BT LPE200, LPE220, LPE250 Repair Manual 7572514

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BT LPE200, LPE220, LPE250 Repair Manual 7572514

$30.00

Type Of Manual: Repair Manual
Manual ID: 7572514
: Service Manual PDF
Number of Pages: 528
Size: 34.4MB
Format: PDF

Category: BT Service Manual PDF

Model List:
- LPE200, LPE220, LPE250

1. Table of 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. Login via ID key option
4.5. Tiller arm lowered for driving
4.6. Driving in fork direction
4.7. Driving in the drive wheel direction
4.8. Neutral position braking
4.9. Reverse braking
4.10. Mechanical braking
4.11. Emergency reversal
4.12. Fork lifting
4.13. 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. Hydraulic calibration 2
5.8.3. Calibration of weight measuring 3
5.8.4. Calibration of overload 4
5.8.5. Calibration of tilt angle 5
5.8.6. Calibration of weight measuring 6
6. Installation and commissioning
6.1. Transporting the truck
6.2. Transporting the mast
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 when handling batteries
6.4.2. Installing the battery
6.5. Managing 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 collision 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. Hoods, covers C0340
9.2.1. Overview
9.2.2. Replacing the service cover
9.2.3. Replacing the side cover
9.2.4. Replacing the cover (without gate)
9.2.5. Replacing the gate cover
9.2.6. Replacing the emblem cover
9.2.7. Replacing the upper cover
9.2.8. Replacing the steering adapter cover
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
9.4. 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. Replacing the initial pressure spring
9.5.7. Replacing the PowerTrak spring
9.5.8. Replacing the PowerTrak cylinder
9.6. Platform including fixing points C0560
9.6.1. Overview, Standard and Cold store
9.6.2. Overview, platform with fixed side guard
9.6.3. Overview, platform
9.6.4. Replacing the platform
9.6.5. Replacing a platform with fixed side guard
9.6.6. Replacing the gas spring
9.6.7. Checking the gas spring
9.6.8. Replacing the spring
9.6.9. Adjusting platform suspension
9.6.10. Replacing the platform inductive position sensor
9.6.11. Checking the position sensor (B120)
9.6.12. Adjusting the presence sensor
9.7. Operator protection C0840
9.7.1. Gate
9.7.2. Replacing the gate
9.7.3. Replacing the gate damper
9.7.4. Replacing the pad
9.7.5. Replacing the gate bar
9.7.6. Checking the gate bar
9.7.7. Replacing the upper inductive position sensor
9.7.8. Checking the upper inductive position sensor B122
9.7.9. Replacing the lower inductive position sensor
9.7.10. Checking the lower inductive position sensor B121
9.7.11. Fixed side guard
9.7.12. Overview
9.7.13. Replacing the fixed side guard
9.7.14. Photo cells, fixed side guard
9.7.15. Back guard
9.7.16. Overview
9.7.17. Replacing the back guard
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
10.3. Fans
10.3.1. Motor control fans
10.3.2. Overview
10.3.3. 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 speed 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. Adjustment of the parking brake gap
12.2.5. Emergency parking brake release
12.2.6. Replacing the parking brake
12.2.7. Checking the 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 wheel
12.4.1. Replacing the castor wheel assembly
12.4.2. Checking the castor wheels
12.4.3. Replacing the castor wheel (single)
12.4.4. Replacing the castor wheel (twin wheel)
12.5. Fork wheels
12.5.1. Replacing single wheels
12.5.2. Replacing the bogie wheel
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 handle to the tiller arm
13.1.3. Replacing the logic card
13.1.4. Checking the handle
13.1.5. Update the software
13.1.6. Replacing the signal button/switch
13.1.7. Replacement of lift/lower button
13.1.8. Replacing the button
13.1.9. Changing the position of the controls – support arm lift/ fork lift
13.1.10. Replacing the safety reversal 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. Overview steering arm ergo version
13.2.4. Replacing the steering yoke (manual and power steering)
13.2.5. Replacing the steering yoke (ergo version)
13.2.6. Replacing the steering yoke (manual and power steering)
13.2.7. Replacing the safety switch (manual and power steering)
13.2.8. Replacing the safety switch (ergo version)
13.2.9. Height adjustment of the steering adapter
13.2.10. Fixed steering adapter
13.2.11. Replacing the gas strut – height adjustment
13.2.12. Replacing the lock – height adjustment
13.2.13. Checking the lock – height adjustment
13.2.14. Replacing the steering adapter (fixed)
13.2.15. Replacing the steering adapter (adjustable)
13.2.16. Replacing the steering bearings – mechanical steering
13.2.17. Replacing the steering bearings – power steering
13.3. Mechanical steering
13.3.1. Overview
13.3.2. Replacing the steering angle sensor
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
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. Show hour meter values
14.2.4. Show error codes
14.2.5. Show part numbers for software/hardware
14.2.6. Built-in test ICH
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
14.2.12. Service mode
14.3. Battery C5110
14.3.1. Battery replacement
14.3.2. Charging the battery
14.4. Li-ion battery (Hoppecke)
14.4.1. Resetting/restarting the battery
14.5. Inspecting the battery
14.6. Electric panel
14.6.1. Overview
14.7. Transistor panel (ACT)
14.7.1. General
14.7.2. Replacing the transistor panel
14.7.3. Replacing the pump contactor
14.7.4. Replacing the main contactor
14.8. Horn C5160
14.8.1. Horn P4
14.9. Control system
14.9.1. Direction selector/speed regulator
14.9.2. Safety reversing
14.9.3. Battery indicator
14.9.4. Hour counter
14.9.5. Lifting and lowering control
14.9.6. Signal buttons
14.9.7. Option buttons
14.9.8. Display
14.9.9. Keypad/ID unit
14.9.10. Weighing system
14.9.11. Pressure equalization
14.9.12. Logic card (A5)
14.10. Work function harness/fuse
14.10.1. Fuse panel overview
14.11. Sending units and sensors C5800
14.11.1. Inductive sensors
14.11.2. Position sensor
14.11.3. Steering reference sensor
14.11.4. Pressure sensor
14.11.5. Pulse transducer
14.12. Safety sensor
14.12.1. Emergency switch off S21
14.12.2. 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
15.3.11. Replacing the return filter
15.3.12. Replacing the valve coil
15.3.13. Replacing the flow control valve
15.3.14. Pressure limitation
15.3.15. Replacing the pressure limiting valve
15.3.16. Adjusting pressure limitation
15.3.17. Replacing the pressure sensor
15.3.18. Lift cylinder
15.3.19. Replacing the lift cylinders
15.4. Hydraulic connections
15.4.1. Quick change connector
16. Mast C7000
17. Peripherals C8000
18. Options/Extra equipment C9000
18.1. Overview
18.2. Spider expansion unit
18.3. I_Site, previously T.W.I.S
18.4. DC/DC converter
18.5. Collision sensor
18.6. Integrated battery charger C5170
18.6.1. Overview
18.6.2. Description
18.6.3. Connecting the battery charger
18.7. E-bar
18.7.1. Overview
18.7.2. E-bar accessories
18.7.3. Fire extinguisher
19. Instructions for disposal
19.1. General
19.2. Marking of plastics

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