2- 3

 Technical data – M4
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

This page is intentionally left blank

2- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Introduction Maintenance – P1
Safety regulations with maintenance work
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

3- Introduction Maintenance – P1
All points in the service program should be carried out to attain the high-
est safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with BT’s minimum requirements.
The service intervals are based on the running times and can be adapt-
ed to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts: 06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts: 06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)
Ensure the truck is given a regular maintenance service after every 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.

3.1 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 out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electri-
cal connections.
Remove watches, rings or other types of metal jewellery.
• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual
• Always switch off the truck’s power supply before opening the cov-
ers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 1

 Introduction Maintenance – P1
Cleaning and washing
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

• Use paper or a rigid sheet of cardboard when checking for oil leak-
age. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
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 using an electric power source the welding current can
enter the battery.
The battery should therefore be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

3.2 Cleaning and washing

Cleaning and washing of the truck is important to ensure the truck’s reli-
ability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the battery con-
nector.

3- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Introduction Maintenance – P1
Cleaning and washing
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

3.2.1 External cleaning

• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable concentration
• Rinse off loose grime using tepid water
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the chapter
Maintenance and lubrication chart.

3.2.2 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 compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water

3.2.3 Electrical components

• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors, connec-
tions, solenoid valves, etc. using a damp cloth and a cleaning agent
NOTE!
Risk of short-circuiting.
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 3

 Introduction Maintenance – P1
Safe lifting
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

3.3 Safe lifting

All lifting must be carried out on a flat, non-slip and firm surface. Avoid
new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving during
the lift. If the lift applies to the brake wheel, chock the other wheels
so that the truck stands still
• Select a lifting point so that the lift is as easy as possible (one corner
at a time). If the truck has marked lifting points on the under side of
the chassis 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 as possible to the part of the chassis that is to be lifted.
This reduces the risk of the truck tipping over
- so that the truck cannot roll
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.
A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

3- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Preventive maintenance – P2
Maintenance schedule
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

4- Preventive maintenance – P2

4.1 Maintenance schedule

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours – may vary due to ap- 5 20 500 1000 3000
plication
Interval in days/weeks/months – may 1d 1w 6m 12m 36m
vary due to application
0000 Chassis
0000.1 Check all links and locking pins l
0000.2 Check wear on cover/battery locking l
0000.3 Check of cracking and damage l
0000.4 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 Check the lift limit switch l
0560 Platform and mountings
0560.1 Check for any cracks or damage l
0560.2 Check gas damper and cup springs l
1700. Drive motor
1700.1 Check clearance in connections I/T1 I/T

1700.2 Check the carbon brushes in the drive motor M

1700.3 Clean the drive motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing l

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 4- 1

 Preventive maintenance – P2
Maintenance schedule
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours – may vary due to ap- 5 20 500 1000 3000
plication
Interval in days/weeks/months – may 1d 1w 6m 12m 36m
vary due to application
2550 Drive gear
2550.1 Check for leakage I3 I

2550.2 Check the oil level I

2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in I
steering bearing
2550.5 Change the oil in the drive gear L4 L

3100. Brake
3100.1 Clean C
3100.2 Check for wear on the brake disc M
3100.3 Check the clearance in disengaged position M
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tight- I/T
ening torque on bolts
3500.3 Check that the support wheel turns and I
rotates freely
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- I I/L
witch in the upper and lower brake positions.
Lubricate the switch head.
5000.2 Check the function of the collision safety I
switch
5000.3 Check the function of the gate switches I I
5000.4 Check the function of platform switch I I
5000.5 Check the function of the horn I I
4- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB
 Preventive maintenance – P2
Maintenance schedule
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours – may vary due to ap- 5 20 500 1000 3000
plication
Interval in days/weeks/months – may 1d 1w 6m 12m 36m
vary due to application
5000.6 Check for wear on cabling I
5000.7 Check the function of the driver’s control I I
5000.8 Check the error code log and operating times I I
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over M
the cell plates
5110.2 Check connections to battery, truck and I
charger
5110.3 Check that the cell and pole guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery locking I I
5400 Power system
5400.1 Cleaning and checking of mounting in chassis C/T1 C/T

5400.2 Re-tighten 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

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 4- 3

 Preventive maintenance – P2
Maintenance schedule
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

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

M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours – may vary due to ap- 5 20 500 1000 3000
plication
Interval in days/weeks/months – may 1d 1w 6m 12m 36m
vary due to application
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, leakage and I
damaged mountings
6100.4 Check that the oil level is correct I
6100.5 Change the oil and clean the filter L5 L

6600. Lift cylinder

6600.1 Check for leakage I
6600.2 Check the mountings I
6680 Power Trak
6680.1 Check if there is any damage or cracks on I
the PowerTrak spring
6680.2 Grease in the contact pressure spring’s C/L
guides

1 = The connections are re-tightened for the first time after 500 h, and
then every 1000 h/12 months.
2 = The attachment bolts are re-tightened after500 h/ 1 month to 45
Nm.
3 = Check for leakage in conjunction with the first oil change.
4 = The oil is changed for the first time after 500 h/1 month, and then
every 3000 h/36 months
5 = The oil is changed and the filter cleaned for the first time after 500 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.

4- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Preventive maintenance – P2
Maintenance schedule
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

5000 5000

6680

4110

5110

5700

5000

6600

5400
3100
1700

6100
0380 0000 0560

2550

5000

3500

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 4- 5

 Preventive maintenance – P2
Lubrication schedule
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

4.2 Lubrication schedule

Pos. Service point Interval/Operating hours Type of
No. 80 h 500 1000 h 3000 h lubricant
0380 Lubricating nipples (Option) L E
2550 Drive gear O4 C O C
6100 Hydraulic system O5 O B
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.

6100

0000
2550

0380

4- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Oil and grease specifica tion – P3
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

5- Oil and grease specifica tion – P3

Pos. Type of lubri- Specification Application

cant > -15° C < -15o C
A Grease BT 26777 BT 26777 Bearings and bushes
(Spray) (Spray)
B Hydraulic oil ISO-HM32 ISO-VG 32 Hydraulic system
C Transmission oil Hypoid oil SAE Hypoid oil SAE Gears
80W/90 75W
D Grease Staburags Staburags Guide bearing
NBU 8EP NBU 8EP
E Grease BT 73942XX5 BT 73942XX5 Lubricating nipples,
TOTAL N3942 TOTAL N3942 Contact pressure spring

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 5- 1

 Oil and grease specifica tion – P3
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

This page is intentionally left blank

5- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Tools – P4
Super Seal connectors
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

6- Tools – P4

6.1 Super Seal connectors

3
3

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)

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 6- 1

 Tools – P4
AMP connectors
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

6.2 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 Tools for fitting sleeves

2=163788

1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2

1
2

6- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Tools – P4
Molex connectors
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

6.2.1 AMP Connectors, 040 series

Figure Number Application

213130 Pin removal tool

213129 Tools for fitting pins

6.3 Molex connectors

16
9
8
1
Figure Number Application
156937 Tools for fitting pins/sleeves

156936 Tools for fitting sleeves/pins

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 6- 3

 Tools – P4
Grease guns
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

6.4 Grease guns

Figur Nummer Användning

24981 A tool with a pointed nozzle used to apply
grease. Length 170 mm.

755132 Single-hand grease gun with straight discharge

pipe and nozzle.

755142 Two-hand grease gun with angled discharge pipe

fif

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. Fits grease guns with
hose and discharge pipe.

6- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Tools – P4
Other tools
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

6.5 Other tools

Figure Number Application
156263 Service instrument (CAN)

1=163793 Service instrument for pro-

2=163792 gramme changes

08-13022 Driving gear puller

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 6- 5

 Tools – P4
Other tools
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

This page is intentionally left blank

6- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Fork carriage- 0380
Maintenance
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

7- Fork carriage- 0380

7.1 Maintenance
The support arms should be greased regularly according to the mainte-
nance schedule.

Table 1: Lubricating the nipples

Position Placement Picture
1 Behind the support
arms

2 Above the swivel

wheels

3 Behind/above the sup-

port arm wheels

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 7- 1

 Fork carriage- 0380
Maintenance
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Table 1: Lubricating the nipples

Position Placement Picture
4 Behind/above the sup-
port arm wheels, on the
outside

5 On the outside of the

bogie, if there is one.

7- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Fork carriage- 0380
Maintenance
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

7.1.1 Adjusting the play between the fork

carriage and body
The play between the fork carriage and body must be adjusted by plac-
ing shims on both sides. Symmetrical deviation between the body and
fork carriage may not exceed 3 mm.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 7- 3

 Fork carriage- 0380
Maintenance
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

This page is intentionally left blank

7- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Engine suspension– 0450
Component parts
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

8- Engine suspension– 0450

8.1 Component parts

6680
2

21
20
4 5
6
19

7 8

18 11

9
14 13 12 10

15

17
16

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 8- 1

 Engine suspension– 0450
Component parts
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

8.1.1 Component List

Pos. Description Notes

1 Screw 2x M6S 8x30
2 Plate
3 Circlip
4 Console
5 Washer 8x
6 Screw 2x M6S 12x45
7 Lock bracket
8 Screw MC6S 8x12
9 Axle
10 Screw 2x M6S 12x90
11 Grease nipple 2x
12 Pivot pipe
13 Grease nipple 4x
14 Bushing 4x
15 Engine bracket
16 Screw 2x M6S 6x10
17 Axle 2x
18 Washer (0.5 mm) Number
as required
18 Washer (1 mm) Number as
required
19 Bushing 4x
20 Link 2x
21 Grease nipple 2x
6680 PowerTrak system See chapter 6680
“PowerTrak cylinder”

8- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electric drive motor – 1760
Component parts
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

9- Electric drive motor – 1760

9.1 Component parts

16

21
20
14 19
18
13 17

15 10

12
11 8

7
6
5
4
3
1
2

Pos Description Note

1 Screw M6x25
2 Bearing shield
3 Locking ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20
8 Carbon brush
9 Rotor
10 Key
11 Plug

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 9- 1

 Electric drive motor – 1760
Component parts
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Pos Description Note

12 Stator
13 Cable
14 Cable
15 Bearing shield
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Locking ring
21 Locking ring

9.1.1 Dismantling/assembling of motor from

truck
• Switch off the truck and pull out the battery plug.
• Remove the covers for the motor compartment.
• Release the cables for the motor and tiller arm.
• Unscrew the four nuts for the attachment of the motor to the drive gear.
• Loosen the cables for the key switch and emergency switch. Pull out
all the cables from the cover’s cable duct.
• Loosen the cover over the motor compartment and the tiller arm’s
mounting from the motor. Remove the cover over the motor com-
partment together with the tiller arm.
• Carefully lift the motor straight up, without damaging the sealing sur-
faces to the drive gear and place the motor on a clean surface.
• Protect the drive gear from impurities by covering over its opening in
an appropriate manner, e.g. with a piece of plastic.
The requisite service and repair of the motor can now be carried out.

9.1.2 Assembling
Assembling is carried out in the reverse order.
• Carefully lift down the motor in the drive gear to avoid damaging the
seals and gear wheels.
• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm.
• Fit and adjust the brakes as per the instructions. Screw tight the cov-
er and tiller arm, and connect the cables that were previously re-
moved. Check that the polarity is correct.
• The function of the brakes should be checked before the truck is moved.
9- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB
 Electric drive motor – 1760
Service/Repairs
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

9.2 Service/Repairs

9.2.1 Dismantling of motor

16

21
20
14 19
18
13 17

15 10

12
11 8

7
6
5
4
3
1
2
• Release the brake disc’s companion flange by first removing the
locking ring together with the washer in the end of the rotor shaft.
The companion flange can now be lifted off. It may be necessary to
unclamp it with an appropriate tool.
• Remove the four plugs that cover the carbon brushes, move the
springs on the carbon brushes to one side and pull out the carbon
brushes.
• Dismantle the commutator end’s bearing shield (2) together with the
carbon brush bridge (5) and carbon brushes (8) by unscrewing the
eight screws (1). Now put down the motor with a firm resting point
against the edge of the bearing shield, and carefully tap on the rotor
shaft’s end with a rubber mallet.
• Dismantle the drive end’s bearing shield (15) together with the rotor
(9). Make sure not to damage the motor windings when the rotor is
removed from the motor housing.
• After dismantling the motor’s bearing shields and removing the rotor
from the motor housing, the gear wheel in the rotor’s drive end is re-
moved. This is done by unscrewing the nuts on the gear wheel and
then pulling the gear wheel off with a puller. Note that the gear wheel
is locked with Loctite to the rotor shaft.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 9- 3

 Electric drive motor – 1760
Service/Repairs
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

• Now release the inner locking ring together with the underlying
washer. Pull out the rotor shaft from the bearing (18).
• Release the outer locking ring together with its washer, and remove
the bearing from the bearing shield.
• Remove the bearing shield’s seal (17) and carefully clean the bear-
ing shield.
• Fit a new seal in the bearing shield.

9.2.2 Assembling of motor

Assemble the motor in the reverse order.
• Carefully check that the rotor can move freely in the direction of rota-
tion and that the carbon brushes are flush with the commutator.
• Check the motor’s insulation resistance (between respective wind-
ing and the motor housing). For a new motor this should lie between
2 - 3 Mohm. When a used motor has been exposed to impurities an
insulation resistance down to approx. 1 Mohm is acceptable.
• Fit a new O-ring in the drive shaft end’s bearing shield and a new
seal on the collar of the bearing shield.

