BT LWE130 User manual
© BT Europe AB
Service Manual en
LWE130
Valid from serial number: 914369-
Order number: 226057-040
Issued: 2005-09-23 ITS
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© BT Europe AB Service Manual LWE130 Approved by: L-G Andersson
This manual covers following truck models:
Issue date Resp. Changes
2005-09-23 ITS Completely new issue
T-code Model Serial number
675 LWE130 914369-
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Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 1
Technical data – M4 1-1
Tightening torque .......................................... 4
Introduction Maintenance – P1 2-1
Safety regulations with maintenance work.... 1
Cleaning and washing................................... 3
2.2.1 External cleaning ................................................ 3
2.2.2 Cleaning the motor compartment ....................... 3
2.2.3 Electrical components ........................................ 3
Safe lifting...................................................... 4
Lifting points.................................................. 5
2.4.1 Using a lifting device .......................................... 5
2.4.2 Lifting points, using another fork lift truck ........... 5
Maintenance, Lubrication schedule – P2
3-1
Maintenance schedule .................................. 1
Lubrication schedule ..................................... 5
Oil and grease specification – P3 4-1
Tools - P4 5-1
Super Seal connectors.................................. 1
AMP connectors............................................ 2
5.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors.......................................... 3
Grease guns.................................................. 4
Other tools..................................................... 5
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2 Service Manual LWE130 © BT Europe AB
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
Drive unit/drive gear – 2000 6-1
Component parts.......................................... 1
Service and repairs....................................... 2
6.2.1 Dismantling the motor from the truck .................. 2
6.2.2 Inspection/replacement of the carbon brushes ... 2
6.2.3 Replacing the drive gear ..................................... 3
6.2.4 Cleaning .............................................................. 3
6.2.5 Brakes, Maintenance .......................................... 4
6.2.6 Replacing the brake disc .................................... 4
Steering system – 4000 7-1
Components ................................................. 1
Electrical system – 5000 12-1
General......................................................... 1
12.1.1 Firmware (truck control software) ....................... 1
Nomenclature ............................................... 1
Electrical equipment overview ...................... 2
12.3.1 Electric component overview .............................. 4
Accessing main electrical panel.................... 6
Electrical circuit overview.............................. 7
Symbol list .................................................... 8
Electrical wiring diagram.............................. 9
Functional description.................................. 14
12.8.1 Theory of operation .......................................... 14
12.8.2 Transistor regulator .......................................... 18
General ............................................................. 18
Safety ................................................................ 18
12.8.3 On-board battery charger ................................. 20
General ............................................................. 20
Charging ........................................................... 20
12.8.4 Battery charge status ....................................... 21
Battery display (option) ..................................... 21
12.8.5 Built-in battery charger for charging on trucks .. 22
General ............................................................. 22
Installation recommendations for ‘connection
point’ on truck ................................................... 22
Installation in truck ............................................ 23
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Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 3
Charging ........................................................... 25
Troubleshooting ................................................ 25
Technical data .................................................. 25
12.8.6 Speed limitation ............................................... 26
12.8.7 Hour meter ....................................................... 26
12.8.8 Hand terminal ................................................... 27
General ............................................................. 27
Connecting the hand terminal .......................... 27
Hand terminal overview .................................... 27
Hand terminal menus ....................................... 29
Diagnostic and troubleshooting................... 30
12.9.1 General ............................................................ 30
12.9.2 Display of error codes ...................................... 30
Direct display of error codes ............................. 30
Hand terminal display of error codes ................ 30
Error code history ............................................. 31
12.9.3 List of error codes ............................................ 32
12.9.4 TESTER function ............................................. 35
Parameters & adjustments.......................... 37
12.10.1 General .......................................................... 37
