BT LPE200, LPE220 Repair Manual 7572516-040
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BT LPE200, LPE220 Repair Manual 7572516-040

$30.00

  • Type Of Manual: Repair Manual
  • Manual ID: 7572516-040
  • : Service Manual PDF
  • Number of Pages: 614
  • Size: 110.0MB
  • Format: PDF
Category:

Product details

  • Model List:

    • LPE200, LPE220
  • 1. Contents
  • 2. General introduction
  • 2.1. How to use this manual
  • 2.2. Warning levels and symbols
  • 2.3. Pictograms
  • 3. General safety rules
  • 3.1. Work safety
  • 3.2. Electrical systems
  • 3.3. Safe lifting
  • 3.4. Truck modifications
  • 4. Operation and connection sequences
  • 4.1. Symbols on keypad and display
  • 4.2. Battery is connected
  • 4.3. Login via keypad
  • 4.4. Tiller arm lowered for driving
  • 4.5. Driving in fork direction
  • 4.6. Driving in the drive wheel direction
  • 4.7. Neutral position braking
  • 4.8. Reverse braking
  • 4.9. Mechanical braking
  • 4.10. Emergency reversal
  • 4.11. Fork lifting
  • 4.12. Fork lowering
  • 5. Parameters
  • 5.1. General parameters
  • 5.1.1. Show/change parameters
  • 5.2. Operator parameters
  • 5.2.1. Overview
  • 5.2.2. Connection to logged-in operator
  • 5.3. General service parameters
  • 5.3.1. Overview
  • 5.3.2. Description
  • 5.4. Service parameters, travel functions
  • 5.4.1. Overview
  • 5.4.2. Description
  • 5.5. Service parameters, hydraulic functions
  • 5.5.1. Description
  • 5.6. Factory parameters
  • 5.6.1. Overview
  • 5.6.2. Description
  • 5.7. Calibration parameters
  • 5.7.1. Overview
  • 5.8. Calibration
  • 5.8.1. Steering angle calibration 1
  • 5.8.2. Calibration 2 (Not applicable)
  • 5.8.3. Calibration of weight measuring 3
  • 5.8.4. Calibration 4 (Not applicable)
  • 5.8.5. Calibration 5 (Not applicable)
  • 5.8.6. Calibration of weight measuring 6
  • 5.8.7. Calibration 7 (Not applicable)
  • 5.8.8. Calibration 8 (Not applicable)
  • 5.8.9. Calibration 9 (Not applicable)
  • 5.8.10. Steering angle manual steering 10
  • 5.8.11. Calibration of weight measuring 11
  • 6. Installation and commissioning
  • 6.1. Transporting the truck
  • 6.2. Transporting the fork carriage
  • 6.3. Lifting the truck
  • 6.3.1. Lift using an eye bolt
  • 6.3.2. Lift using a jack
  • 6.4. Battery installation
  • 6.4.1. Safety for battery handling
  • 6.4.2. Installing the battery
  • 6.5. Using PIN codes
  • 6.5.1. General
  • 6.5.2. PIN code for resetting after a collision
  • 6.5.3. Programming PIN codes
  • 6.5.4. PIN code defaults
  • 6.6. Setting parameters
  • 6.6.1. Setting impact sensor parameters (option)
  • 6.6.2. Setting battery parameters
  • 6.7. Function check
  • 7. Maintenance
  • 7.1. Introduction
  • 7.2. Maintenance instructions
  • 7.2.1. Cleaning and washing
  • 7.2.2. High-pressure washers
  • 7.2.3. Degreasing agents
  • 7.2.4. Cleaning the exterior
  • 7.2.5. Cleaning the chain
  • 7.2.6. Cleaning the motor compartment
  • 7.2.7. Electric components
  • 7.3. Oil and grease specification
  • 7.4. Symbols
  • 7.5. Periodic maintenance
  • 8. Troubleshooting
  • 8.1. Towing a defective truck
  • 8.1.1. Tow using a tow truck and tow wagon
  • 8.2. Auxiliary functions
  • 8.2.1. Emergency driving mode
  • 8.3. Error code history
  • 8.3.1. Extended error log
  • 8.4. Error code system
  • 8.5. Error codes
  • 8.6. Service information
  • 8.7. Digital input/output status
  • 8.7.1. Test mode 9
  • 8.7.2. Test mode 12 Expansion unit SEU (option).
