Service Manual En: LWE180, LWE200, LPE200-6/8
Service Manual En: LWE180, LWE200, LPE200-6/8
Service Manual En: LWE180, LWE200, LPE200-6/8
© BT Europe AB
Document revisions:
1- Table of contents
2- Technical data ..................................................................................... 2-1
2.1 General tightening torques............................................................. 2-4
2.1.1 Galvanised, non-oiled bolts ............................................. 2-4
2.1.2 Untreated, oiled bolts ....................................................... 2-4
2- Technical data
NOTE:
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will achieve the correct torque value for
galvanised bolts. Do not tighten more than the values set out in the ta-
ble, as the bolts may otherwise be destroyed.
3- Introduction, maintenance
All points in the service program shall be included to attain the highest
safety and a least possible truck downtime. The service intervals are
only a guide and do not need to be followed strictly. The truck driver
must adapt these to local conditions, but it is important that the intervals
meet BT's minimum demands.
The service intervals are based on operating times and can be adapted
to most normal 8 hour shifts. The following operating hours have be
used when calculating the interval.
Day time: 08.00-17.00 (20 hours/week)
2-shifts: 06.00-14.00, 14.00-22.00 (40 hours/week)
3-shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)
Ensure the truck is given regular maintenance services according to
the maintenance schedule. The truck's safety, efficiency and service
life is dependent on the service and maintenance it is given.
Only use BT approved spare parts during service and repairs
• Bear in mind that the oil in the transmission and hydraulic system
can be hot.
WARNING!
Risk of burn injuries
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only new and clean oil may be used in the hydraulic system.
WARNING!
The hydraulic system can be damaged.
Hydraulic components can be damaged, if the oil is contaminated.
Always use new and clean oil in the hydraulic system.
• Store and transport changed oil according to applicable local direc-
tions.
• Do not flush solvents and the like used for cleaning down drains that
are not intended for this purpose. Follow local directions that apply
for destruction.
• Disconnect the battery when welding on the truck.
NOTE!
The battery can be damaged.
When using electric welding equipment, the welding current can en-
ter the battery.
The battery must be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
using sand blasting equipment or paint remover when welding or
grinding on painted surfaces.
CAUTION!
Unhealthy gases.
Heated paint gives off unhealthy gases
Remove 100 mm of paint from around the working area.
1= Connections are tightened for the first time after 500 hours and then
every 1000 hrs/ 12 months.
2= Mounting bolts are tightened after 500 hrs/6 month to 45 Nm.
3= Check for leakage in connection with the first oil change.
4= The oil is changed for the first time after 500 hrs/6 month and then
every 3000 hrs/36 months.
5= The oil is changed and the filter cleaned for the first time after
500 hrs/6 month and then every 1000 hrs/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 time intervals are addressed, the points with
shorter time intervals should also be addressed unless otherwise stat-
ed above.
5000 5000
6680
4110
5110
5700
5000
6600
5400
3100
1700
6100
0380 0000 0560
2550
5000
3500
6100
0000
2550
0380
3- 10 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB
Introduction, maintenance
Oil and grease specification
Order number Date Valid from serial number T-code
221609-040 2006-11-17 723984- 660,661,662
4- Tools
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
and nozzle.
5.1 Maintenance
The support arms should be greased regularly according to the mainte-
nance schedule.
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
7.1.2 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.
7.2 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.
7.2.3 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.
8.1 General
These service instructions cover descriptions of service performed at
the customer site. Complete reconditioning of the driving gear must be
performed in the workshop by trained technicians.
2
3
5
16
15
14
13
9
8
7
6
12
11
10
8.6.1 Disassembly
1. Disassemble the drive unit from the truck.
2. Remove the lower cover.
3. Loosen the nut. Remove the nut and washer.
4. Press out the drive shaft.
5. Pull of the bearing from the drive shaft is a bearing remover.
6. Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing remover, then measure the to-
tal thickness of the spacing washers and replace them prior to as-
sembly.