9.2.3 Cleaning
An extremely critical factor to ensure correct functioning of the motor is
that it is kept as clean as possible. The motor and the motor compart-
ment must be regularly checked for dust, oil, and other impurities.
A vacuum 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 detergent that does not damage the windings. Use
detergent sparingly to avoid it penetrating into the parts of the motor.
Residual detergent should be removed with an appropriate solvent, if it
leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to use a
solvent that is sprayed onto the parts. It is important that the detergent
is applied in a way to prevent dirt from penetrating into the parts of the
motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is done
then the rotor must always be dried with the application of heat. There
must be adequate ventilation during the drying process, and the drying
should continue until a number of measurements of the insulation
resistance provide equivalent and approved results.

9- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electric drive motor – 1760
Technical data
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

9.3 Technical data

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

Type TSL140S-DS20 TSL140S-DS30 TSL140B-DS40
Output (kW) 1.0 1.2 1,7
Intermittence S2 60 min S2 60 min S2 60 min
Minimum length of car- 13 13 13
bon brush (mm)
Minimum commutator 47 47 60
diameter (mm)
Resistance, shunt field 0,55 0,55 0,498
winding Ω at 25 C°
Resistance, armature 0,0156 0,0156 0,0161
winding,Ω at 24 C°
Insulation resistance >= 1Mohm >= 1Mohm >= 1Mohm
between windings and
motor housing
Weight (kg) 14 14 17

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 9- 5

 Electric drive motor – 1760
Technical data
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

This page is intentionally left blank

9- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Mechanical drive gear unit – 2550
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

10- Mechanical drive gear unit –

2550

3
4
5

6
01

7
8
24
9

25 27
10 26
11
28

13
12 14
32
31
30
15 29

19
18

17
16

20
23
21 22

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 10- 1

 Mechanical drive gear unit – 2550
Component parts
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

10.1 Component parts

Pos Description Note

01 Drive gear complete
2 Air valve
3 Cover
4 Oil stick
5 Washer
6 Gasket
7 Nut Tightening torque 70 Nm
Locked with punch mark
8 Washer
9 Gear wheel Primary gear
10 Conical roller bearing
11 Shims
12 Screw Top cover and gear housing
Tightening torque 26.6 Nm
Lock with Loctite 242
13 Shims
14 Conical roller bearing
15 Pinion/ Crown gear Cog clearance 0.09-0.15 mm
Pretension bearing with 2-5/100
Stamped size on pinion adjusted
with shims
16 Nut Tightening torque 300 Nm
Locked with punch mark
17 Shims
18 Conical roller bearing
19 Shims
20 Screw Bottom cover and gear housing
Tightening torque 26.6 Nm
Lock with Loctite 242
21 Screw Bottom cover and gear housing
Tightening torque 26.6 Nm
Lock with Loctite 242
22 Cover

10- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Mechanical drive gear unit – 2550
Component parts
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Pos Description Note

23 Gasket
24 Gear wheel Motor gear
25 Washer
26 Nut Tightening torque 30 Nm
Locked with punch mark
Lock with Loctite 603
27 Screw Motor and gear housing
28 Nut Tightening torque 26.6 Nm
Lock with Loctite 242
29 Conical roller bearing
30 Shims
31 Seal
32 Drive shaft

10.1.1 Technical data

Type of truck LWE180, LWE200, LPE200-8

LPE200-6
Type of gear 2-step angle gear 2-step angle gear
Gear ratio 19,14:1 16,29:1
Oil volume, litres 1,0 1,0
Oil type Hypoid oil Hypoid oil
Viscosity, normal tem- SAE 80W/90 SAE 80W/90
perature
Viscosity, <-15°C SAE 75W SAE 75W

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 10- 3

 Mechanical drive gear unit – 2550
Leakage from top cover
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

10.2 Leakage from top cover

Dismantling
• Lift up the truck, and block up to ensure that it is stable.
• Unscrew the drive wheel.
• Unscrew the M8 nuts (28), that hold the gear and motor, with a box
wrench. Support the gear so that it does not drop.
• Release the M8 bolts (12), that hold the cover (3), with a 6 mm hex
socket wrench.
• Change the gasket (6).

Assembling
Assemble in reverse order.
• Tighten the four M8 bolts and the four M8 nuts to a torque of 26.6 Nm
Lock with Loctite 242.
• Tighten the drive gear’s 5 bolts to a torque of 65 Nm.

10.3 Changing of the drive shaft’s

sealing ring
The drive shaft’s sealing ring can be changed with the gear mounted in
the truck.
Follow the instructions below if oil is leaking from the drive shaft.

Dismantling
• Unscrew the drive wheel 1).
• Remove the lower cover and drain off the oil (22).
• Release the drive shaft nut. Remove the nut and washer (16,17).
• Carefully tap out the drive shaft with a brass drift and hammer (32).
• Pull off the bearing from the drive shaft with tool 08-13022 (29).
• Check that the bearing washers are not damaged. If they have been
damaged by the puller tool, measure the total thickness of the shim
washers and change them before assembling (30).
• Remove the sealing ring from the drive shaft (31).

10- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Mechanical drive gear unit – 2550
Changing of the drive shaft’s sealing ring
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Assembling
Assemble the gear after changing the drive shaft’s sealing ring in
reverse order.
Pay special attention to the following during assembling:
• Fill the sealing ring with grease after fitting it on the drive shaft.
• Make sure that only undamaged shim washers with the same total
thickness as the originals are put on the drive shaft.
• Press the bearing on the drive shaft and make sure not to damage
the bearing’s shim washers.
• When fitting the drive shaft with bearing, shim washers and seal,
make sure that the shaft keys correspond with the crown gear’s keys
and that the bearing and seal are correctly positioned in the gear
housing before the shaft is pressed in completely.
• Put the distance ring on the drive shaft end, and put on the shaft nut.
Always use a new nut. Tighten the shaft nut to a torque of 300 Nm
and lock it with a punch mark in the middle. The drive shaft nut
should be lubricated before it is put on the shaft.
• Change the gasket before fitting the bottom cover. Make sure that it
is not damaged. Fit the cover and tighten the bolts to a torque of 26.6
Nm. The bolts should be lubricated before they are fitted. Fill up with
oil in accordance with the instructions for replenishing the oil.
Fit the drive gear and tighten the bolts to a torque of 65 Nm.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 10- 5

 Mechanical drive gear unit – 2550
Changing of the drive shaft’s sealing ring
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

This page is intentionally left blank

10- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electro magnetic brake – 3370
Main components
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

11- Electro magnetic brake – 3370

LWE180, LWE200, LPE200-6

11.1 Main components

1 9
2
8
3

4
7

5 6

Pos No Description
1 Magnetic coil
2 Cap screws
3 Electrical wire
4 Pressure plate
5 Pressure springs
6 Flange
7 Mounting bolts
8 Brake disc
9 Hub

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 11- 1

 Electro magnetic brake – 3370
Maintenance
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

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

11.2.1 Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been
reduced to 5,5 mm.
• Disconnect the electrical wires of the brake.
• Undo and remove the three fastening bolts.
• Loosen the brake disc from the hub and check for wear and tear. Re-
place the brake disc if the surface is unevenly worn.
• Reassemble the brake.
• Reconnect the electrical wiring.

11- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electro magnetic brake – 3370
Main components
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

12- Electro magnetic brake – 3370

LPE200-8

12.1 Main components

9 1
8
2

6
4

Pos No Description
1 Magnetic coil
2 Electrical wire
3 Pressure plate
4 Pressure springs
5 Friction plate
6 Adjustment locking nut
7 Brake disc
8 Mounting bolts
9 Hub

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 12- 1

 Electro magnetic brake – 3370
Maintenance
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

12.2 Maintenance
Basically the brake is maintenance free in normal work environments.
However it is recommended according to the preventive maintenance
schedule to check the brake disc for wear and the gap between the
magnetic coil housing and the pressure plate on a regular basis.

12.2.1 Basic Adjustment of gap

9,5 Nm

0,3

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

Adjustment:
• Loosen the tension of the three mounting bolts .
• Turn the lock nuts anti-clockwise and tighten the bolts slightly while
checking the gap on three points with a 0.3 mm feeler gauge.
• Tighten the mounting bolts 9,5 Nm and recheck the gap with the
feeler gauge.

12.2.2 Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been
reduced to 6 mm.
• Disconnect the electrical wires of the brake.
• Loosen and remove the three mounting bolts and remove the brake coil.
• Replace the brake disc on the hub and make a visual inspection of
the wear of the friction plate. Replace the friction plate if the surface
is worn uneven.
• Unwind the lock nuts on the coil at least 6 mm to make sure there is a
gap between the coil and the pressure plate when the coil is refitted.
• Mount the coil on the motor end and carry out adjustment of the gap
according to chapter “Basic Adjustment of gap”.
• Reconnect the electrical wiring.

12- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Steering system – 4000
Component parts, tiller arm
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

13- Steering system – 4000

13.1 Component parts, tiller arm

1

9 10

11
13 12

15
14
17 16

18

19

20
21
22

Pos Description Note

1 Screw 4
2 Washer
3 Handle
4 Screw 4

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 13- 1

 Steering system – 4000
Adjustments
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Pos Description Note

5 Washer 2
6 Cable holder
7 Gas damper
8 Bracket
9 Stop screw
10 Screw 4
11 Ball joint
12 Screw
13 Distance
14 Bush 2
15 Damper 2
16 Axle
17 Cam
18 Distance
19 Screw
20 Distance
21 Distance
22 Switch S 10

13.2 Adjustments

13.2.1 Adjusting of brake microswitch

Switch (23) is always adjusted to its lowest position.
• Unscrew the screws (13, 20) that hold the switch and the distance.
• Press down the switch and tighten the screws.
• Check that the switch is actuated by the cam (18) in the arm’s top
and bottom position.

13- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Steering system – 4000
Tiller arm handle
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

13.3 Tiller arm handle

28
29
27 26
24 14
25 14
23 22
17
21 18

20 16
19 15
14
30 14

31 13
12
10 11
32 9
8

35 33
34

5 6 7
4

1 2
3

Pos Description Note

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic card
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
15 Spring
16 Pushbutton Not used

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 13- 3

 Steering system – 4000
Tiller arm handle
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Pos Description Note

17 Arm
18 Holder
19 Spring
20 Control switch
21 Axle
22 Sliding bearing
23 Control stop
24 Arm
25 Spring holder
26 Spring
27 Spring holder
28 Sliding bearing
29 Control switch
30 Button for safe reversing
31 Arm
32 Spring
33 Lower cover
34 Screw M4x40
35 Screw 2xM5x45 - 2xM5x60

13.3.1 Dismantling/Assembling
• Dismantle cover (2), (keyboard option).
• Remove the screws (35), hold top cover firm (7).
• Disconnect the cable connected to the electronic card (4).
• Remove the screws (34).
• Carefully lift off the lower cover (33), and place a finger between the
lower cover (33) and button (30) to hold the button (30) in place.
Assemble in reverse order.
NOTE!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure to take the necessary precautions before working with the
electronics.

13- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Steering system – 4000
Tiller arm handle
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Change from ignition key to keyboard (2)

• Connect the CAN-key to the truck.
• Enter parameter mode (P).
• Change parameter 39 to value = 3 or 4.
• Set the required PIN-code by using parameter 10.
• Switch off the truck.
• Dismantle the cover(2) on the tiller arm.
• Fit the keyboard.
• Remove the ignition key, fit the strap.
• Fit the cover in the key hole.
• Start the truck using the chosen PIN-code.

Change from keyboard to ignition key (2)

• Connect the CAN-key to the truck.
• Enter parameter mode (P).
• Change parameter 39 to value = 1 or 2.
• Switch off the truck.
• Remove the keyboard (2) on the tiller arm.
• Fit the cover.
• Remove the strap.
• Remove the cover.
• Fit the ignition key.
• Start the truck.

Changing of signal button/switch (9, 10)

• Dismantle the button as per the diagram.

• Disconnect the connection for the switch on the electronic card (4).
• Press out the switch from its mounting.
Assemble in reverse order.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 13- 5

 Steering system – 4000
Tiller arm handle
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Changing of lift/lowering button (13)

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

A A

• Unscrew the holder (18) so that the arm (12) comes loose.
Assemble in everse order.

Changing of pushbutton (16)

• Press the button by hand sideways.
• Place a screwdriver as per the diagram and carefully pry the button
loose.

• Unscrew the button’s holder and arm.

Assemble in reverse order.

13- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Electrical components
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14- Electrical System – 5000

14.1 Electrical components

S17 S10
S31
S21
X41
X5
Y1
X1
F50
M3
F51
F1
R1 Y41

K10
F3
M1
K30
A1

H1

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 1

 Electrical System – 5000
Electrical components
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

A17

14- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Symbol List and Wiring Diagram
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14.2 Symbol List and Wiring Diagram

Symbol Description Function Comments

A1 Transistor regulator
A2 Electronic card
A6 Display Display of truck functions
A17 Keypad Login with PIN code Option

F1 Fuse Drive motor circuits 130 A

F3 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 Speed controls Forward/backward

A2:S10-
S18

M1 Motor Drive motor

M3 Motor Pump motor

P1 Pressure sensor Load monitoring Digital (Applies to

LPE200-8)

R1 PTC resistance Power supply 15 Ohm

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 3

 Electrical System – 5000
Symbol List and Wiring Diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Symbol Description Function Comments

S111 Switch Option
S112 Switch Option
S113 Switch Option
S114 Switch Option
S115 Switch Option
S116 Switch Option
S10 Inductive switch Mechanical activation of the Brake handle
brake
S17 Switch Key
S18 Switch Button for horn
S19 Switch Man on the platform (Applies to LPE200-8)
A2:S17 Switch Emergency reversing
S21 Switch Emergency switch
S31 Inductive 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 to LPE200-8)

Y1 Electromechanical Mechanical brake

brake
Y41 Solenoid valve Fork lowering

X1 Coupling Battery
X9 Connection point CAN communication (Extra
I/O)
X41 Connection point CAN communication (Exter-
nal)

14- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Symbol List and Wiring Diagram
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14.2.1 Wiring Diagram LWE180, LWE 200, LPE200-6

1/6 Prod C
224726

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 5

 Electrical System – 5000
Symbol List and Wiring Diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

2/6, Prod C
224726
INP. SUPPLY +24VDC
TRANSISTOR REGULATOR

INP. LIFT LIMIT

CAN HIGH

CAN LOW
16

15
A1

8
120
119
24

49
Bl
S31

Sv
Br
EMERCENCY SWITCH OFF

2
S21

120
119
21

24

40
Sh. 1

Sh. 3

Sh. 3
Sh. 1 3
Sh. 1 6

14- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 221609-040

ONLY KEY BOARD ELECTRONIC CARD, TILLER ARM

Order number

© BT Europe AB
A2
KEY
S17 X5
20 22
Sh. 1 X3 2 INP. +24VDC

X5
119 119
Date

Sh. 2 X3 3 CAN, HIGH

X5
120 120
2006-03-13

Sh. 2 X3 7 CAN, LOW

X5
40 40
Sh. 2 6 X3 6 INP. 0VDC

X9 S17
20 1 BELLY BUTTOM
723984-

Service Manual
40 2
S1-S9 S10-S18
SPEED REF. VALUE
X41 119 3
1 20
120 4 S19
2 40 FORK LIFT
CAN CONNECTION
Valid from serial number

3 119
S20
FORK LOWER
4 120

CAN, SERVICE CONNECTOR

S18:1
X4 1 INP. HORN 1
1 2

LWE180, LWE200, LPE200-6/8

X4 2 OUT. 0 VDC HORN 1
T-code

S18:2
660,661,662

X1 1 INP. HORN 2
1 2

X1 2 OUT. 0 VDC HORN 2

224726
Electrical System – 5000
Symbol List and Wiring Diagram

3/6, Prod C

14- 7
 Electrical System – 5000
Symbol List and Wiring Diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

4/6, Prod C
224726
ELECTRONIC CARD

ENABLE
+5V DC

0V DC
LCLK
SCK
SI
X12 1

X12 2

X12 3

X12 4

X12 5

X12 6
A2

X1 1

X1 2

X1 3

X1 4

X1 5

X1 6
8 8 8 8
ELECTRONIC CARD
A6

14- 8 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Symbol List and Wiring Diagram
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

5/6, Prod C
ELECTRONIC CARD

LED_GREEN

224726
LED_RED
2580

369#

0V DC
147-

123

456

789

-0#

X11 10
X11 1

X11 2

X11 3

X11 4

X11 5

X11 6

X11 7

X11 8

X11 9
A2

3
6
9
I
2
5
8
0
1
4
7
KEY BOARD
A17

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 9

14- 10
T-code
OPTION
ONBOARD CHARGER
660,661,662

START INTERLOCK ELECTRONIC CARD

ONBOARD CHARGER A5
S170 K10
Symbol List and Wiring Diagram

24 23 A1 A2 64
Sh. 2 4 OUT. MAIN CONTACTOR
Electrical System – 5000

723984-

ONBOARD CHARGER, PLUG. A/B

Service Manual
ONBOARD CHARGER
A30

1 (RED) (RED)
Sh. 1 + OUT. POSITIVE CHARGER VOLTAGE
Valid from serial number

40 (BLACK) (BLACK)
Sh. 3 - OUT. NEGATIVE CHARGER VOLTAGE

PLUG. A
MAINS, VAC
Date

PLUG. B
MAINS, VAC
2006-03-13

LWE180, LWE200, LPE200-6/8

MAINS, EARTH
221609-040
Order number

224726
6/6, Prod C

© BT Europe AB
 221609-040
Order number

© BT Europe AB
TRANSISTOR REGULATOR
A1

X1 G1 24V X1
1 + - 40
Sh. 11 - INP. POWER SUPPLY 0VDC

R1 F1
2 3
Date

INP. POWER SUPPLY +24VDC

130A DRIVE MOTOR +
PTC 15~E PUMP MOTOR
F50 F3 M3 M1
20 2 1 9 1 2 10 A2/E2 D1/E1 A1 A2 6
Sh. 3 M M M OUT. ARMATURE
2006-03-13

7,5A 130A

F51 S
21 E1 E2 4
Sh. 2 S2 OUT. FIELD
7,5A

FEXTERNAL EQUIPMENT
5
S1 OUT. FIELD
723984-

40

Service Manual
Sh. 2

X10 Y1 X10
24 1 2 31
Sh. 2 5 OUT. BRAKE A

S10
X10 X10
Bn Bl 57
12 INP. TILLER ARM IN DRIVE POS.

Bu
Valid from serial number

X10

K10
A1 A2 64
4 OUT. MAIN CONTACTOR

K30
14.2.2 Wiring Diagram LPE200-8

A1 A2 45
6 OUT. PUMP CONTACTOR

LWE180, LWE200, LPE200-6/8

T-code

Y41
1 2 38
2 OUT. LOWER VALVE
660,661,662

H1 39
7 OUT. SIGNAL HORN
- +

IN

221397
Electrical System – 5000
Symbol List and Wiring Diagram

1/11, Prod C

14- 11
14- 12
T-code
660,661,662

TRANSISTOR REGULATOR
A1
EMERGENCY SWITCH OFF
S21
21 1 2 24
Sh. 1 16 INP. SUPPLY +24VDC
Symbol List and Wiring Diagram
Electrical System – 5000

24
723984-

Sh. 1 6

P1
63
10 INP. PRESSURE SWITCH

Service Manual
p

S31
1 2 49
15
Valid from serial number

INP. LIFT LIMIT

3
40
Sh. 1 3
Date

119 119
Sh. 3 1 CAN HIGH
2006-03-13

120 120

LWE180, LWE200, LPE200-6/8

Sh. 3 8 CAN LOW
221609-040
Order number

221397
2/11, Prod C

© BT Europe AB
 ONLY KEY BOARD ELECTRONIC CARD, TILLER ARM
221609-040

A2
KEY
Order number

© BT Europe AB
S17 X5
20 22
Sh. 1 X3 2 INP. +24VDC

X5
119 119
Sh. 2 X3 3 CAN, HIGH
Date

X5
120 120
Sh. 2 X3 7 CAN, LOW
2006-03-13

X5
40 40
Sh. 2 6 X3 6 INP. 0VDC

S17
BELLY BUTTON
X9
20 1
723984-

Service Manual
S1-S9 S10-S18
X41 40 2 SPEED REF. VALUE
1 20
119 3
2 40 S19
120 4 FORK LIFT
3 119
CAN CONNECTION
S20
3 120 FORK LOWER
Valid from serial number

CAN, SERVICE CONNECTOR

S18:1
1 2
X4 1 INP. HORN 1

X4 2 OUT. 0 VDC HORN 1

LWE180, LWE200, LPE200-6/8

S18:2
T-code

1 2
X1 1 INP. HORN 2
660,661,662

X1 2 OUT. 0 VDC HORN 2

221397
Electrical System – 5000
Symbol List and Wiring Diagram

3/11, Prod C

14- 13
 Electrical System – 5000
Symbol List and Wiring Diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

4/11, Prod C
221397
ELECTRONIC CARD

ENABLE
+5V DC

0V DC
LCLK
SCK
SI
X12 1

X12 2

X12 3

X12 4

X12 5

X12 6
A2

X1 1

X1 2

X1 3

X1 4

X1 5

X1 6
8 8 8 8
DISPLAY
A6

14- 14 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Symbol List and Wiring Diagram
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

5/11, Prod C
221397
ELECTRONIC CARD

LED_GREEN

LED_RED
2580

369#

0V DC
147-

123

456

789

-0#

X11 10
X11 1

X11 2

X11 3

X11 4

X11 5

X11 6

X11 7

X11 8

X11 9
A2

3
6
9
I
2
5
8
0
1
4
7
KEY BOARD
A17

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 15

 Electrical System – 5000
Symbol List and Wiring Diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM

6/11, Prod C
TRANSISTOR REGULATOR

221397
INP. GATES UP
13

14
11
A1

65

66

58
PLATFORM FOLDING UP, WITH GATES

X:S19

2
S53

3
X:S19

1
2
S59

3
1
24

40
Sh. 2 7

Sh. 3 7

14- 16 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Symbol List and Wiring Diagram
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM

221397
TRANSISTOR REGULATOR

7/11
INP. GATES UP
13

14
11
A1

65

66

58
PLATFORM STAYING DOWN, WITH GATES

2
S19

S53
3 3
1

1
2
S59

3
1
24

40
Sh. 6 8

Sh. 6 8

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 17

14- 18
T-code
660,661,662
Symbol List and Wiring Diagram

BACK PROTECTION, WITH FIXED PLATFORM

Electrical System – 5000

SIDE PROTECTION, WITH FIXED PLATFORM

723984-

Service Manual
TRANSISTOR REGULATOR
A1
S19
24 1 2 65
Sh. 7 9 11 INP. MAN ON PLATFORM

3
Valid from serial number

40
Sh. 7 9

X:S59 X:S59
66
13 INP. PLATFORM NOT FOLDED UP
Date
2006-03-13

LWE180, LWE200, LPE200-6/8

X:S53 X:S53
58
14 INP. GATES UP
221609-040
Order number

221397
8/11, Prod C

© BT Europe AB
 Electrical System – 5000
Symbol List and Wiring Diagram
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

INP. PLATFORM NOT FOLDED UP

9/11, Prod C
INP. MAN ON PLATFORM

221397
TRANSISTOR REGULATOR

INP. GATES UP
13

14
11
A1

65

66

58
PLATFORM STAYING DOWN, WITHOUT GATES

2
S19

3
1

2
S59

3
1
24

40
Sh. 8 10

Sh. 8 10

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 19

 Electrical System – 5000
Symbol List and Wiring Diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM
TRANSISTOR REGULATOR

10/11, Prod C
INP. GATES UP

221397
13

14
11
A1

65

66

58
PLATFORM FOLDING UP, WITHOUT GATES

X:S19
X:S19

2
S59

3
1
24

40
Sh. 9 11

Sh. 9 11

14- 20 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 221609-040
Order number

© BT Europe AB
OPTION
ONBOARD CHARGER
Date

START INTERLOCK ELECTRONIC CARD

ONBOARD CHARGER A5
2006-03-13

S170 K10
24 23 A1 A2 64
Sh. 10 4 OUT. MAIN CONTACTOR

ONBOARD CHARGER, PLUG. A/B

723984-

Service Manual
ONBOARD CHARGER
A30

1 (RED) (RED)
Sh. 1 + OUT. POSITIVE CHARGER VOLTAGE

40 (BLACK) (BLACK)
Sh. 10 - OUT. NEGATIVE CHARGER VOLTAGE
Valid from serial number

PLUG. A
MAINS, VAC

PLUG. B
MAINS, VAC

LWE180, LWE200, LPE200-6/8

MAINS, EARTH
T-code
660,661,662

221397
Electrical System – 5000
Symbol List and Wiring Diagram

11/11, Prod C

14- 21
 Electrical System – 5000
Operating description
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.3 Operating description

14.3.1 Starting truck

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

14.3.2 Driving speed ≤ 6 km/h

When driving at a speed of 6 km/h
A1 - the switch for driving brake (S10) must be closed, and the
B- - Speed controls must be activated in any direction.
S1
T1
Ish S2

-
A2
M- 14.3.3 Braking in neutral mode
+
Shunt

A • when the speed controls are in neutral mode, the engine functions
Ia A1
T2 as a generator. The braking energy is fed back to the battery.
K10 B+
• The brake (Y1) is engaged when the truck stops completely even if
the tiller arm is in drive position.
• Energy is fed back to the battery (see diagram below).
• The transistors (T2) for the brake circuit generated are not live.
A1

B-
S1
T1
Ish S2

- M-
A2
+
Shunt

A
Ia A1

T2
K10 B+

14.3.4 Braking in neutral mode on a slope

If the driver releases the speed control on a slope and the truck does
not stop within a certain space of time, the electrical brake is automati-
cally engaged.

14- 22 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
Hour meter
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14.3.5 Braking
The brake is always engaged when the truck is started with the tiller
arm in the top or bottom position (S10 open). The brake is released
once all the requirements for driving have been fulfilled, and the truck
begins to move.
Requirements for the truck to be able to brake:
• S10 open.