  • 8.8. Built-in test function for the tiller arm
  • 8.8.1. Display test
  • 8.8.2. Speed control
  • 8.8.3. Safety reversing
  • 8.8.4. Controls for lifting/lowering
  • 8.8.5. Sensilift
  • 8.8.6. Keypad
  • 9. Chassis C0000
  • 9.1. Overview
  • 9.2. Inspection covers C0340
  • 9.2.1. Overview
  • 9.2.2. Replacing the service cover
  • 9.2.3. Replacing a side cover
  • 9.2.4. Replacing the cover (without gate)
  • 9.2.5. Replacing the gate cover
  • 9.2.6. Replacing a badge cover
  • 9.2.7. Replacing an upper cover
  • 9.2.8. Replacing the steering adapter cover
  • 9.2.9. Replacing the rubber seals
  • 9.3. Fork frame C0380
  • 9.3.1. Overview fork frame
  • 9.3.2. Replacing the fork carriage
  • 9.3.3. Checking the fork carriage
  • 9.3.4. Replacing the torsion tube-linkage-wheel fork
  • 9.3.5. Checking the torsion tube-linkage-wheel fork
  • 9.3.6. Replacing the roller on the torsion tube
  • 9.3.7. Weld the push rod
  • 9.4. Battery compartment parts C0390
  • 9.4.1. Battery lock, fixed
  • 9.4.2. Battery lock, quick
  • 9.5. Drive unit suspension C0450
  • 9.5.1. Overview
  • 9.5.2. Overview,
  • 9.5.3. Replacing the drive unit suspension
  • 9.5.4. Relieving spring force using the special tool
  • 9.5.5. Tensioning spring force using the special tool
  • 9.5.6. Adjusting the tool.
  • 9.5.7. Replacing the initial pressure spring
  • 9.5.8. Replacing the PowerTrak spring
  • 9.5.9. Replacing the PowerTrak cylinder
  • 9.6. Platform including fixing points C0560
  • 9.6.1. Overview, Standard and Cold store
  • 9.6.2. Overview, platform
  • 9.6.3. Replacing the platform
  • 9.6.4. Replacing an gas strut
  • 9.6.5. Checking the gas spring
  • 9.6.6. Replacing the spring
  • 9.6.7. Adjusting the platform suspension
  • 9.6.8. Replacing the platform inductive position sensor
  • 9.6.9. Checking the position sensor (B120), std platform
  • 9.6.10. Adjusting the presence sensor
  • 9.6.11. Fixed side guard
  • 9.6.12. Overview
  • 9.6.13. Replacing the fixed side guard
  • 9.6.14. Photo cells, fixed side guard
  • 9.6.15. Overview, platform with fixed side guard
  • 9.6.16. Replacing a platform with fixed side guard
  • 9.6.17. Checking the position sensor (B120), fixed side guards
  • 9.6.18. Adjusting the presence sensor
  • 9.6.19. Adjusting platform suspension
  • 9.6.20. Back guard
  • 9.6.21. Overview
  • 9.6.22. Replacing the back guard
  • 9.6.23. Checking the position sensor (B120), back guard
  • 9.6.24. Adjusting the presence sensor
  • 9.6.25. Adjusting platform suspension
  • 9.7. Operator protection C0840
  • 9.7.1. Gate
  • 9.7.2. Replacing a gate
  • 9.7.3. Replacing the gate damper
  • 9.7.4. Replacing the gate damper
  • 9.7.5. Replacing the pad
  • 9.7.6. Replacing the gate bar
  • 9.7.7. Checking the gate bar
  • 9.7.8. Replacing the upper inductive position sensor
  • 9.7.9. Checking the upper inductive position sensor B121
  • 9.7.10. Replacing the lower inductive position sensor
  • 9.7.11. Checking the lower inductive position sensor B122
  • 9.8. Signs, warnings, labels C0850
  • 10. Motors C1000
  • 10.1. Electric pump motor C1710
  • 10.1.1. Overview
  • 10.1.2. Replacing the pump motor
  • 10.1.3. Replacing the carbon brushes
  • 10.2. Steering motor C1730
  • 10.2.1. Overview
  • 10.2.2. Replacing the steering motor
  • 10.2.3. Removing the control unit
  • 10.2.4. Installing the control unit