7. Remove the gasket ring from the drive shaft.
8.6.2 Assembly
Following replacement of the gasket ring, follow the instructions below.
1. Position the outer bearing of the drive shaft in the gear housing.
2. Press the new gasket ring into the gear housing.
When pressing the gasket ring into place, exercise care to make
sure it is correctly positioned.
3. Press the drive shaft into the gear.
Check to make sure the drive shaft splines interconnect with the
drive wheel splines.
4. Screw on the nut and tighten to the torque indicated in the table.
Be sure to always to use a new nut. Prior to assembly, apply
grease on the nut.
5. Before fitting the lower cover, assemble a new seal and apply Loc-
tite.
6. Replace the cover and tighten the bolts to the torque indicated in
the table.
Make sure the seal is not damaged. Prior to assembly, apply
grease on the bolts.
7. Fill with oil.
8. Assemble the drive wheel and tighten the wheel nuts diagonally to
the torque indicated in the table.
Prior to assembly, apply grease on threads.
9. Install the drive unit in the truck.
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
9.1.2 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
9.2.2 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.
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.
9 10
11
13 12
15
14
17 16
18
19
20
21
22
10.2 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
10.3.1 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.
11.1 General
The electrical system of the truck is based on the PowerDrive platform.
• The main power source is a 24 V DC traction battery.
• The travel drive motor is a separate excitation type (SEM) . The trav-
el drive motor is operated by an enclosed transistor regulator relying
on pulse width modulation (PWM) technology. The transistor regula-
tor also controls the input and output signals for truck travel and lift-
ing operations.
• The lift unit motor is a conventional DC motor without any external
field winding connections. Switch-on of the hydraulic unit's electric
motor is achieved using a contactor.
• All electric units communicate via a CAN bus with an IC card in the
steering unit handle. This card contains a processor and software
that controls and monitors truck functions. A set of parameters used
to adjust truck functions and characteristics is stored in the card. The
card also monitors error conditions that may occur.
11.1.2 Nomenclature
Items shown in square brackets [ ] refer to electric component designa-
tions as stated in the electrical wiring diagrams. See “11.2.1 Electric
component overview” on page 5.
{high} refers to a voltage level that is approximately the same as the
supply voltage level.
{low} refers to a voltage level of approximately 0 Volt.
1
10
18
S113 S116
S112 S115
S111 S114
S18:1 S18:2
A2:S20
A2:S19
A2:S22
A2:S21
L1 A2:S17 L1
A17
S31 S17
X41
F50
F51
A30 R1
F1
K10
F3 Y1
K30 M1
A1
H1
X1
G1
S10
S53
S17
M3
P1
S19 Y41
S59
E1 S E2
11.3.2 Overview
2 1
3 F1 R1
(+) POWER 24VDC M1
24 6 A2 A1 X1
(16) SUPPLY 24VDC ARMATURE (M) M
40
(-) POWER 0VDC
4 S
G1
+
E2 E1
FIELD (S2)
-
ONLY 8 KM/H
5 X1
FIELD (S1)
63
(10) PRESSURE SWITCH
P1 K10 40
p 64
MAIN CONTACTOR (4)
49
(15) LIFT LIMIT CHARGER
S31 F51
A1 21
S21
24 57
(12) TILLER ARM IN DRIVE POS. F3
S10 M3
A1 A2
M
OPTIONS
ONLY 8 KM/H
45 24
PUMP CONTACTOR (6)
65 K30
(11) MAN ON PLATFORM H1
S19
39
SIGNAL HORN (7) Y1
66 31
(13) PLATFORM NOT BRAKE A (5)
FOLDED UP Y41
38
S59 LOWER VALVE (2)
58
(14) GATES UP
CAN HIGH/LOW
S53 (1/8)
24 F52
X41 F50
20
40 120 EXT. EQUIP.
