BT LPE200, LPE220 Repair Manual 7572516-040

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bt lpe200 lpe220 repair manual 7572516 040 2

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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: BT Service Manual PDF

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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