BT Forklift LPE200 Repair Manual – PDF DOWNLOAD

BT Forklift LPE200 Repair Manual – PDF DOWNLOAD

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BT Forklift LPE200 Repair Manual – PDF DOWNLOAD

Language : English
Pages : 206
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BT Forklift LPE200 Repair Manual – PDF DOWNLOAD

1. Contents.................................................................  3
2. General introduction.....................................................  9
	2.1 How to use this manual..............................................  9
	2.2 Warning symbols..................................................... 10
	2.3 Pictograms.......................................................... 11
		2.3.1 Screws/Nuts................................................... 11
3. General safety rules..................................................... 13
	3.1 Work safety......................................................... 13
	3.2 Electrical system................................................... 15
	3.3 Safe lifting........................................................ 16
	3.4 Truck modifications................................................. 17
4. Operation and connection sequences....................................... 19
	4.1 Function description................................................ 19
		4.1.1 Operating principle........................................... 19
5. Parameters and adjustments............................................... 25
	5.1 General............................................................. 25
	5.2 Displaying parameters - without the CAN service key................. 26
	5.3 Adjusting operator parameters – without the CAN service key......... 27
	5.4 Displaying & changing parameters - CAN service key connected........ 27
		Changing a parameter................................................ 28
	5.5 List of operator parameters......................................... 29
		5.5.1 Description of operator parameters............................ 30
			# 1 - Creep speed (P320-8)...................................... 30
			# 2 - Max. speed................................................ 30
			#3 - Acceleration............................................... 30
			# 4 - Neutral speed reduction................................... 30
			# 5 - Logout.................................................... 30
			# 9 - OTP - Optimal Truck Performance (option).................. 30
			Travel speed reduction - steering angle......................... 30
	5.6 List of service parameters.......................................... 31
		5.6.1 Description of service parameters............................. 32
			# 10 - PIN code................................................. 32
			To store a new PIN code:........................................ 32
			To delete a stored PIN code:.................................... 33
			# 14 – Creep speed.............................................. 33
			# 15 - Non-configurable options................................. 33
			Setting non-configurable options................................ 33
			# 16 - Configurable option #1................................... 34
			# 17 - Configurable option #2................................... 34
			# 18 - Configurable option #3................................... 34
			# 19 - Configurable option #4................................... 34
			# 20 - Hour meter selection..................................... 35
			#21 - Battery size.............................................. 35
			Instructions for verifying the parameter setting................ 36
			Instructions for verifying the parameter setting................ 37
			# 22 - Brake switch............................................. 38
			# 25 - Service intervals........................................ 38
			# 28 - Button selection......................................... 38
			# 39 - Login method & operator parameter access................. 38
			Expanded keypad - General....................................... 39
			Expanded keypad – Programming................................... 40
		5.6.2 Configurable “Option” parameters.............................. 42
			General......................................................... 42
			Parameters #16 to #19 configurable options...................... 42
			Changing configurable optional functions........................ 43
6. Installation and commissioning........................................... 55
	6.1 Transporting the truck.............................................. 55
	6.2 Transporting the mast............................................... 55
	6.3 Lifting the truck................................................... 56
	6.4 Battery installation................................................ 57
	6.5 Battery replacement................................................. 57
		6.5.1 Changing the battery without the help of a battery changer.... 58
		6.5.2 Changing the battery with a battery changing table............ 59
7. Maintenance.............................................................. 61
	7.1 Introduction........................................................ 61
	7.2 Maintenance instructions............................................ 61
		7.2.1 Cleaning and washing.......................................... 61
		7.2.2 High-pressure washers......................................... 61
		7.2.3 Degreasing agents............................................. 62
		7.2.4 Cleaning the exterior......................................... 62
		7.2.5 Cleaning the chain............................................ 62
		7.2.6 Cleaning the motor compartment................................ 62
		7.2.7 Electric components........................................... 62
	7.3 Checks for cracks................................................... 64
		7.3.1 Visual inspection............................................. 64
		7.3.2 Crack detection............................................... 65
			Crack detection with liquid penetrant........................... 65
			Crack detection with magnetic yoke.............................. 65
	7.4 Maintenance schedule................................................ 66
	7.5 Fuses............................................................... 72
8. Diagnostics and troubleshooting.......................................... 73
	8.1 General............................................................. 73
	8.2 Towing a defective truck............................................ 73
		Tow using a tow truck and tow wagon:................................ 73
	8.3 Error code history.................................................. 74
		8.3.1 List of error codes........................................... 74
	8.4 Transistor regulator troubleshooting and error codes................ 89
		General............................................................. 89
		Transistor regulator error.......................................... 90
		Resetting errors.................................................... 91
		Safety.............................................................. 91
	8.5 Built-in test function.............................................. 92
		Digital inputs/outputs test mode.................................... 93
		Transistor regulator inputs......................................... 93
		Transistor regulator outputs........................................ 94
		Digital input to electronic card [A2]............................... 95
		Extra functions..................................................... 95
	8.6 Display test function............................................... 96
	8.7 Technical specifications – Curtis 1243.............................. 97
9. PowerTrak cylinder....................................................... 99
	9.1 Component parts..................................................... 99
	9.2 Removing the PowerTrak cylinder and spring guides...................100
10. Truck traction..........................................................101
	10.1 Component parts....................................................101
	10.2 Removing the motor from the truck..................................102
		10.2.1 Assembly.....................................................102
	10.3 Service/repairs....................................................103
		10.3.1 Disassembly of the motor.....................................103
		10.3.2 Motor installation...........................................104
		10.3.3 Cleaning.....................................................104