  • 10.3. Motor control fans
  • 10.3.1. Overview
  • 10.3.2. Replacing the motor control fans
  • 10.4. Drive motor
  • 10.4.1. Tightening torques – Drive motor
  • 10.5. , 2.5 kW
  • 10.5.1. Overview
  • 10.5.2. Connecting wiring harness 1.8 – 2.5 kW
  • 10.5.3. Replacing the drive motor 1.8, 2.5 kW
  • 10.6. KW
  • 10.6.1. Overview
  • 10.6.2. Connecting wiring harness, 2.8 kW
  • 10.6.3. Replacing the motor 2.8 kW
  • 10.6.4. Replacing the temperature sensor
  • 10.6.5. Replacing the rpm-sensor
  • 10.6.6. Replacing the speed sensor toothed wheel
  • 10.6.7. Cleaning
  • 11. Transmission/Drive gear C2000
  • 11.1. Description
  • 11.2. Gears
  • 11.2.1. Small gear
  • 11.2.2. Overview
  • 11.2.3. Large gear
  • 11.2.4. Overview
  • 11.3. Replacing the drive gear
  • 11.3.1. Removing the drive gear
  • 11.3.2. Fitting the drive gear
  • 11.4. Oil check and oil change, large gear
  • 11.4.1. Draining oil
  • 11.4.2. Checking/refilling oil
  • 11.4.3. Replacing the steering bearing
  • 11.5. Oil check and oil change, small gear
  • 11.5.1. Draining oil
  • 11.5.2. Checking/refilling oil
  • 11.5.3. Replacing the steering bearing
  • 11.5.4. Replacing studs
  • 11.6. Replacing the wheel hub seal
  • 11.6.1. Removing the seal
  • 11.6.2. Fitting the seal
  • 12. Brake system/Wheels C3000
  • 12.1. Brake system C3100
  • 12.1.1. Description
  • 12.2. Parking brake – C3370
  • 12.2.1. Overview
  • 12.2.2. Checking the parking brake gap (adjustable brakes only)
  • 12.2.3. Checking the parking brake gap (only for the small brake 21Nm in standard configuration)
  • 12.2.4. Adjusting the parking brake gap
  • 12.2.5. Emergency release of the parking brake
  • 12.2.6. Replacing the parking brake
  • 12.2.7. Checking the emergency stop/parking brake
  • 12.2.8. Replacing the friction disc
  • 12.2.9. Replacing the brake hub
  • 12.2.10. Cleaning the parking brake
  • 12.3. Drive wheel
  • 12.3.1. Overview
  • 12.3.2. Replacing the drive wheel
  • 12.4. Castor wheels
  • 12.4.1. Replacing the castor wheel assembly
  • 12.4.2. Checking the castor wheels
  • 12.4.3. Replacing the castor wheel (single)
  • 12.5. Fork wheels
  • 12.5.1. Replacing single wheels
  • 12.5.2. Replacing bogie wheels
  • 12.5.3. Replacing the wheel fork bushing
  • 12.6. Wheel wear
  • 13. Steering system C4000
  • 13.1. Steering arm C4110
  • 13.1.1. Overview
  • 13.1.2. Replacing the keypad C9420
  • 13.1.3. Replacing the tiller arm cover
  • 13.1.4. Replacing the upper cover C4110
  • 13.1.5. Replacing the tiller arm handle
  • 13.1.6. Replacing the logic card
  • 13.1.7. Checking the handle
  • 13.1.8. Update the software
  • 13.1.9. Replacing the signal button/switch
  • 13.1.10. Replacing the lift/lower button
  • 13.1.11. Replacing the button
  • 13.1.12. Replacing the symbol disc – support arm lift/fork lift
  • 13.1.13. Replacing the safety reversing switch
  • 13.2. Steering arm C4110
  • 13.2.1. Overview steering arm manual steering
  • 13.2.2. Overview steering arm power steering
  • 13.2.3. Replacing the tiller arm (manual and power steering)
  • 13.2.4. Replacing the tiller arm suspension (manual and power steering)
  • 13.2.5. Replacing the safety switch (manual and power steering)
  • 13.2.6. Replacing the steering yoke
  • 13.3. Tiller arm, E-man
  • 13.3.1. Overview, tiller arm E-man