119
OPTION ONBOARD CHARGER
1/6 Prod C
224726
2/6, Prod C
224726
INP. SUPPLY +24VDC
TRANSISTOR REGULATOR
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
© BT Europe AB
A2
KEY
S17 X5
20 22
Sh. 1 X3 2 INP. +24VDC
X5
119 119
Date
X5
120 120
2006-11-17
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
S18:2
660,661,662
X1 1 INP. HORN 2
1 2
224726
Electrical wiring diagram
Electrical System – 5000
3/6, Prod C
11- 11
Electrical System – 5000
Electrical wiring diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-11-17 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
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
723984-
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
2006-11-17
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
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
A1 A2 45
6 OUT. PUMP CONTACTOR
Y41
11.3.4 Wiring Diagram LPE200-8
1 2 38
2 OUT. LOWER VALVE
660,661,662
H1 39
7 OUT. SIGNAL HORN
- +
IN
221397
Electrical wiring diagram
Electrical System – 5000
1/11, Prod C
11- 15
11- 16
T-code
660,661,662
TRANSISTOR REGULATOR
Electrical wiring diagram
A1
EMERGENCY SWITCH OFF
S21
21 1 2 24
Sh. 1 16 INP. SUPPLY +24VDC
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
3
40
Sh. 1 3
Date
119 119
Sh. 3 1 CAN HIGH
2006-11-17
120 120
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
2006-11-17
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
S18:1
1 2
X4 1 INP. HORN 1
1 2
X1 1 INP. HORN 2
660,661,662
221397
Electrical wiring diagram
Electrical System – 5000
3/11, Prod C
11- 17
Electrical System – 5000
Electrical wiring diagram
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-11-17 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
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
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
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
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
2006-11-17
221397
8/11, Prod C
© BT Europe AB
Electrical System – 5000
Electrical wiring diagram
Order number Date Valid from serial number T-code
221609-040 2006-11-17 723984- 660,661,662
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
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
© BT Europe AB
OPTION
ONBOARD CHARGER
Date
S170 K10
24 23 A1 A2 64
Sh. 10 4 OUT. MAIN CONTACTOR
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
221397
Electrical wiring diagram
Electrical System – 5000
11/11, Prod C
11- 25
Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-11-17 221609-040
A2
Electronic
card
TLS
A36 Extra / Customised
A5 SEU function(s)
Steer servo
CAN bus
A3
Pump
controller
X41
CAN service
connector
A1
Traction
controller
Fig. 1 Connection architecture for SEU
Fig. 1 shows how the SEU is used to allow a greater number of func-
tions to be controlled via the CAN bus. The SEU has one 42-pin mul-
tipin connector which handles all inputs, outputs, CAN and supply sig-
nals.
© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 11- 31
Electrical System – 5000
Functional description
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-11-17 221609-040
Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
Drive motor time:
Total time drive motor has been in operation
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.
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.
Technical data
Charging
WARNING!
Please note that when charging valve-regulated batteries (Evolution
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 number 723984-936512
The charger is designed for batteries with a capacity from approx. 100
Ah to 320 Ah.
Charging starts automatically when the charger is connected. During
charging, the status indicator lights in orange. When charging has been
completed, the status indicator switches to a green light.
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.
The charger has a built-in monitor system that monitors the tempera-
ture and charging duration. If a fault occurs, the charger can interrupt
the charging process or limit the amount of charging.
Machine number 936513-
The charger is designed for freely ventilated batteries with a capacity
from approx. 100 Ah to 350 Ah as well as for valve-regulated batteries
with capacities of 134 Ah, 174 Ah and 201 Ah.
When connecting the charger, first the battery type is indicated. For
valve-regulated batteries, the indicator lights green for three seconds,
while for freely ventilated batteries it lights orange for three seconds.
After this, the charger setting is indicated through a number of blinks
corresponding to the selected setting (see “ Adjusting the charger” on
page 37).
Once the setting has been indicated, charging starts. During charging,
the status indicator lights in orange. When charging has been complet-
ed, the status indicator switches to a green light.
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.
The charger has a built-in monitor system that monitors the tempera-
ture and charging duration. If a fault occurs, the charger can interrupt
the charging process or limit the amount of charging.
Valve-regulated batteries
Switch Battery size Output I2 current Max. current, trickle
current 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
11.5.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Operator parameters and Service parameters.