14.3.6 Lifting the forks

• S34
• S31 closed.
• Battery status OK (if battery capacity remaining is > 20 %).

14.3.7 Lowering the forks

• S41 activated.

14.3.8 Horn
• S18 activated.

14.4 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 meter. The “B” symbol lights up.
• You can now select type of hour meter by pressing the speed con-
trol.
1A = Key time
A 2b = Movement time
3c = Drive motor time
4d =Pump motor time
5s = Time remaining until service
E D C B

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 23

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.5 Error codes

• Press and hold S18 while turning S17 to “ON” position.
• Press and hold S18 until E = error codes is displayed.
• When E is selected, the “E” symbol will light up as an indication of
what is shown in the display.
• The 50 most recent error codes are stored. The latest error is 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 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 A shock sensor has reported values that exceed
cause the truck’s tolerance values.
Driving may be too hard
Check that the shock sensor’s limit values are
correctly set.
Check that the shock sensor is correctly posi-
tioned./The brake engages and stops the truck.
The TLS reset command activates the truck

Code C4
Description TLS: Use of the truck has been blocked
Possible error Truck use can be “blocked” by a TLS command. /
cause The truck cannot be used until a new TLS com-
mand cancels the blocking of the truck

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 Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Code C19
Description Parameter caution. Displayed for 5 seconds.
Possible error The parameters have probably been changed.
cause 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 caution.
Possible error Problem with the speed control sensors.
cause The toggle switch may have been activated when
starting or there may be a fault on one of the sen-
sors on the electronic card. (tiller arm head)
Action 1. Restart with the speed control in neutral
position.
2. Replace the electronic card.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 25

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Code C28
Description Emergency switch caution
Possible error The emergency switch has been activated.
cause 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
battery contacts.
4. If PTC resistor R1 is very hot, remove the
battery contact and allow the resistor to
cool.
Restart.

Code C29
Description Service warning
Possible error Time for service.
cause The service counter has not been reset since the
last service.

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 Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

LPE200-6, LPE200-8

Code C31
Description Pressure switch warning.
Possible error A problem with the pressure switch. Check that
cause the voltage is approximately 24 V between cables
24 and 40 connected 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 Battery voltage < 17 volt.
cause The battery parameters are not correctly set.
Time to charge up the battery.
Action 1. Check parameter 21, battery size and type.
2. Check the battery contact and the pole
connections on the battery
3. Check the key switch, S17, poor contact
causes unpermitted voltage drop.
The electrical system measures the voltage inside
the travel regulator.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 27

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Code C42
Description Warning of high battery voltage
Possible error Battery voltage > 33 volt.
cause Energy return feed to battery during motor braking
with a fully-charged battery.
Action 1. The fault disappears after a few lifts, once
the battery has been run down slightly.
2. Check the cabling, the battery contact and
the contact points on main contactor K10.

Code C43
Description The travel regulator shuts off due to excess or
subnormal temperature.
Possible error Too intensive operation or ambient temperature
cause too cold.
Error in the travel regulator.
Temperature levels below -25oC or above +85oC
reduce running speed.
Action 1. Check that the M12 fan is functioning. (Ap-
plies to P 24)
2. Check that the travel regulator is installed
with good contact with the chassis.

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 Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Code C90 (Option)

Description Extra I/0 (0) CAN communication error
Possible error Data from extra I/0 box /(0) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.

Code C91 (Option)

Description Extra I/0 (1) CAN communication error
Possible error Data from extra I/0 box /(1) not being received by
cause [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 Incorrect setting of options in the extra I/0 box (0)
cause Check the outputs’ allocation on the I/0 expansion
box (0)

Code C93 (Option)

Description Configuration error Extra I/0 (1)
Possible error Incorrect setting of options in the extra I/0 box (1)
cause Check the outputs’ allocation on the I/0 expansion
box (1)

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 29

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Code E101
Description Travel regulator does not correspond with the type
of truck
Possible error Incorrect travel regulator or electronic card has
cause 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 Error in the travel regulator, output. A1/3.
cause Incorrect value on parameter 22
Action Check cabling and contacts. Measure Ohms on
the magnet coil (Y1) for the brake. Value 13-15
ohm.
Check parameter 22

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 Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Code E106
Description Digital outputs short-circuited or exceeding field
current limit.
Possible error Problem regulating the field current.
cause 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. Unfortunately it is not pos-
sible to measure ohms for the field winding us-
ing a standard universal instrument, since the
winding has a value as low as 0.3 ohm.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 31

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Code E107
Description Contactor K10 does not close.
Possible error Problem with main contactor points or coil.
cause Contactor’s operating cabling off/not connected.
Interruption in the travel regulator’s output, A1/4.
Action 1. Check if the contactor is activated.
2. If the contactor is working, check the contact
points and accompanying cabling.
3. If the contactor is not working, check the coil
and accompanying cabling. Measure Ohms
for the coil. Value 25-30 ohm.
4. Check the travel regulator’s output, A1/4.

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 Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Code E108
Description Contactor K10 does not open.
Possible error Main contactor points welded.
cause Short circuit in the travel regulator’s output A1/4.
Action 1. Check that the contactor’s contact points are
not welded together.
2. Check that the R1 resistor is not short-
circuited.
3. If the contact points are OK, but the contactor
engaged, check cable 64 and the travel regu-
lator’s output A1/4.

Code E110
Description System error.
Possible error Temporary error/error in the travel regulator.
cause
Action 1. Restart the machine.
2. Replace travel regulator.

Code E140
Description Error in control total.
Possible error Fault on the internal micro-monitoring (tiller arm
cause head), incorrect software or circuit board.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 33

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Code E141
Description Software problem.
Possible error Fault on the internal monitoring (tiller arm head),
cause incorrect software or circuit board.
Action 1. Restart the machine.
2. Download the program again.
3. Replace the electronic card
w

Code E150
Description Fault in the data communication.
Possible error Break on the CAN cable.
cause
Action 1. Check the 119 and 120 cables and their con-
tacts.
2. Replace travel regulator.

Code E151
Description Tx error in data communication.
Possible error Travel regulator not responding.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
2. Replace travel regulator.

Code E157
Description Bus shut off.
Possible error CAN bus problem.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
2. Replace travel regulator.
3. Replace the electronic card

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 Electrical System – 5000
Error codes
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Code E159
Description Transgression error.
Possible error CAN bus problem.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
2. Replace travel regulator.
3. Replace the electronic card

Code E160
Description Error in safety reversing function
Possible error Error in important sensor part.
cause
Action 1. Replace the electronic card

Code E200
Description Open field.
Possible error Shunt field’s circuit open.
cause
Action 1. Check the field winding connections E1 and
E2. Unfortunately it is not possible to measure
ohms for the field winding using a standard
universal instrument, since the winding has a
value as low as 0.3 ohm.
2. Check cables 4 and 5 and outputs S1 and S2
3. Replace travel regulator

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 35

 Electrical System – 5000
Error codes
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Code E201
Description M minus error.
Possible error Problem with switch transistor in the armature cir-
cause cuit inside the travel regulator.
Action 1. Check cable and connections 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 Fault on armature current sensor in travel regula-
cause tor
Action Replace travel regulator

Code E214
Description CAN timeout in power amplifier.
Possible error The motor monitor is reporting an unexpected
cause data loss from the electronic card in the tiller arm
head.
Action 1. Check cables 119 and 120 between electronic
card and travel regulator.
2. Replace electronic card
3. Replace travel regulator.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14.6 Parameters
A • Press and hold S18 while turning S17 to “ON” position.
• Press and hold S18 until P = parameters is displayed.
• You have now selected P = parameters and the symbol “C” is lit as
an indication of what is now shown in the display.
• Press L1 up or down and scroll to the parameter you want to change
E D C B or view.
• Press S18 once to access the parameter.
• Press L1 up or down to specify the parameter value.
• Press S18 once to confirm the change.
• Turn S17 to the off position.
You have now changed the parameter and the new setting will come
into force the next time you start the machine.
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.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 37

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.6.1 Operator parameters – LWE180, 200

Parameter Designa- Unit Min Max. Step Std Description
tion .
01 Travel speed, % 40 100 5 100 Travel speed, Turtle but-
Turtle button ton
40: Slow speed
100: Full speed
02 Max. travel % 40 100 5 100 Max. travel speed
speed 40: Slow speed
100: Full speed
03 Acceleration 10 100 5 50 10: Slow acceleration
100: Fastest acceleration
04 Braking in 5 100 5 50 Indicates motor braking
neutral posi- when the control lever is
tion set to the neutral position.
5: Slight motor braking
100: Maximum motor
braking
05 Log-out 1min 0 20 1 20 Time until truck is
switched off when keypad
is in use. The time is
counted from when the
last power-consuming
component was used.
Value = 0 results in 4
hours.
In increments of 1

14.6.2 arameter description LWE180, 200

Parameter 1
The travel speed when the Turtle button is used can be adjusted.

Parameter 2
The maximum travel speed can be adjusted.

Parameter 3
The lower the parameter value, the longer it takes for the truck to reach
the maximum speed.

Parameter 4
Indicates motor braking power when the (L1) lever is set to the neutral
position. The lower the parameter value, the longer the motor braking
time.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Parameter 5
The time until the truck is switched off when the keypad is in use. The
time is counted from when the last power-consuming component was
used. Value = 0 results in 4 hours.

14.6.3 Operator parameters – LPE200-6

Parameter Designa- Unit Min Max. Step Std Description
tion . s
1 0 0 0 0
02 Max. travel % 10 100 5 100 Max. travel speed
speed 10: Slow speed
100: Full speed
03 Acceleration 10 100 5 80 10: Slow acceleration
100: Fastest acceleration
04 Braking in 5 100 5 70 Indicates motor braking
neutral posi- when the control lever is
tion set to the neutral position.
5: Slight motor braking
100: Maximum motor
braking
05 Log-out 1min 0 20 1 20 Time until truck is
switched off when keypad
is in use. The time is
counted from when the
last power-consuming
component was used.
Value = 0 results in 4
hours.
In increments of 1

14.6.4 Parameter description LPE200-6

Parameter 2
The maximum travel speed can be adjusted.

Parameter 3
The lower the parameter value, the longer it takes for the truck to reach
the maximum speed.

Parameter 4
Indicates motor braking power when the (L1) lever is set to the neutral
position. The lower the parameter value, the longer the motor braking
time.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 39

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Parameter 5
Time until truck is switched off when keypad is in use. The time is
counted from when the last power-consuming component was used.
Value = 0 results in 4 hours.

14.6.5 Operator parameters – LPE200-8

Parameter Designa- Unit Min Max. Step Std Description

tion .
01 Creep speed % 10 100 5 100 Max. travel speed in low-
speed range (gates not
activated)
02 Max. travel % 10 100 5 100 Max. travel speed in high-
speed speed range (gates acti-
vated)
10: Slow speed
100: Full speed
03 Acceleration 10 100 5 80 10: Slow acceleration
100: Fastest acceleration
04 Braking in 5 100 5 70 Indicates motor braking when
neutral posi- the control lever is set to the
tion neutral position.
5: Slight motor braking
100: Maximum motor
braking
05 Log-out 1min 0 20 1 20 Time until truck is
switched off when keypad
is in use. The time is
counted from when the
last power-consuming
component was used.
Value = 0 results in 4
hours.
In increments of 1

14.6.6 Parameter description LPE200-8

Parameter 1
Max. travel speed in the low-speed range. Gates are not activated.

Parameter 2
The maximum travel speed can be adjusted. Gates are activated.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Parameter 3
The lower the parameter value, the longer it takes for the truck to reach
the maximum speed.

Parameter 4
Indicates motor braking power when the (L1) lever is set to the neutral
position. The lower the parameter value, the longer the motor braking
time.

Parameter 5
Time until truck is switched off when keypad is in use. The time is
counted from when the last power-consuming component was used.
Value = 0 results in 4 hours.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 41

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.6.7 Service parameters

A • Connect the CAN key to X41.
• Press and hold S18 while turning S17 to “ON” position.
• Press and hold S18 until P = parameters is displayed.
• You have now selected P = parameters and the symbol “C” is lit as
an indication of what is now shown in the display.
E D C B • Press L1 up or down and scroll to the parameter you want to change
or view.
• Press S18 once to access the parameter.
• Press L1 up or down to specify the parameter value.
• Press S18 once to confirm the change.
• Turn S17 to the off position.
You have now changed the parameter and the new setting will come
into force the next time you start the machine.
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).
14 Crawling -10 10 1 The amount of power the mon-
speed itor should emit when you
reach the first speed sensor
can be specified here.
-10: low speed for the first
speed sensor.
10: high speed for the first
speed sensor
0 LPE200-6/8
-5 LWE180-200
15 Non-config- See “Option parameters” on page 44,
urable option
0 to 9
16 Configurable See “Option parameters” on page 44,
option #1
17 Configurable
option #2
18 Configurable
option #3
19 Configurable
option #4

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Parameter Description Unit Min Max Step Std Description

. . .
20 Hour meter 1 5 1 2 Select hour meter.
option
21 Battery size 1 20 1 Selection of battery size.
5 LPE200-6, LWE180,200
7 LPE200-8
22 Inductive 0 1 1 1 0: Mechanical switch
sensor 1: Inductive sensor
25 Service inter- 1h 0 2000 50 100 Option for setting service timer
val
28 Lift button 1 3 1 1 Button selection
selection
39 Password 1 12 1 1 States which level of authoriza-
tion the driver has for the
parameters.
Odd values specify open driver
parameters, even values spec-
ify that driver parameters must
be opened using the CAN key

14.6.8 Parameter description

Parameter 10
NOTE!
The functionality of parameter #10 is set aside if the value of parame-
ter #39 is set to 5,6,7 or 8. The PIN codes are managed using the so-
called expanded keypad. See section Expanded keypad - General on
page 56 for more detailed information.
Ten drivers can have their own PIN code to gain access to the truck.
Each driver can set all driver parameters individually.
On delivery the PIN code is set to 1 and this only applies for driver no. 1.
Code 0 is not accepted as a solitary code.
When you wish to start the truck enter your code and press the green
button numbered 1.
When you want to switch off the truck, press the red button numbered 0.
When the CAN key is connected, you can start the truck by simply
pressing the green button numbered 1. Switch off by pressing the red
button numbered 0.

