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Service Manual En: LWE180, LWE200, LPE200-6/8
Service Manual En: LWE180, LWE200, LPE200-6/8
© BT Europe AB
Issue date Resp. Changes
2004-12-16 ITS Completely new issue (Prel.)
Some chapters in this manual covers only certain of the T-codes above.
1- Table of contents
Tools – P4 6-1
Other tools..................................................... 4
Component parts........................................... 1
7.1.1 Component List .................................................. 2
Maintenance ................................................. 2
10.2.1 Exchange of brake disc ...................................... 2
Maintenance ................................................. 2
11.2.1 Basic Adjustment of gap ..................................... 2
Adjustment: ......................................................... 2
11.2.2 Exchange of brake disc ...................................... 2
Adjustments .................................................. 2
12.2.1 Adjusting of brake microswitch .......................... 2
Tiller arm handle............................................ 3
12.3.1 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
Error codes.................................................. 17
Parameters.................................................. 30
13.6.1 Operator parameters ........................................ 30
13.6.2 Parameter description ...................................... 31
Parameter 1 ...................................................... 31
Parameter 2 ...................................................... 31
Parameter 3 ...................................................... 31
Parameter 4 ...................................................... 31
Parameter 5 ...................................................... 31
General ......................................................... 1
Component parts........................................... 1
General ......................................................... 1
Charging........................................................ 1
General ......................................................... 1
Connection .................................................... 1
Layout ........................................................... 2
17.3.1 Main program screen ......................................... 2
17.3.2 Nodes ................................................................. 2
17.3.3 Icons .................................................................. 3
Disconnection function.................................. 4
Parameters function...................................... 8
Diagnostics function...................................... 8
17.9.1 Representation of signal colours ........................ 9
17.9.2 “Tiller arm” tab .................................................... 9
17.9.3 “Drive Controller” tab (transistor regulator - travel)
10
17.9.4 “Pump controller” tab (transistor regulator - pump)
11
17.9.5 “EPS” steering servo tab .................................. 12
Other menu functions .................................. 13
17.10.1 Save to file ...................................................... 13
17.10.2 Download from file .......................................... 13
17.10.3 Reset CAN adapter ........................................ 13
17.10.4 Delete error code log ...................................... 13
17.10.5 Reset hour meter ............................................ 13
17.10.6 Read error code log ........................................ 13
17.10.7 Adjust date and time ....................................... 14
17.10.8 Adjusting the hour meter on older cards ........ 14
17.10.9 Help ................................................................ 14
About the TruckCom application ....................... 14
17.10.10 Exit ............................................................... 14
Specifications .............................................. 14
Installation ................................................... 15
17.12.1 Installation on a PC with Windows®
95/98 15
17.12.2 Installation on a PC with Windows XP/2000 .. 16
17.12.3 Installation on a PC with Windows NT ........... 21
17.12.4 In case of communication problems with CAN 21
17.12.5 To uninstall ..................................................... 21
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 0,55
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
Fuses
Drive motor circuits, A 125 125 125
Pump motor circuits, A 125 125 125
Control circuits, A 7,5 7,5 7,5
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.
• 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.
4- Preventive maintenance – P2
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 micro- I I/L
switch in the upper and lower brake posi-
tions. 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
1 = The connections are re-tightened for the first time after 80 h, and
then every 1000 h/12 months.
2 = The attachment bolts are re-tightened after 80 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 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.
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.
5000 5000
6680
4110
5110
5700
5000
6600
5400
3100
1700
6100
0380 0000 0560
2550
5000
3500
6100
0000
2550
0380
6- Tools – P4
3
3
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
6680
2
21
20
4 5
6
19
7 8
18 11
9
14 13 12 10
15
17
16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
8.1.2 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.
8- 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 2004-12-16 723984- 660,661,662
8.2 Service/Repairs
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.
• 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.
8.2.3 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.
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
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.
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).
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.
4
7
5 6
Pos No Description
1 Magnetic coil
2 Cap screws
3 Electrical wire
4 Pressure plate
5 Adjustment locking nut
6 Pressure springs
7 Flange
8 Mounting bolts
9 Brake disc
10 Hub
10.2 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.
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
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 and the gap between the
magnetic coil housing and the pressure plate on a regular basis.
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.
9 10
11
13 12
15
14
17 16
18
19
20
21
22
12.2 Adjustments
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
12.3.1 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.
• Disconnect the connection for the switch on the electronic card (4).
• Press out the switch from its mounting.
Assemble in reverse order.
A A
• Unscrew the holder (18) so that the arm (12) comes loose.
Assemble in everse order.