• Operator parameters (1 to 9) - These parameters are used to tailor
the driving characteristics of a truck for a specific operator or opera-
tion. A maximum of 10 operator parameter sets, so called operator
profiles, can be stored in a truck. Operator parameters can be ad-
justed directly without the requirement for a suitable CAN service
key.1
• Service parameters (10 to 40) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as operator parameters. Service
parameters can ONLY be adjusted when a suitable CAN service key
is plugged into the truck.2
Fig. 6
Parameters symbol lights.
When pressing the speed control [L1] forwards repeatedly, the first
operator profile will be displayed. Continue to press [L1] in the forward
direction and the next operator profile will be displayed (operator no. 2),
etc. until the last operator (operator no. 10). See Fig. 7
Once the 10 operator profile have been displayed, the truck service
parameters will be displayed as [L1] is repeatedly pressed in the for-
ward direction.
Operator parameter no.
Profile no. Changing a parameter
Fig. 7 • Select the required parameter.
• Press horn button [S18].
# 3 - Acceleration
The lower value of the parameter the longer time it takes to accelerate
the truck to top speed.
# 5 - Logout
The time until the truck will be switched off when a key pad is used.
Time is counted from when the latest power consumer is used.
Value = 0 gives 4 hours.
# 14 - Creep speed
Defines the speed you will get when you reach the first speed sensor.
Function OFF
Basic setting
Function ON
1 "Turtle" function 1 0 0
2 to 9 For future use - - -
2 Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
3 Drive motor time:
Total time drive motor has been in operation
# 21 - Battery size
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.
Recommendation on parameter setting for freely ventilated batteries
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.
# 22 - Brake switch
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1
# 25 - Service interval
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.
# 28 - Button selection
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
A driver profile is activated, on normal login, by all PIN codes whose block
no. is activated.
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.
General
Parameters #16 to #19 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parame-
ters configure and control the behavior of the Spider expansion unit
(SEU) which must be fitted in the truck. See “11.4.2 Spider expansion
unit (SEU)” on page 31. This method of implementation allows the
standard software program to be used without the need for a special-
ised software. Normally, these parameters are configured by the manu-
facturer when the truck is modified or customized. It is advisable to up-
load the parameter settings from trucks which are modified. In the event
the main control card[A2] is changed, the original parameter settings
can then be transferred to the new card thus ensuring the special option
functions correctly.
Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a
maximum of 4 preprogrammed “base options” to be activated and con-
figured to suit a specific special option or customisation. See table
below.
OPTION ASSIGNATION
Argument: #1, #2, #3 & #4 hold configurable values for the option
Argument value (range depends on argument)
Value depends on option and argument selected
See separate table
16 - 1- 1
OPTION CONFIGURATION
Table 18: Base option 6 - Lift height restriction by SEU i/p &
override
Argument #0 Option designator
Initial display Values Meaning
6 Sets relevant option parameter to handle base option 6
11.6.1 General
The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control [L1].
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 posi-
tion.
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 bat-
tery contacts.
4. If PTC resistor R1 is very hot, remove the bat-
tery 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.
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 con-
nections 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.
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.
B+ M-
STATUS
MODEL VOLTAGE
SERIAL CURRENT
A1
M A2
General
Curtis 1243 is a regulator [A1] for controlling shunt motors. Varying the
voltage applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
S1 S2
involves varying the “on” time of the MOS-FET transistors regulating
the armature current.
Switching of the rotational direction is achieved by switching the polari-
ty on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
tor bridge for the armature winding.
STATUS
MODEL VOLTAGE
SERIAL CURRENT
Resetting errors
To reset an error turn [S17] to off and then on again.
Safety
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
WARNING!
Risk of short-circuiting.
Remove all watches, jewellery and always use insulated tools only.
6 PWM Armature in %
7 Status Curtis
Horn [A2:S18]
Extra functions
Extra function 5
Extra function 4
Extra function 3
Extra function 2
Extra function 1
12.1 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
12.3.2 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
49