  • 13.3.2. Replacing the tiller arm cover (E-man)
  • 13.3.3. Replacing the upper cover (E-man)
  • 13.3.4. Replacing the tiller arm handle (E-man)
  • 13.3.5. Replacing the safety switch (E-man)
  • 13.3.6. Replacing the tiller arm (E-Man)
  • 13.4. Power steering
  • 13.4.1. Safety
  • 13.4.2. Overview
  • 13.5. Steering angle sensor C4350
  • 13.5.1. Replacing the steering angle sensor servo unit
  • 13.5.2. Replacing the steering damper
  • 13.5.3. Calibrating the steering damper/reference sensor
  • 13.5.4. Steering adapter (power steering)
  • 13.5.5. Replacing the gas strut – height adjustment
  • 13.5.6. Replacing the lock – height adjustment
  • 13.5.7. Checking the lock – height adjustment
  • 13.5.8. Replacing the steering adapter (power steering)
  • 13.5.9. Replacing the steering bearing (power steering)
  • 13.5.10. Replacing the mechanical stop of the steer axle (power steering)
  • 13.6. Mechanical steering
  • 13.6.1. Overview
  • 13.6.2. Steering adapter, mech. steering
  • 13.6.3. Replacing the steering adapter (fixed)
  • 13.6.4. Replacing the steering angle sensor
  • 13.6.5. Replacing the steering bearing – mechanical steering
  • 13.6.6. Replacing the mechanical stop of the steer axle
  • 14. Electrical system C5000
  • 14.1. General
  • 14.1.1. Truck firmware applications
  • 14.2. Menus
  • 14.2.1. Menu navigation
  • 14.2.2. Menu information
  • 14.2.3. Display hour counter values
  • 14.2.4. Show error codes
  • 14.2.5. Show part numbers for software/hardware
  • 14.2.6. Built-in test A5 (A5)
  • 14.2.7. Show collisions
  • 14.2.8. Show/change parameters
  • 14.2.9. Emergency driving mode
  • 14.2.10. Calibration
  • 14.2.11. Show/change PIN code
  • 14.3. Battery C5110
  • 14.3.1. Battery replacement
  • 14.3.2. Charging the battery
  • 14.4. Electric panel
  • 14.4.1. Overview
  • 14.5. Motor control T1 (ACT)
  • 14.5.1. General
  • 14.5.2. Replacing the motor control
  • 14.5.3. Replacing the pump contactor
  • 14.5.4. Replacing the main contactor
  • 14.6. Horn C5160
  • 14.6.1. Horn P4
  • 14.7. Control system
  • 14.7.1. Direction selector/speed regulator
  • 14.7.2. Safety reversing
  • 14.7.3. Battery indicator
  • 14.7.4. Hour counter
  • 14.7.5. Lifting and lowering control – support arm/fork lift
  • 14.7.6. Signal buttons
  • 14.7.7. Option buttons
  • 14.7.8. Display
  • 14.7.9. Keypad/ID unit
  • 14.7.10. Weighing system
  • 14.7.11. Pressure equalization
  • 14.7.12. Logic card (A5)
  • 14.8. Work function harness/fuse
  • 14.8.1. Fuse panel overview
  • 14.9. Sending units and sensors C5800
  • 14.9.1. Inductive sensors
  • 14.9.2. Position sensor
  • 14.9.3. Steering reference sensor
  • 14.9.4. Pressure sensor
  • 14.9.5. Pulse transducer
  • 14.10. Safety sensor
  • 14.10.1. Emergency switch off S21
  • 14.10.2. Photocell
  • 15. Hydraulic system C6000
  • 15.1. General
  • 15.2. Hydraulic hygiene
  • 15.2.1. Washing
  • 15.2.2. Packaging
  • 15.2.3. Handling
  • 15.2.4. Storage
  • 15.2.5. Work procedures
  • 15.3. Hydraulic system
  • 15.3.1. Overview
  • 15.3.2. Hydraulic unit
  • 15.3.3. Tightening torques for hydraulic unit
  • 15.3.4. Replacing the hydraulic unit
  • 15.3.5. Tank
  • 15.3.6. Changing oil
  • 15.3.7. Replacing the tank
  • 15.3.8. Valve unit
  • 15.3.9. Hydraulic pump
  • 15.3.10. Replacing the hydraulic pump
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