Parameter 14
Specifies the speed you will have when you reach the first speed sensor.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 43

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Parameter 15 - Non-configurable option

See “Option parameters” on page 44,

Parameter 16 - Configurable option #1

See “Option parameters” on page 44,

Parameter 17 - Configurable option #2

See “Option parameters” on page 44,

Parameter 18 - Configurable option #3

See “Option parameters” on page 44,

Parameter 19 - Configurable option #4

See “Option parameters” on page 44,

Option parameters
WARNING !
Do not try to change these parameter unless you have specific knowl-
edge of the truck options or truck modifications. This service manual
only covers the truck’s standard equipment. Specially modified
trucks may require you to have 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 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 options function correctly.

Parameter #15 Non-configurable options

Up to 16 so-called sub-parameters are stored under parameter #15.
Their status is either ON or OFF and they do not require any other
adjustments. They are therefore called non-configurable options.

Changing non-configurable options

• Ensure the truck is in parameter mode.

The parameter symbol is lit.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

• Select parameter #15 using [L1].

The first set-up of sub-parameters 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 2: for more information.
• Press the S18 horn button once to confirm the new setting.

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

• Switch off the truck by pressing on the keypad.

The non-configurable option is now activated.
• Check that the function works correctly before the truck is put back
in operation.
P

Table 2: Parameter #15 Non-configurable option

Function name Value Note!
Sub-parameter no.

Function OFF

Basic setting
Function ON

1 "Turtle" function 1 0 0
2 to 9 For future use - - -

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 3:List of
configurable optional functions” on page 48. These are thus called the
configurable optional functions.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 45

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

• 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 independent variable has a value you can change to configure
the function.
Parameter no. (range 16-19)
Independent variable: #0 is the option designation
Independent variable value (range 0-63)
0= no option has been activated for this parameter
1 to 63 = Pre-programmed option number. See separate table.)
16 - 0 - 1

SETTING THE OPTIONAL FUNCTION

Independent variable: #1, #2, #3 & #4 contain the optional function valu
Independent variable value (the range depends on the function referred
The value depends on the option and independent variable selected.
See separate table
16 - 1- 1

CONFIGURING THE OPTIONAL FUNCTION

Fig. 1Summary – option parameter

Changing configurable optional functions

In order to activate a configurable optional function, it must first be
assigned a parameter from #16 to #19. This is done by changing inde-
pendent variable #0 to the pre-programmed option number. Once this
has been done, the independent variable for the option must be config-
ured. This is done by changing the values for independent variables #1,
#2, #3 and #4.
• Ensure the truck is in parameter mode.

The parameter symbol is lit.

• Select parameter #16, #17, #18 or #19 using [L1].

Independent variable #0 is displayed
The independent variable value is displayed after 1 second. The value
“0” means that an optional function has not been assigned to this
parameter, and the speed control L1 in this case displays the next
parameter if you continue to activate it.
• Press the horn button S18.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

The parameter symbol flashes.

• Enter the independent variable value #0 by repeatedly operating the

speed control L1 in either direction. See Table 3:
• Press the S18 horn button once to confirm the new setting.

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

• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.
• Press the horn button S18.

The parameter symbol flashes.

• Enter the independent variable value #1 by repeatedly operating the

speed control L1 in either direction. See the list of optional functions
in Table 3:
• Press the S18 horn button once to confirm the new setting.

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

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

• Switch off the truck by pressing on the keypad.

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

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 47

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Table 3: List of configurable optional functions

Independent Independent vari- Independent var- Independent varia-
variable #1 able #2 iable #3 ble #4
Independent variable #0 = 1: The option button controls the spider output
0:Spider 0 0:Digital output 1 1-6:option button 1-6 Type of function:
1:Spider 1 1:Digital output 2 0:instantaneous
2: :Digital output 3 1:butterfly switch
3: :Digital output 4
Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input
0:Spider 0 0-7:Digital input 1-8 0-12:reduced speed 0:high-speed range
1:Spider 1 40-100% 1:low-speed range
(i.e. 40+5*arg3 e.g. 2: both ranges
4: 40+5*4=60%)
Independent variable #0 = 3:Activate the spider output for specific movements
0:Spider 0 0:Digital output 1 Select movements. Initial position:
1:Spider 1 1:Digital output 2 See Table 4: 0: shines constantly
2: :Digital output 3 1: flashes 1 Hz
3: :Digital output 4 2: flashes 2 Hz
Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input
0:Spider 0 0-7:Digital input 1-8 0-30:Holding time 0- Not used
1:Spider 1 30 minutes

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Table 3: List of configurable optional functions

Independent Independent vari- Independent var- Independent varia-
variable #1 able #2 iable #3 ble #4
Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs
0:Spider 0 0: Lift, digital input 1 0: Blocking of lower- 0: Fork lift/lowering
1:Spider 1 Lowering, digital ing disconnected 1: Support arm lift/lower-
input 2 1: Blocking of lower- ing
Blocking of lower- ing connected
ing, input 3
1: Lift, digital input 2
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
Independent variable #0 = 6:Lift height limitation with by-pass
0:Spider 0 0-7: Limit 1-6: By-pass, Not used
1:Spider 1 switch for option switch 1-6
digital input 1-8

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 49

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Table 4: Option 3 – Choice of movement

Selected movement Independent
variable #3
- 0
Driving forward 1
Driving backward 2
Driving forward or backward 3
Fork lift 4
Fork lift or driving forward 5
Fork lift or driving backward 6
Fork lift or driving forward or driving back- 7
ward
Fork lowering 8
Fork lowering or driving forward 9
Fork lowering or driving backward 10
Fork lowering or driving forward or driving 11
backward
Fork lift or fork lowering 12
Fork lift or fork lowering or driving forward 13
Fork lift or fork lowering or driving backward 14
Fork lift or fork lowering or driving forward or 15
driving backward
All other movements (AOM) 16
Driving forward or AOM 17
Driving backward or AOM 18
Driving forward or driving backward or AOM 19
Fork lift or AOM 20
Fork lift or driving forward or AOM 21
Fork lift or driving backward or AOM 22
Fork lift or driving forward or driving back- 23
ward or AOM
Fork lowering or AOM 24
Fork lowering or driving forward or AOM 25

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Table 4: Option 3 – Choice of movement

Selected movement Independent
variable #3
Fork lowering or driving backward or AOM 26
Fork lowering or driving forward or driving 27
backward or AOM
Fork lift or fork lowering or AOM 28
Fork lift or fork lowering or driving forward or 29
AOM
Fork lift or fork lowering or driving backward 30
or AOM
Fork lift or fork lowering or driving forward or 31
driving backward or AOM

Parameter 20
You decide yourself what the hour meter will show.
1A = Key time
2b = Movement time
3c = Drive motor time
4d =Pump motor time
5s = Time for service

Parameter 21
You must specify the type of battery the truck is equipped with.
In order to set the meter for the battery’s level of discharge, the follow-
ing should be taken into account:
• Acid concentration when the battery is fully charged, to check the
grade of the battery. Must be between 1.27-1.29.
• When the lifting capacity is disconnected (the battery is 80 % dis-
charged), the value must be close to, but not below, 1.14.
The acid concentration can vary depending on the battery make.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 51

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Recommendation on parameter setting for freely

ventilated batteries

Parameter 21 Battery size Battery size

LWE180, LWE200, LPE200-8
LPE200-6
1

Less dis- 2
charge 3
4
5 260Ah - 320Ah
Standard value
6 190Ah - 250Ah
7 120Ah - 180Ah 260Ah - 320Ah
Standard value
8 190Ah - 250Ah
9 120Ah - 180Ah
10
11

Greater dis- 12
charge 13
14
15
16
17
18
19
20

WARNING !
The service 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.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Remove the battery from the truck and allow to rest for at least two
hours. NB! No charging or discharging during this period.
• 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 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.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 53

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Recommendation on parameter setting for valve-

controlled batteries (VRLA)

Parameter 21 Battery size Battery size

LWE180, LWE200, LPE200-8
LPE200-6
1

Less discharge 2 260Ah - 320Ah

3 190Ah - 250Ah
4 120Ah - 180Ah 260Ah - 320Ah
5 190Ah - 250Ah
6 120Ah - 180Ah
7
8
9
10
11
12
13
Greater dis-
charge 14
15
16
17
18
19
20

WARNING !
The service 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.

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Disconnect the battery from the truck and allow the battery to rest for
at least two hours. NB! No charging or discharging during this peri-
od.
• Measure the battery voltage at room temperature. If the voltage is
less than Uend, see the table below, the parameter value must be re-
duced. If the value significantly exceeds 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.

Battery type Battery voltage at rest, Uend

Hawker Evolution 24,24 V

Parameter 22
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1

Parameter 25
Using this parameter you can specify a limit for when the next service is
to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for
a service, warning 29 (C29) is shown in the display.

Parameter 28
Using this parameter you can select which button is to be used for lift/
lower.
1 = Bottom lift/lower button activated (default)
2 = Top lift/lower button activated
3 = Both lift/lower buttons are activated

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 55

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Parameter 39

Login method and driver parameter access

This parameter determines which function will used for log-in and
whether or not the operator is allowed to adjust the operator parameter
settings.
• Value 1 - Key switch installed - Operator parameters accessible
without CAN service key.
• Value 2 - Key switch installed - Operator parameters NOT accessi-
ble without CAN service key.
• Value 3 - Keypad (standard 10 PIN codes) - Operator parameters
accessible without CAN service key.
• Value 4 - Keypad (standard 10 PIN codes) - Operator parameters
NOT accessible without CAN service key.
• Value 5 - Extended keypad (100 PIN codes) - Operator parameters
accessible without CAN service key.
• Value 6 - Extended keypad (100 PIN codes) - Operator parameters
NOT accessible without CAN service key.
• Value 7 - Extended keypad (100 PIN codes) + TLS - Operator pa-
rameters accessible without CAN service key.
• Value 8 - Extended keypad (100 PIN codes) + TLS - Operator pa-
rameters NOT accessible without CAN service key.
• Value 9 – ID unit – Driver parameters accessible without CAN serv-
ice key.
• Value 10 – ID unit – Driver parameters NOT accessible without CAN
service key.
• Value 11 – ID unit + TLS – Driver parameters accessible without
CAN service key.
• Value 12 – ID unit + TLS – Driver parameters NOT accessible with-
out 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 to manage a
maximum of 100 unique PIN codes.
If the expanded keypad function is activated, the standard manage-
ment of PIN codes normally accessible via parameter #10 is set aside.

Expanded keypad - Programming

A number of PIN codes can be made accessible by activating the so-
called block. Block no. 0 is activated as standard. This means that 3 dif-
ferent driver profiles are available from the start. Activation of other

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

blocks means that all PIN codes for the block are accessible (See Table
6:). If all 10 blocks are activated, there will be 10 PIN codes available for
the driver profile.
The truck program stores a standard list of PIN codes as per Table 6:
These PIN codes can be changed to any value, but you should avoid
the same PIN code in different driver profiles.
To start programming the expanded keypad:
• Connect an appropriate CAN service key to X41

• Enter code 341671 and press on the keypad.

• Select the programming command from Table 5:

Table 5: Programming command - expanded keypad

Progamming Function Notes
Reset to factory settings Block 1 - 9 is deacti-
Press “1” + vated. Original PIN
codes reset as per
Table 6:
PIN codes in the block can be B= Block no. 0 - 9
Press “2” + B + used
PIN codes in the block cannot B= Block no. 0 - 9
Press “3” + B + be used
Programming a new PIN code B= Block no. 0 - 9
Press “4” + B + F + NNNN + F= Driver profile no.
0-9
NNNN = PIN code

• Switch off the truck by pressing on the keypad.

The expanded keypad programming is now complete
Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN
codes to be valid.
Carry out a practical test by logging in using some of the new PIN
codes. It is important to establish that the correct driver profile has been
activated when a certain PIN code has been entered, especially if a
specific driver profile has been set for a specific application/goods han-
dling.
Table 6: 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.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 57

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

The truck program does not approve login using the PIN code “0000”.
Service personnel should keep notes on activated blocks, changed PIN
codes and specially-set driver profiles.
NOTE!
Resetting the expanded keypad does NOT affect the driver profile set-
tings.