S17 S10
S31
S21
X41
X5
Y1
X1
F50
M3
F51
F1
R1 Y41
K10
F3
M1
K30
A1
H1
A17
G1 Battery 24 V
H1 Horn
X1 Coupling Battery
X9 Connection point CAN communication (Extra
I/O)
X41 Connection point CAN communication (Exter-
nal)
-
A2
M- 13.3.3 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+
13.3.5 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.
13.3.8 Horn
• S18 activated.
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
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.
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.
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.
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.
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
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.
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.
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.
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
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
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.
13.6 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.
Parameter 2
The maximum speed can be adjusted.
Parameter 3
The lower the parameter value, the longer it takes for the truck to
achieve maximum speed.
Parameter 4
Specifies the motor braking power when the lever (L1) is put into neu-
tral. The lower the parameter value, the longer the braking time.
Parameter 5
The time it takes for the truck to switch off when the keypad is used.
The time counts down from the moment the last power-consuming unit
is used.
Value = 0 gives 4 hours.
Parameter 14
Specifies the speed you will have when you reach the first speed sensor.
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.
Function OFF
Basic setting
Function ON
1 "Turtle" function 1 0 0
2 to 9 For future use - - -
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
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.
Less dis- 2
charge 3
4
5 260Ah - 320Ah
Standardvärde
6 190Ah - 250Ah
7 120Ah - 180Ah 260Ah - 320Ah
Standardvärde
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.
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.
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
Parameter 39
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
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
• The figure with the highest value is active (marked with an arrow).
• Power amplifier, inputs.
A 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
• 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
• 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
• 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
STATUS
MODEL VOLTAGE
SERIAL CURRENT
13.8.1 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
13.9 Troubleshooting
13.9.1 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.
13.9.3 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.
14.1 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.
Y41
4
M3 P 5
14.3.2 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
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.
1 2
Y41
5
M3
P 6
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.
2
4
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
16.1 General
SMCI is a battery charger intended for valve-regulated or freely venti-
lated lead acid batteries. It is adapted for batteries from about 100 Ah
up to 320 Ah.
A B The charger which uses advanced switch techniques is connected to a
normal (grounded 230 V single phase) socket (B) and the built-in micro
controller then controls charging following the pre-set charging curve.
During charging the charging process is displayed with a status indica-
tor on the standby housing (A).
The micro controller also controls charging with respect to charging
time and temperature in the charger so that charging can be limited,
e.g. if a fault occurs in some cell in the battery or when there is insuffi-
cient cooling of the charger.
SMCI 300 is delivered pre-set for 24 v and with software intended for
charging valve-regulated or freely ventilated lead acid batteries.
The size and type of the battery are selected using the switch on the
C side of the fan(C) which is accessible via a slotted head screwdriver.
16.2 Charging
Connect the charger to the mains. When charging starts after a few
seconds, the orange status indicator on the standby housing(A) lights
up. Yhis indicator remains lit until the battery is fully charged and the
indicator turns to green.
Charging time varies depending on the type of battery and the degree
of discharge. Normally the charger is started after working hours and
the battery is fully charged the next morning. A highly discharged freely
ventilated battery of 320 Ah may need up to 14 hours re-charging time,
a VR battery even longer.
Some time after charging (depending on, for example, type of battery)
SMCI 300 switches to maitenance charging. The green indicator
remains lit to show that the battery is fully cgarged.
When charging is completed, the mains plug is placed in the standby
housing.
Size 250x115x67 mm
Weight 1,6 kg
Ambient temperature -25°C till +40°C
Mains voltage 90-255 V AC 45-400 Hz
(Reduced charging current for mains volt-
age below 200 V
Rated voltage 24 V DC
Rated current 30 A
Max output 750 W
Efficiency > 86%
Battery type Freely ventilated lead batteries (with
water refilling). Valve regulated (VR) lead
batteries.
Protection IP 20
General Temperature regulated cooling fan, pro-
tected against faulty polarisation
17.1 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.
17.2 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.
17.3 Layout
Tool
buttons
Nodes
Icons
17.3.2 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.
17.3.3 Icons
Icon Description
Node OK is shown when contact is made with a
node and no errors have been reported.
Truck report
GB“17.7Truck report function” on page 7
Diagnostics
Exit
REC MACHINE
Type
123456
NAME
GREEN
RED
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
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
diagram.
• 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.
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.
17.10.9 Help
About the TruckCom application
To see program information, select <Help | About TruckCom... > or use
the tool button [Information].
17.10.10 Exit
To exit the program, select <File | Exit > or use the tool button [Exit].
17.11 Specifications
17.12 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®.
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.
Right-click with the mouse in the right box to enter a new value of the
DWORD type and with the name
EnableConnectInterruptIoctl.
EnableConnectInterruptIoctl
The Device Parameters folder should look like the one in the picture.
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.
17.12.5 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.