12.10.2 Adjusting parameters ..................................... 37
12.10.3 List of parameters .......................................... 38
12.10.4 Description of parameters .............................. 39
Acceleration ramp time (ACC.DELAY) ............. 39
Deceleration ramp time (DECELER.DELAY) ... 39
Neutral braking intensity (RELEASE BRAKING) .... 39
Reverse braking intensity (INVERSION BRAKING) 39
Maximum travel speed (CUTBACK SPEED 3) 39
Reset service counter (CHECK UP DONE) ..... 39
Select service warning type (CHECK UP TYPE) .. 39
“Time to next service” (CHECK UP HOURS) ... 40
12.10.5 Transferring parameter sets ........................... 40
General ............................................................. 40
From the truck to the hand terminal ................. 41
From the hand terminal to the truck ................. 42
12.10.6 Calibrating the speed potentiometer .............. 42
General ............................................................. 42
Procedure ......................................................... 43
Technical specifications .............................. 44
12.11.1 Transistor regulator SEM-X ........................... 44
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4 Service Manual LWE130 © BT Europe AB
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
Hydraulic system – 6000 13-1
Hydraulic chart and list of symbols................ 1
Description.................................................... 2
Lift ....................................................................... 2
Lower .................................................................. 2
Operating pressure ............................................. 2
Pressure limit valve ............................................. 2
Adjustments.................................................. 3
Adjustment of the pressure limit valve ................ 3
Tools............................................................. 4
Destruction instructions 14-1
General......................................................... 1
Procedure..................................................... 1
Abbreviations................................................ 2
Sorting .......................................................... 2
Chassis (0300).............................................. 3
Hoods, hatches (0340) ................................. 3
Electric Pump Motor (1710) ......................... 3
Drive assembly/drive motor (1760/2550)...... 4
Wheels (3500) .............................................. 5
Tiller arm (4110) ........................................... 5
General electrical equipment (5100)............. 6
Hydraulic unit (6100)..................................... 7
Hydraulic cables/cylinders (6230/6610)........ 7
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Technical data – M4
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 1-1
1-Technical data – M4
Model LW13
Drive motor
Type TSL115-16
Output 0,5 kW
Duty cycle S2, 60 min
Minimum carbon brush length 14,5 mm
Nominal commutator diameter 43 mm
Minimum commutator diameter 40 mm
Resistance, shunt field winding at 25 C° 1,3 Ω
Resistance armature winding at 24 °C 0,0156 Ω
Insulation resistance between the windings and motor casing >=1 Mohm
Weight 25 kg
Brake
Type 891.270.0
Braking force 9 Nm
Output 28 W
Resistance coil 20,8 Ω
Minimum thickness brake disc 6,75 mm
Thickness of a new brake disc 6,90 mm
Transmission/drive gear
Type 2-stage drive gear
Gear ratio 24,8:1
Volume of grease 0,3 kg
Type of grease SHELL RETINAX G
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1-2 Service Manual LWE130 © BT Europe AB
Technical data – M4
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
Wheels
Drive wheel Ø250x60 mm
Axle pressure without load 175 kg
Axle pressure at rated load 570 kg
Tightening torque for wheel bolts 20 Nm
Fork wheel Ø85x75 mm
Axle pressure without load 2x18 kg
Axle pressure at rated load 2x496 kg
Support castors Ø100x40 mm
Axle pressure without load 2x30 kg
Axle pressure at rated load 2x24 kg
Hydraulic system
Output 1,2 kW
Duty cycle 10 %
Minimum carbon brush length 7,5 %
Minimum commutator thickness/diameter 4,75 mm
Pressure at rated load 110 bar
Overflow pressure 130 bar
Pump flow 4,7 litre/minute
Tank volume 1,0 litre
Oil type Hydraulic oil
Normal temperature ISO-L-HM32
Fuses
Drive motor circuits (Common with the pump) 50 A
Pump motor circuits (Common with the drive motor) 50 A
Control circuits 5 A
Battery charger 10 A
Model LW13
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Technical data – M4
Order number Date Valid from serial number T-code
226057-040 2005-09-23 914369- 675
© BT Europe AB Service Manual LWE130 1-3
Battery compartment, Batteries
Dimensions LxWxH 278x175x190 mm
Capacity 50 Ah
Weigh 2x18 kg
Driving speed
Without load 5,4 km/h (1,5 m/s)
With rated load 4,0 km/h (1,1 m/s)
Lift/lowering speed
Lift without load 1,7 s
Lift with rated load 3,0 s
Lowering without load 3,0 s
Lowering with rated load 3,0 s
Power consumption
Driving without load 13 A
Driving with rated load ?
Lift without load ?
Lift with rated load ?
Incline climbing ability
With rated load 5 %
Without load 10 %
Measurement, L2 420 mm
Turning radius WA 1410 mm
Lift height 205 mm
Weight
Truck without battery, Medium 200 kg
Model LW13
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1-4 Service Manual LWE130 © BT Europe AB
Technical data – M4
Tightening torque
T-code Valid from serial number Date Order number
675 914369- 2005-09-23 226057-040
1.1 Tightening torque
Description Amount Tightening
torque Procedure
Screws 820 Nm
Wheel bolts 20 Nm
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