Table 6: Standard PIN code assignment with the expanded keypad

Driver 0 1 2 3 4 5 6 7 8 9
profile
no.
Block 0 0000 0001 0002 0003 0000 0000 0000 0000 0000 0000
Block 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
Block 8 2876 4731 1022 5377 3257 7334 9009 7881 8843 7436
Block 9 3242 3162 5878 2828 1910 6907 2136 5730 2957 7691
_

Service indication
A • Connect CAN key to X41 and start the truck
• Battery status is shown and symbol “D” is lit
• Press S18 to go to display mode.
See the table below.
E D C B

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Flashing symbol Data

B A speed reference value has been sent
to Curtis
C Digital inputs to Curtis and hall sensors.
* See explanation below
BC Battery voltage (V)
D Armature voltage (A)
BD Field current (A)
CD PWM (pulse width modulation) armature
in percentage
BCD Status of Curtis

*These are displayed by segments of three of the figures being marked

(A).
• The figure with the highest value is active (marked with an arrow).

A • Power amplifier, inputs.

T

Segment Function
A
B
E D C B
C S31, input A1:15
D S10, input A1:12
A
E
F B
G F
G S10, input A1:5
E C
DP DP
D

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 59

 Electrical System – 5000
Parameters
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

• The figure with the second highest value is active (marked with an
arrow).
A • Power amplifier, inputs

Segment Function
A
E D C B B
C Y41, output A1:2
D Y1, output A1:3

A E K10, output A1:4

F H1, output A1:7
F B
G G Y1, output A1:5

E C DP K30, output A1:6

DP
D

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 Electrical System – 5000
Parameters
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

• The figure with the third highest value is active (marked with an ar-
row).
A • Digital input from control sensors.

Segment Function
A
E D C B
B
C
A D Forks up
E Forks down
F B
G F Support arm up

E C G Support arm down

DP DP Horn
D

• The figure with the fourth highest value is active (marked with an ar-
row).
A
Segment Function
A Extra function 6
B Extra function 5
E D C B C Extra function 4
D Extra function 3
E Extra function 2
F Extra function 1
G
DP

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 61

 Electrical System – 5000
Part number
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.7 Part number

A
• Press and hold S18 while turning S17 to “ON” position.
• Press S18 until Pn = part number is displayed.
• You have now selected Pn = part number and the symbol ”D” is lit as
an indication of what is now shown in the display. Initially, Pn =
E D C B number is displayed for the component’s entire unit.
• By scrolling with L1, you can get the following information:
• SPn = Part number for software.
• HPn = Part number for hardware.
• HSn = Serial number for hardware.

14.8 Transistor panel

STATUS
MODEL VOLTAGE
SERIAL CURRENT

14.8.1 General
B+ M-
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 transistors that regulate the
A1
M A2 rotor current.
The rotation direction is changed by changing the polarity in the field
winding (S1-S2). The regulator is equipped with a transistor-fitted four-
quadrant bridge for the field winding and a single-quadrant bridge for
the rotor winding.

S1 S2

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 Electrical System – 5000
Troubleshooting
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14.9 Troubleshooting
14.9.1 Error codes and troubleshooting

STATUS
MODEL VOLTAGE
SERIAL CURRENT

The table below describes the error codes that can be displayed with
the status light or read on the hand unit.

STATUS LED Text on hand unit Explanation Possible cause

LED off - No voltage or error in Defective fuse, poor contact, not
the regulator. connected, error in the regulator.
LED on - Error in the regulator. Error in the regulator.
1,1 ¤¤ CURRENT SHUNT Error in the built-in Error in the rotor current sensor in
FAULT current shunt. the motor monitor.
1,2 ¤ ¤¤ HW FAILSAFE CAN timeout in The motor monitor is reporting an
power amplifier. unexpected data loss from the
tiller arm head.
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short Problem with switch transistor in
circuited to B-. the rotor circuit inside the motor
monitor.
3,1 ¤¤¤ ¤ CONT COIL/FLD Voltage too high for Attempt to extract more current than
SHORT contactor feed or the output device can manage.
short-circuited field Problem regulating the field current.
winding. Internal monitoring error.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding. Shunt field open, defective cable,
defective motor monitor.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage. 1. Battery voltage < 17 volt.
VOLTAGE 2. Battery poles affected by corro-
sion.
3. Loose battery or regulator con-
nections.
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Voltage too high. 1. Battery voltage > 33 volt.
4,3 ¤¤¤¤ ¤¤¤ THERMAL CUT- Too high/too low 1. Temp. > 85oC or < -25oC
BACK temperature reduc- 2. The truck is overloaded.
tion. 3. Incorrectly installed transistor
regulator.
4. Operation under extreme con-
ditions.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 63

 Electrical System – 5000
Troubleshooting
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.9.2 Reset error

When you want to clear an error, first turn S17 to the “OFF” position and
then “ON” again.

Error Reset when

OVERVOLTAGE The battery voltage is below 33 V.
THERMAL CUTBACK The temperature is within the permitted
interval.
THROTTLE FAULT 1, 2 The fault has been dealt with.
LOW BATTERY VOLT- When the battery voltage exceeds 16
AGE V.

14.9.3 Safety
The regulator is a heavy current component. When it is used on a bat-
tery-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.

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 Electrical System – 5000
Technical specifications – Curtis 1243
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

14.10 Technical specifications – Curtis

1243

Value Unit Explanation

Operating voltage 24 Volt
Top voltage limit 33 Volt
Bottom voltage limit 16 Volt Minimum operating voltage
Electrical insulation against cold 500 V AC Minimum
chassis
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
KSI input current 50 mA
Logical voltage value in > 7.5; High Volt
< 1; Low
Logical input current value 15 mA
Operating temperature -40 to +50 °C
Upper temperature limit, reduction 85 °C
Lower temperature limit, reduction -25 °C

* Under special test conditions.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 65

 Electrical System – 5000
TLS - Truck log system (optional)
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.11 TLS - Truck log system (optional)

General
The truck log system, which is CAN based, is either an integrated sys-
tem (SD16) or a freestanding supplementary system (S16). A collision
sensor can also be connected.
The TLS communicates wirelessly with a base station (RG3) once the
truck is within range. The base station then receives information on
what the truck has done since they last communicated with one anoth-
er.

Built-in system PC

A2 RG3
Electronic card
Add-on system
CAN bus

TLS SD16
TLS S16
CAN bus

Shock sensor
Shock sensor

A1
Traction controller I/O-unit

Registration
To register the truck with the base station, follow the instructions below:
• Position the truck close to the base station.
• Press and hold the green button for approx. 5-10 seconds until
three LEDs on the base station start flashing at the same time.
The base station can now communicate with the truck whenever it is
within range.

Logging in/out SD16

Logging in and out is performed as usual via the keyboard on the han-
dle (or by using an ID unit). The difference is that communication pass-
es through the TLS, which makes all the decisions.

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 Electrical System – 5000
TLS - Truck log system (optional)
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Logging in/out S16

Logging in and out is performed using the keyboard on the TLS.

Collision sensor
If there is a collision sensor installed on the CAN bus, it registers when
the truck bumps into something. If the impact exceeds a certain level, it
is classified as a collision and the truck comes to a halt. It can be reset
by entering the PIN code for “resetting the collision sensor” (see table
below).

Settings
Additional equipment (software and wiring) from Davis Derby is
required to change the TLS settings.

Table 7: Settings TLS

Function Description Default setting
PIN code PIN code for different driver 00001 (profile 1)
profiles. 00002 (profile 2)
00003 (profile 3)
11111 (resetting the collision sensor)
Logoff time Time in minutes (1-254) that the 255 (not switched off)
truck is inactive before it is
switched off.
Impact level Determines how sensitive the 5 % (sideways)
truck is to an impact. 5 % (forwards/backwards)
Department Only applies when ID unit is 14
installed.
Type of truck Only applies when ID unit is 16
installed.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 67

 Electrical System – 5000
TLS - Truck log system (optional)
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14.11.1 ID unit (optional)

General
The ID unit is used to start the truck. A smart card or an ID key (see
image below) is used instead of a PIN code. It is standard for 2 ID keys
to be enclosed with the unit. These have standard settings for use with
all types of truck and departments.
Login is performed by pressing the green button and then holding the
smart card/ID key close to the ID unit. If the information on the card is
confirmed, the truck starts with the correct driver profile and the green
LED lights up. If the information on the card is not confirmed, a red LED
lights up for 0.7-0.8 seconds. If no information is detected within 5 sec-
onds, the procedure must be repeated.
Logging off is performed by pressing the red button. The red LED then
lights up for 0.7-0.8 seconds.

A2
Electronic card

Installation
NOTE:
During commissioning of the truck (or the ID unit), the ID unit should
be programmed with a specific department and truck type. To avoid
unauthorised use, rider-controlled trucks and ‘walkie’ trucks, at the
very least, must be programmed as different types of truck.
• Connect the service key.
• Set the ID unit to parameter 39. (If values 9-12 are not available, the
software must be upgraded with the aid of TruckCom.)
• Remove the service key.
• Disconnect the battery contact.
• Replace the keypad with the ID unit. Take care during connection
and disconnection.
• Connect the battery contact.
• Start the truck by pressing the green button and then, within 5 sec-
onds, holding a smart card or ID key close to the scanner on the ID
unit. (If the service key is connected, you need only press the green
button.) The green LED lights up if login was approved, and the red
LED lights up if an invalid smart card/ID key has been used. (Smart
cards/ID keys are preprogrammed with a standardised start code.)
14- 68 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB
 Electrical System – 5000
TLS - Truck log system (optional)
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

• Switch off the truck by pressing the red button. The red LED lights
up.

Settings
Up to 16 types of truck and 14 departments can be used with the sys-
tem. A smart card/ID key can be programmed for several departments
and types of truck, depending on what the driver is authorised to use.
A smart card/ID key can also be used to program the ID unit if the type
of card is changed (see table below). The truck then detects the depart-
ment and type of truck selected on the smart card/ID key. When the ID
unit is programmed, a red LED lights up for 0.7-0.8 seconds.

Table 8: Settings ID unit

Truck Description Default
setting
Department Up to 14 departments in any combination (1-14) All
Type of truck Up to 16 types of truck in any combination (1-16) All
Smart card/ID key Description Default
setting
Department Up to 14 departments in any combination (1-14) 14
Type of truck Up to 16 types of truck in any combination (1-16) 16
Type of card Driver card (1) or programming card (3) 1
Driver profile Profile for different driver parameters (0-9) 0
Driver ID - -

A programming unit from Davis Derby (see image below) is required in

order to be able to program a smart card/ID key. The unit is connected
to a normal PC.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 69

 Electrical System – 5000
TLS - Truck log system (optional)
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

• Connect the programming unit to the PC’s Com port using the ac-
companying cable.
• Turn on the PC and open the programming software.
• Connect the programming unit to the mains power.
See separate manual (232629) for more information on programming.

14- 70 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Electrical System – 5000
TLS - Truck log system (optional)
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

This page is intentionally left blank

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 14- 71

 Electrical System – 5000
TLS - Truck log system (optional)
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

14- 72 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Hydraulic/Pneumatik – 6000
General
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

15- Hydraulic/Pneumatik – 6000

15.1 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.

15.2 Hydraulic chart and list of symbols

LWE180, LWE200
n

Y41
4

M3 P 5

15.2.1 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 Pump
T Tank 1,2 litre (B20 0,5 litre)
Y41 Valve Lowering valve for the forks

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 15- 1

 Hydraulic/Pneumatik – 6000
Adjustments LWE180
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

15.3 Adjustments LWE180

15.3.1 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but
may need to be adjusted if the valve or the complete hydraulic unit is
replaced.
The truck should be capable of lifting a load of between 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 the truck can lift
it.
• If the truck lifts 1800 kg, place a further 100 kg on the forks. Check
whether the truck can lift the load.
• If the truck lifts 1900 kg, adjust the pressure limit by turning the ad-
juster screw (2) anticlockwise using a 4 mm allen key until the truck
cannot lift the load.

15- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Hydraulic/Pneumatik – 6000
Adjustments LWE180
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

15.3.2 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.

A B

12

8
26,5 13,5

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 15- 3

 Hydraulic/Pneumatik – 6000
Adjustments LWE200
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

15.4 Adjustments LWE200

15.4.1 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but
may need to be adjusted if the valve or the complete hydraulic 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 100 kg on the forks. Check
whether the truck can lift the load.
• If the truck lifts 2100 kg, adjust the pressure limit by turning the ad-
juster screw (2) anticlockwise using a 4 mm allen key until the truck
cannot lift the load.

15- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Hydraulic/Pneumatik – 6000
Hydraulic chart and list of symbols
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

15.5 Hydraulic chart and list of symbols

LPE200-6, LPE200-8
n

1 2

Y41
5

M3
P 6

15.5.1 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

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 15- 5

 Hydraulic/Pneumatik – 6000
Adjusting the pressure limit valve
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

15.6 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but
may need to be adjusted if the valve or the complete hydraulic 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 100 kg on the forks. Check
whether the truck can lift the load.
• If the truck lifts 2100 kg, adjust the pressure limit by turning the ad-
juster screw (2) anticlockwise using a 4 mm allen key until the truck
cannot lift the load.

15- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 PowerTrak cylinder – 6680
Component parts
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

16- PowerTrak cylinder – 6680

16.1 Component parts

3

2
4

Pos Description Note

1 PowerTrak spring
2 PowerTrak cylinder
3 Spring guide 2
4 Drive unit

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 16- 1

 PowerTrak cylinder – 6680
Dismantling of PowerTrak cylinder
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

16.2 Dismantling of PowerTrak cylinder

1 Make sure that the truck is unloaded and that the forks are lowered.
2
• Turn the key to neutral and pull out the battery plug.
3
• Dismantle top covers and head.
• Release the hydraulic hose (1).

4
• Carefully unscrew the screws (2) to the clamp (3) that holds the
spring guides.
• Lift out the PowerTrak cylinder (4).
Assemble in reverse order.

49

The measurement between washer and screw head should be 49 mm.

WARNING!
Risk of injury.
There is a risk of personal injury in conjunction with work on the Pow-
erTrak system.
Follow the instructions carefully.

16- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Battery charger (built-in) – 8340
General
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

A B 17- Battery charger (built-in) – 8340

17.1 General
The SMCI 300 is a 24 V battery charger with firmware designed to
charge freely ventilated or valve-regulated plumbic acid batteries (Evo-
lution type). Chargers on trucks with machine numbers 723984-936512
are designed for battery sizes ranging from approx. 100 Ah up to 320
Ah. Chargers on trucks with machine numbers from 936513- are
designed for freely ventilated batteries with sizes ranging from approx.
100 Ah to 350 Ah and for valve-regulated batteries in sizes 134 Ah, 174
Ah and 201 Ah.
The charger relies on state-of-the-art switching technology and should
C be connected to an earthed 220-240 V single phase wall socket (B).
The built-in microcomputer controls the charging process according to
the pre-programmed charging curve. During charging, the charging
process is displayed using a status indicator on the charger panel (A).
The micro-controller also supervises charging with regard to the charg-
ing time and temperature. This enables interruption of charging, for
example if a fault is detected in a battery cell or in case of insufficient
cooling of the charger.
The battery size and battery type can be selected with the switch locat-
ed on the ventilation panel (C). Set the switch using a flat screwdriver.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 1

 Battery charger (built-in) – 8340
Technical data – charger
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

17.2 Technical data – charger

Dimensions 250x115x67 mm
Weight 1.6 kg
Ambient temperature -25° C to +40° C
Line voltage 90-255 V AC 45-400 Hz
Note! The charging current is
reduced in case of a line voltage
below 200 V
Rated voltage 24 V DC
Rated current 30 A
Max. output power 800 W
Efficiency > 86%
Battery types Freely ventilated lead batteries with
water filling, Valve-regulated (VR)
lead batteries
Protection class IP 20
Other Temperature regulated cooling fan
Protected against incorrect polari-
sation.

In order for chargers on trucks with

machine numbers from 936513- to
switch on, the battery voltage must
be between 19.8 and 34.7 V

17.3 Charging
WARNING!
Please note that when charging valve-regulated batteries (Evolution
A B type), the SMCI300 has been designed to charge batteries that are
used in normal room temperature, i.e. +15°C to +30°C. For other tem-
peratures, the charger must be loaded with different firmware, availa-
ble from the charger dealer.

Machine numbers 723984-936512

Connect the charger to the mains (B). A few seconds after charging
starts, the orange status indicator on the parking device (A) lights up.
This indicator remains lit until the battery has been fully charged, at
which time it changes colour to green.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
C
17- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB
 Battery charger (built-in) – 8340
Troubleshooting and service
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

discharged freely ventilated 320 Ah battery may need up to 14 hours of

recharging, while a VR battery may require even longer time.
Once charging has been completed, after a certain time depending e.g.
on the battery type, the SMCI 300 switches to trickle charging. The
green indication remains lit to indicate the battery has been completely
charged.
Following completed charging, return the power plug to the parking
device (B).

Machine numbers 936513-

Connect the charger to the mains (B). Before charging starts, the bat-
tery type will be indicated for three seconds. Continuous green indica-
tion is used for valve-regulated batteries (Evolution type) and continu-
ous orange indication for freely ventilated batteries.
After this, the charger setting is indicated through a number of blinks
corresponding to the selected setting (see Table on page 5)
Charging begins once the charger setting has been indicated. Charging
in progress is displayed by the orange status indicator lighting up next
to the parking device. This indicator remains lit until the battery has
been fully charged, at which time it changes colour to green.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
discharged freely ventilated 320 Ah battery may need up to 14 hours of
recharging, while a VR battery may require even longer time. A 201 Ah
Evolution battery, for example, may require up to 14 hours or recharg-
ing.
Once charging has been completed, after a certain time depending e.g.
on the battery type, the SMCI300 switches to trickle charging. The
green indication remains lit to indicate the battery has been completely
charged.
Following completed charging, return the power plug to the parking
device.

17.4 Troubleshooting and service

First check whether the charger indicates an error. A red blinking indi-
cator means that the charger has not detected any connected battery
or that a battery has not been set with the selection switch. Check the
switch position, cables, terminals and other battery connections. Meas-
ure the battery voltage.
If the charger still does not operate, contact the supplier for service.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 3

 Battery charger (built-in) – 8340
Setting the charger (applies to machine numbers 723984-936512)
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

17.5 Setting the charger (applies to

machine numbers 723984-936512)
Freely ventilated batteries

Switch Battery size I2 current Max. current,

Output trickle charging
current
0 No charging (red LED lit) - - -
1 100-119 Ah 22 A 5.5 A 0.6 A
2 120-144 Ah 26 A 6.6 A 0.7 A
3 145-174 Ah 30 A 8.0 A 0.8 A
4 175-209 Ah 30 A 9.6 A 1.0 A
5 210-249 Ah 30 A 11.5 A 1.2 A
6 250-299 Ah 30 A 13.7 A 1.4 A
7 300-350 Ah 30 A 16.2 A 1.6 A

Valve-regulated batteries

Switch Battery size Output I2 current Max. current,

current trickle charging
8 No charging - - -
9 300-350 Ah 30 A 3.8 A 1.6 A
A 250-299 Ah 30 A 3.4 A 1.4 A
B 210-249 Ah 30 A 2.8 A 1.2 A
C 175-209 Ah 28 A 2.4 A 1.0 A
D 145-174 Ah 22 AA 1.9 A 0.8 A
E 120-144 Ah 18 A 1.5 A 0.6 A
F 100-119 Ah 15 A 1.3 A 0.6 A

17- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Battery charger (built-in) – 8340
Setting the charger (applies to machine numbers 723984-936512)
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

17.5.1 Current levels at different charger

settings (applies to machine numbers
936513-)
Freely ventilated batteries

Switch Battery voltage Battery Battery Indica- Max. charg-

posi- type size tion ing current
tion = I1
0 No charging - - Continuous -
red
1 24 V Freely venti- 100-119Ah 1 blink, 22 A
lated Orange
2 24 V Freely venti- 120-144 Ah 2 blinks, 26 A
lated Orange
3 24 V Freely venti- 145-174 Ah 3 blinks, 30 A
lated Orange
4 24 V Freely venti- 175-209 Ah 4 blinks, 30 A
lated Orange
5 24 V Freely venti- 210-249 Ah 5 blinks, 30 A
lated Orange
6 24 V Freely venti- 250-299 Ah 6 blinks, 30 A
lated Orange
7 24 V Freely venti- 300-350 Ah 7 blinks, 30 A
lated Orange
8 No charging - - Continuous -
red

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 17- 5

 Battery charger (built-in) – 8340
Setting the charger (applies to machine numbers 723984-936512)
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Valve-regulated batteries (Evolution type)

Switch Battery voltage Battery Battery Indica- Max. charg-

posi- type size tion ing current
tion = I1
9 24 V Valve-regu- 134 Ah 1 blink, 23 A
lated green
A 24 V Valve-regu- 174 Ah 2 blinks, 30 A
lated green
B 24 V Valve-regu- 201 Ah 3 blinks, 30 A
lated green
C No charging - - Continuous -
red
D No charging - - Continuous -
red
E No charging - - Continuous -
red
F No charging - - Continuous -
red

17- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Control/computer equipment – 8700
General
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18- Control/computer equipment –

8700
TruckCom 3.5 User Manual -for trucks using the “PowerDrive” platform.
This Manual is valid for version 3.5 of TruckCom p/n 182145-008.

18.1 General
TruckCom is a communication program which communicates with
trucks equipped with CAN (Controller Area Network) communication.
It enables the following tasks to be performed:
• downloading truck control software.
• viewing and adjusting operator / truck parameters and hour meters.
Additionally, the truck’s parameter set (including hour meter values)
can be saved to file and reloaded later.
• viewing diagnostic data for various digital inputs / outputs and ana-
logue data including voltages, currents and certain temperatures.
The program is a Windows program running under Windows® 95/98,
Windows® XP/2000 and Windows® NT.

18.2 Connection
A CAN interface of the CPC-PP type is needed to connect it to the
truck, with attendant cable. Connect the interface via the printer port on
a PC. Connect the cable between the interface and the truck's CAN ter-
minal.
The CAN interface is supplied with power from the truck electronics and
is protected from any high voltages in the truck if a fault should occur.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 1

 Control/computer equipment – 8700
Layout
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.3 Layout

18.3.1 Main program screen

Information
Menu bar window

Tool
buttons

Nodes

Icons

Tool button bar

Fig. 2Main TruckCom program screen

The Main window opens when the program is started. This shows the
menu bar, tool buttons, workspace, log window and status window.

18.3.2 Nodes
Devices which are connected to and communicate via the CAN inter-
face are called nodes. The nodes detected on the bus are shown in the
node window. The current node status and input component/informa-
tion is shown with different icons.

Fig. 3A typical node window dis-

play

18- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Control/computer equipment – 8700
Layout
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18.3.3 Icons
Icon Description
Node OK is shown when contact is made with a
node and no errors have been reported.

Node not connected is shown when there is no

contact with a node in the network.

Node not OK is shown when an error has been

reported by a node. Click on node to obtain more
information.
Program version is shown when information is
available on which software is installed. Click to
obtain more information.
Information is shown when a node has information
on, for example, error codes.

Truck report
GB“18.7Truck report function” on page 7

Parameters is shown when a node has information

on a parameter.

Diagnostics

Exit

18.3.4 Tool buttons and menu bar

The tool button bar allows direct access to the program’s most common
functions. The menu bar allows access to all the program functions.
Explanations of each menu bar item are given in the relevant section.

Search for Disconnect Truck

units from PC Download report

Parameters Diagnostics Information Exit

Fig. 4Tool button bar

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 3

 Control/computer equipment – 8700
Connection function
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.3.5 Information window

The right section of the main window contains a status window where
different messages are shown.
To see previous messages, use the scroll arrows in the right margin.

18.3.6 Status bar

There is a status bar at the bottom of the main window, which shows
variable status when the program is run.

REC MACHINE

The following are shown from the left:

Help text "pop-up" via the mouse cursor, connected/not connected to
network, truck type connected, initiation result of CAN interface and the
present time.

18.4 Connection function

To connect the PC the network, select the Scan units function. This can
be done with the menu <Nodes | Scan units> or with the tool button
[Scan nodes].
This should also be done when the truck is supplied with voltage and in
normal drive mode.
The program will now run a check and installation of the CAN interface.
A diagnosis will also be carried out to check which units are connected
in the system. The result of this diagnosis is shown in the Node window.

18.5 Disconnection function

Select the Disconnect function to disconnect from the network. This
can be done with the menu <Nodes | Set PC off-Line > or with the tool
button [Set PC off-Line].
The CAN interface is then reset and the CAN cable can be disconnect-
ed if so required. This enables connection to another truck without hav-
ing to close the program.

18- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Control/computer equipment – 8700
Downloading program function
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18.6 Downloading program function

To download a new program to one of the nodes, select the Download
software function. This can be done with the menu <Tools | Download
software... > or with the tool button [Download].

Type

123456

18.6.1 Normal downloading (truck with key)

Select Open.. to open the file to be downloaded into a node. The file
name, file type and version number are shown in the window for file
information. If it is file for a controller, indicate which type of controller is
to receive the file. Start downloading by selecting Start... and by restart-
ing the truck by turning the key off and on twice.
Restart must be made within 20 seconds from when the Start button
has been activated.
Close the download window when the download is ready, and then dis-
connect the PC from the network. A new connection can now be made
to verify the new program.

18.6.2 Normal downloading (truck with

keypad)
Select Open to open the file to be downloaded into a node. The file
name, file type and version number are shown in the file information
dialogue box. If it is file for a controller, indicate which type of controller
is to receive the file. Start downloading by depressing and then releas-
ing the red key on the keypad.
The truck must be restarted within 20 seconds from the time the Start
key has been actuated.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 5

 Control/computer equipment – 8700
Downloading program function
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

When downloading has been completed, close the download dialogue

box and then disconnect the PC from the network. It is now possible to
reconnect to verify the new application.

18.6.3 Emergency downloading (truck with

keypad)
• Disconnect the battery connector.
• Select OK in the dialogue box.
• Keep the red key on the keypad depressed while reconnecting the
battery connector.
• Release the red key to commence downloading.