	10.4 Technical data.....................................................105
	10.5 Engine mounts......................................................106
		10.5.1 Component parts..............................................106
		10.5.2 Component List...............................................107
11. Drive/Transmission assembly.............................................109
	11.1 General............................................................109
	11.2 Component parts....................................................110
	11.3 Disassembly of the drive unit from the truck.......................112
	11.4 Assembly of the drive unit in the truck............................112
	11.5 Oil check or change................................................113
		11.5.1 Checking/refilling the oil...................................113
		11.5.2 Oil change...................................................113
	11.6 Replacing the sealing ring.........................................113
		11.6.1 Dismantling..................................................113
		11.6.2 Fitting......................................................114
	11.7 Leakage from top cover.............................................114
12. Brake system/Wheels.....................................................115
	12.1 P320-6.............................................................115
		12.1.1 Main components..............................................115
		12.1.2 Maintenance..................................................116
			Replacing the brake disc........................................116
	12.2 Brake P320-8.......................................................117
		12.2.1 Main components..............................................117
		12.2.2 Maintenance..................................................118
			Replacing the brake disc........................................118
			Adjusting clearance.............................................118
	12.3 Fork wheels........................................................119
		12.3.1 Single wheel installation....................................119
		12.3.2 Fitting the bogie wheel......................................120
	12.4 Fork wheel installation............................................120
		12.4.1 Bogie wheel..................................................120
	12.5 Wheel fork.........................................................122
		12.5.1 Installing new bushings......................................122
		12.5.2 Components...................................................122
13. Steering system.........................................................123
	13.1 Components parts, tiller arm.......................................123
	13.2 Adjustments........................................................124
		13.2.1 Adjusting the brake microswitch..............................124
		13.2.2 Tiller arm handle............................................125
		13.2.3 Disassembling/assembling the steering unit handle............127
			Disassembly.....................................................128
			Assembly........................................................129
14. Electrical system 5000..................................................135
	14.1 General............................................................135
		14.1.1 Part number for software/hardware............................135
		14.1.2 Terminology..................................................136
	14.2 Battery............................................................137
		14.2.1 Replacing the battery........................................137
		14.2.2 Charging the battery.........................................138
	14.3 Hour counter and battery status....................................140
15. Hydraulic system........................................................141
	15.1 General............................................................141
		15.1.1 Tools........................................................141
	15.2 Adjusting the pressure-limiting valve..............................142
16. Fork carriage...........................................................143
	16.1 Adjusting clearance between the fork carriage and frame............143
	16.2 Remove the fork carriage...........................................144
17. Accessories.............................................................149
	17.1 Built-in battery charger (option)..................................149
		Technical data......................................................149
		Charging............................................................150
		Troubleshooting and service.........................................151
		Adjusting the charger...............................................151
	17.2 DC/DC converter....................................................153
		17.2.1 Drilling for 12 V socket installation........................153
		17.2.2 Installation of the DC/DC converter and 12 V socket..........154
		17.2.3 Wiring diagram...............................................155
		17.2.4 Material.....................................................155
	17.3 Spider expansion unit (SEU)........................................156
	17.4 TLS - Truck log system (optional)..................................157
		General.............................................................157
		Registration........................................................157
		Logging in/out SD16.................................................157
		Logging in/out S16..................................................157
		Collision sensor....................................................158
		Settings............................................................158
	17.5 ID unit (optional).................................................158
	17.6 OTP - Optimal Truck Performance....................................159
		Travel speed reduction - steering angle.............................159
18. Instructions for disposal...............................................161
	18.1 General............................................................161
	18.2 Marking of plastics................................................161
		18.2.1 General marking of products and packaging....................161
		18.2.2 Marking according to the manufacturer’s standards............162
			Abbreviations...................................................162
			Marking examples................................................162
	18.3 Pressure vessels...................................................163
		18.3.1 Gas struts...................................................163
	18.4 Sorting categories.................................................164
19. Electrical components and electrical diagram............................167
	19.1 Electric components................................................167
		19.1.1 List of electrical components................................169
	19.2 Wiring diagram.....................................................171
		19.2.1 List of symbols..............................................171
		19.2.2 Overview.....................................................172
		19.2.3 Wiring diagram P320..........................................173
20. Hydraulics schematics...................................................187
	20.1 P320...............................................................187
		20.1.1 List of symbols..............................................187
21. Tool....................................................................189
	21.1 Super Seal connectors..............................................189
	21.2 AMP connectors.....................................................190
		21.2.1 AMP connectors, Multilock series 040.........................191
	21.3 Molex connectors...................................................191
	21.4 Other tools........................................................192
22. Service data and grease specifications..................................195
	22.1 General tightening torques.........................................195
		22.1.1 Galvanised, non-oiled screws.................................195
		22.1.2 Untreated, oiled bolts.......................................195
	22.2 Lubrication chart..................................................196
	22.3 Oil and grease specification.......................................197
23. Technical data..........................................................199