18.6.4 Downloading in old versions of logic

card
To download to older versions of electronic cards which do not support
restart with key, the button Old card... should be used instead of Start...
Downloading is carried out in the same way, except that restart is done
by using the battery lug instead of the key.

18.6.5 Emergency downloading (truck with

keypad)
E141 will be shown in the truck’s display when starting, if for any reason
there is no program in the electronics card (interrupted downloading).
Communication with the truck via the PC will then be minimised. Use
“E141” to download the program in the card.
On some trucks, a counter, which continuously counts up, is displayed.
NOTE!
Once programmed, the logic cards in some trucks can only be up-
graded with the same basic firmware. In other words, it is not possible
to replace the basic firmware (other machine type).

18- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

 Control/computer equipment – 8700
Truck report function
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18.7 Truck report function

It is possible to generate a report to a file or disk with the truck’s config-
uration and status. Select menu <Tools | Generate truck report...> or
with the tool button Truck report. Save the report in Report.file.

NAME

Example of information generated in the truck report:

[GENERAL] [ERROR LOG]
REPORT DATE-TIME=2004-01-19 11:11:58 01=104 00007.5
CPC-PP SERIAL No=8002041 02=104 00007.5
MACHINE NUMBER=555555 03=104 00007.5
CUSTOMER=CUSTOMER 1 04=104 00007.5
TECHNICIAN=NONAME 05=104 00007.5
COMPANY=Other -
NOTES=Test report -
-
[CAN NODES] 09=104 00005.0
MAIN CARD=0
CURTIS DRIVE CONTROLLER=16
[MAIN CARD CONFIGURATION]
SOFTWARE=181179-001 [DRIVER PARAMETERS]
HARDWARE=167833-004 1=100
SERIAL NO=53676 2=100
3=75
[DRIVE CONTROLLER CONFIGURATION] -
SOFTWARE=5 -
DRIVE CURRENT LIMIT (A)=300 -
FIELD MAXIMUM (A)=34 100=0
SERIAL NO=52857
MFG Date:=26/05/03
HOUR METERS]
A IGNITION TIME=81
B TOTAL MOVEMENT=7 [TRUCK PARAMETERS]
C DRIVE MOTOR TIME=7 11=0
D PUMP MOTOR TIME=0 12=0
S SERVICE TIME=7 13=0

The contents of certain rows can vary according to truck type.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 7

 Control/computer equipment – 8700
Parameters function
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.8 Parameters function

To change the truck parameters, select the Parameter function. This
can be done with the menu <Tools | Change parameters > or with the
tool button Parameters.
NOTE!
The truck must in Normal mode (i.e. not Parameter mode) when con-
necting TruckCom. Otherwise TruckCom will report “Unable to deter-
mine truck brand”
The parameter numbers follow the description in the respective truck
Service Manuals, section 5000.
The parameter window shows the information and the current settings
for all parameters. The parameters are divided into 4 tabs.
• [Driver] - driver; driver parameters and PIN code storing
• [Truck] - truck; service parameters
• [Time] - time; time-related service parameters
• [Option parameters] - option parameters. (no. 15 to 19)
WARNING!
Do not attempt to make any adjustments to the option parameters un-
less you have sufficient knowledge of the truck’s options/ modified
functions. Specially modified trucks may require that you have ac-
cess to special service information.
Improper adjustment of the option service parameters may result in a
malfunction.

18.9 Diagnostics function

To access diagnostics, select the Diagnostic function. This can be done
with the menu <Tools | Diagnostic...> or with the tool button Diagnostic.
NOTE!
If the value “---” is shown in a field, or a “read status LED” is red, the
communication has been interrupted for some reason and error data
cannot be shown.
NOTE!
The tab information displayed in the diagnostics mode depends on
the type of truck connected.

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 Control/computer equipment – 8700
Diagnostics function
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18.9.1 Representation of signal colours

The screen dumps shown in the following section have been modified
to improve legibility in black & white print.
WHITE

GREEN

RED

18.9.2 “Tiller arm” tab

Clicking on the tiller arm tab will display a dialogue showing the following:
• Speed lever -the status of the speed control and travel direction se-
lector. The status of each individual hall element is displayed.
• Buttons -The status of the control buttons is displayed. “Sxx” refers
to the switch designations as given in the circuit diagram.
• Option -Status of option buttons
• Battery -The measured battery voltage
• R14 -Shows the measured signal voltage from the lift/lower control
• R15 -Not used at present

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 9

 Control/computer equipment – 8700
Diagnostics function
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.9.3 “Drive Controller” tab (transistor

regulator - travel)

Clicking on the Drive Controller tab will display a dialogue showing the
following:
• Status of digital inputs and outputs of the transistor regulator. pin re-
fers to the motor controller pin designations as given in the circuit di-
agram.
• Field PWM - The effective power output supplied to the field circuit
as a percentage.
• Armature PWM - The effective power output supplied to the arma-
ture circuit as a percentage
• Field current - The current flowing in the field circuit in Amperes.
• Armature current - The current flowing in the Armature circuit in Am-
peres
• Raw throttle data - The received speed control signal as a percent-
age.
• Temperature - The temperature of the output stage of the transistor
controller in degrees Celsius
• Inp pin 10 - The input voltage from the mode/pressure sensor.
“digital o” indicates the digital status of the input.
• Inp pin 11-The input voltage from the man-on platform sensor.
“digital o” indicates the digital status of the input.

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 Control/computer equipment – 8700
Diagnostics function
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18.9.4 “Pump controller” tab (transistor

regulator - pump)

If the truck is equipped with a lift/lower transistor regulator, the Pump

controller tab displays the following:
• Status of digital inputs and outputs of the transistor regulator. pin re-
fers to the motor controller pin designations as given in the circuit di-
agram.
• Field PWM, Armature PWM, Field current, Armature current, Tem-
perature - Measured values from the transistor regulator for the
pump motor. See the explanation on page 10
• Raw throttle data - The received lift/lower signal as a percentage.
• Out pin9 - The output signal to the proportional lowering valve as a
percentage.
• Inp pin 10 - The input voltage from the pressure sensor.
“digital o” indicates the digital status of the input.
• Inp pin 11 - The input voltage from the pressure sensor.
“digital o” indicates the digital status of the input.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 11

 Control/computer equipment – 8700
Diagnostics function
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.9.5 “EPS” steering servo tab

Clicking on the “EPS” tab will display a dialogue showing the following:
“Status”
• “Operational” - Indicates the status of the servo’s control system
• “EPS enabled” - Indicates the status of the servo’s power stage output.
• “Reference switch reached” - indicates status of drive wheel in cen-
tre reference switch.
• “Reference position found” - indicates whether a successful steering
in centre has been performed.
• “EPS in power save mode” - Shows whether the steering servo is in
the standby mode (following a certain amount of inactivity).
“Actual values” (Measured values)
• “Temperature EPS” - The temperature of the steering servo output
stage in degrees Celsius.
• “DC bus voltage” - Supply voltage to steering servo
• “Wheel position” - Shows the estimated steering angle of the drive
wheel.
• “Voltage analog input 1, pin5”- The measured DC input signal (0)
from the steering potentiometer.

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 Control/computer equipment – 8700
Other menu functions
Order number Date Valid from serial number T-code
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• “Voltage analog input 2, pin13”- The measured DC input signal (1)

from the steering potentiometer.
• “Current” - the measured current supplied to the steer servo motor in
Ampere
• “Actual velocity” -The measured rotational speed of the steer servo
motor shaft in r.p.m.

18.10 Other menu functions

18.10.1 Save to file

The truck parameters can be saved in the PC for downloading at a later
date.
Select <File | Save to file | Parameters >. All parameters in the nodes
which are connected to the bus will be scanned in and saved in a file.
If only the hour meters are needed, select <File | Save to file | Hour
meters >.

18.10.2 Download from file

A set of parameters can be downloaded from the PC to the truck. Select
<File | Load from file | Parameters >. The parameters in the file will be
copied to the nodes connected to the bus. If only the hour meter set-
tings are needed, select <File | Load from file | Hour meters >.

18.10.3 Reset CAN adapter

If problems should occur when resetting the CAN adapter connected to
the PC, this can normally be done manually by making sure that the
adapter is supplied with voltage and then selecting <Nodes | Reset
CPC-PP >.

18.10.4 Delete error code log

To delete the truck’s error code log, start the truck in parameter mode
and then select < Tools | Erase error log >.

18.10.5 Reset hour meter

To reset the truck’s hour meter, start the truck in drive mode and then
select < Tools | Reset hour meters >.

18.10.6 Read error code log

To show the truck’s error code log, select < Tools | Read error log >.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 13

 Control/computer equipment – 8700
Specifications
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.10.7 Adjust date and time

To quickly adjust the truck’s data and time, select < Tools | Adjust date
& time >. The time given in the PC will now be downloaded into the
truck.
NOTE!
This does not apply to trucks without a real-time clock.

18.10.8 Adjusting the hour meter on older

cards
To adjust the hour meter on trucks with older cards, select
< Tools | Adjust Hour meters >. The time given in the PC will now be
downloaded into the truck.

18.10.9 Help
About the TruckCom application
To see program information, select <Help | About TruckCom... > or use
the tool button [Information].

18.10.10 Exit
To exit the program, select <File | Exit > or use the tool button [Exit].

18.11 Specifications

Table 9: CAN interface specification

Description Value Unit
Power consumption 40-120 mA
Supply voltage 11-28 V
Transfer rate 125 kbit/s
Storage temperature -20-80 0
C
Operating temperature 0-60 0
C

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 Control/computer equipment – 8700
Installation
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

18.12 Installation
NOTE!
The program must be installed from the hard disk.
NOTE!
The software application in the computer can be damaged, which is
why the PC installation should be performed by someone with the re-
quired knowledge. BT does not accept any responsibility for any er-
rors that occur during the installation.
NOTE!
All references to PC operating system actions, menus and commands
are based on the English language version of Windows®.

18.12.1 Installation on a PC with Windows®

95/98
If a previous version of the TruckCom application has been installed on
the PC, it will be necessary to edit the System.ini file.
Start the Msconfig.exe application by selecting the Start button, select-
ing Run and then typing msconfig.
Click on System.ini and open the folder (386Enh).
Unmark the option at Device=C:\Windows\Cpcppvd.vxd.
Save the change and close the application.
Now continue with installation
The software application is supplied on a CD or via a network. Start
installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found.
Then follow the on-screen instructions.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 15

 Control/computer equipment – 8700
Installation
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

18.12.2 Installation on a PC with Windows XP/

2000
To make the application work, it is necessary to first enter a value in the
Windows® Registry and then make a few changes in the Windows®
Control panel.
Due to the built-in Windows® security, this must be done manually.
The instructions below provide step-by-step guidance to enable these
changes and make the interface operate under Windows XP and Win-
dows 2000.
The changes can be made either before or after TruckCom is installed.
• Open the Registry Editor. To do this, select the Start button, then
Run, type regedit and hit Enter.

• Mark the Enum folder which can be found under

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet inside the
Registry Editor.

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 Control/computer equipment – 8700
Installation
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Select the Edit option, then Find and type PortName to search for the
correct folder.
NOTE!
The location of the folder differs between different computers (some
may be .. \Enum\Root\.., while others could be ...\Enum\ACPI\... etc.).
Thus be sure to search for the correct folder.

When the folder is found, check that LPTx (x=1, 2, 3, 4) is displayed in

the PortName data field and that the folder name is Device Parameters.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 17

 Control/computer equipment – 8700
Installation
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Right-click with the mouse in the right box to enter a new value of the
DWORD type and with the name
EnableConnectInterruptIoctl.

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 Control/computer equipment – 8700
Installation
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Change the value in data field 1 by right-clicking on the name and

selecting Modify.

EnableConnectInterruptIoctl

The Device Parameters folder should look like the one in the picture.

The Registry change is now complete. Close the Registry Editor.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 19

 Control/computer equipment – 8700
Installation
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-03-13 221609-040

Changes in Windows® Control Panel

Select the Start button. Choose Settings, then Control Panel and dou-
ble-click on System, then select Hardware.
Click on Device Manager and open Ports (Com & LPT).

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 Control/computer equipment – 8700
Installation
Order number Date Valid from serial number T-code
221609-040 2006-03-13 723984- 660,661,662

Double-click on the LPT port to be changed, and select the Port Set-
tings tab. Check the "Use any Interrupt assigned to the port" option and
click on OK.

The software application is supplied on a CD or via a network. Start

installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found.
Then follow the on-screen instructions.

18.12.3 Installation on a PC with Windows NT

The software application is supplied on a CD or via a network. Start
installation by running X:\SETUP.EXE, where X:\ is the drive on which
the installation application can be found.
Then follow the on-screen instructions.

18.12.4 In case of communication problems

with CAN
Make sure the computer settings for the printer port in the BIOS Setup
are as follows:
Port address:0378
IRQ: 7
Mode: Output only
For detailed information on how to change the Setup settings, refer to
the User's Guide supplied with the computer.

18.12.5 To uninstall
To uninstall TruckCom under Windows®, select the Start button, Set-
tings, Control Panel, Add/Remove Programs. To uninstall you must
then select the TruckCom Program and click Change/Remove.

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 18- 21

 © BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com