BT LPE Forklift Pallet Mode LWE 180 200 LPE 200 Service Manual PDF

Service Manual
LWE180, LWE200, LPE200-6/8
Valid from serial number: 723984-

Order number: 221609-040
Issued: 2004-12-16 ITS

© BT Europe AB

en


Issue date

Resp.

Changes

2004-12-16

ITS

Completely new issue (Prel.)

This manual covers following truck models:

T-code

Model

Serial number

660

LWE180

723984-

661

LWE200

723984-

662

LPE200

723984-

Some chapters in this manual covers only certain of the T-codes above.

© BT Europe AB

Service Manual LWE180, LWE200, LPE200-6/8Approved by: L-G Anders-


Table of contents
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

1- Table of contents
Technical data – M4

2-1

Introduction Maintenance – P1

3-1

Safety regulations with maintenance work ....

1

Cleaning and washing ...................................

2
3.2.1 External cleaning ................................................ 3
3.2.2 Cleaning the motor compartment ....................... 3
3.2.3 Electrical components ........................................ 3

Safe lifting......................................................

Preventive maintenance – P2

4

4-1

Maintenance schedule ..................................

1

Lubrication schedule .....................................

6

Oil and grease specifica tion – P3

5-1

Tools – P4

6-1

Super Seal connectors ..................................

1

AMP connectors ............................................

2

6.2.1 AMP Connectors, 040 series .............................. 3

Molex connectors ..........................................

3

Other tools.....................................................

4

Engine suspension– 0450

7-1

Component parts...........................................

1
7.1.1 Component List .................................................. 2

© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

1- 1


Table of contents
T-code

660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

Electric drive motor – 1760

8-1

Component parts ..........................................

1
8.1.1 Dismantling/assembling of motor from truck ....... 2
8.1.2 Assembling ......................................................... 2

Service/Repairs ............................................

3
8.2.1 Dismantling of motor ........................................... 3
8.2.2 Assembling of motor ........................................... 4
8.2.3 Cleaning .............................................................. 4

Technical data ..............................................

Mechanical drive gear unit – 2550

5

9-1

Component parts ..........................................

2
9.1.1 Technical data .................................................... 3

Leakage from top cover ................................

4
Dismantling ......................................................... 4
Assembling ......................................................... 4

Changing of the drive shaft’s sealing ring .....

4
Dismantling ......................................................... 4
Assembling ......................................................... 5

Electro magnetic brake – 3370

10-1

Main components .........................................

1

Maintenance .................................................

2
10.2.1 Exchange of brake disc ...................................... 2

Electro magnetic brake – 3370

11-1

Main components .........................................

1

Maintenance .................................................

2
11.2.1 Basic Adjustment of gap ..................................... 2
Adjustment: ......................................................... 2
11.2.2 Exchange of brake disc ...................................... 2

1- 2

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB

Table of contents
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

Steering system – 4000

12-1

Component parts, tiller arm ...........................

1

Adjustments ..................................................

2
12.2.1 Adjusting of brake microswitch .......................... 2

Tiller arm handle............................................
12.3.1 Dismantling/Assembling .....................................
Change from ignition key to keyboard (2) ..........
Change from keyboard to ignition key (2) ..........

Changing of signal button/switch (9, 10) ............
Changing of lift/lowering button (13) ...................
Changing of pushbutton (16) ..............................

Electrical System – 5000

13-1

Electrical components ...................................

1

Symbol List and Wiring Diagram ...................

3

Operating description ..................................
13.3.1 Starting truck ....................................................
13.3.2 Driving speed ≤ 6 km/h ....................................
13.3.3 Braking in neutral mode ...................................
13.3.4 Braking in neutral mode on a slope .................
13.3.5 Braking .............................................................
13.3.6 Lifting the forks .................................................
13.3.7 Lowering the forks ............................................
13.3.8 Horn .................................................................

15
15
15
15

15
16
16
16
16

Hour meter ..................................................

16

Error codes..................................................

17

Parameters..................................................

30
30
31
31
31
31
31
31

13.6.1 Operator parameters ........................................
13.6.2 Parameter description ......................................
Parameter 1 ......................................................
Parameter 2 ......................................................
Parameter 3 ......................................................

Parameter 4 ......................................................
Parameter 5 ......................................................

© BT Europe AB

3
4
5
5
5
6
6

Service Manual

LWE180, LWE200, LPE200-6/8

1- 3


Table of contents
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

13.6.3 Service parameters .......................................... 32
13.6.4 Parameter description ...................................... 33
Parameter 10 .................................................... 33
Parameter 14 .................................................... 33
Parameter 15 - Non-configurable option ........... 33
Parameter 16 - Configurable option #1 ............. 33
Parameter 17 - Configurable option #2 ............. 34
Parameter 18 - Configurable option #3 ............. 34
Parameter 19 - Configurable option #4 ............. 34
Option parameters ............................................ 34
General ............................................................. 34
Parameter #15 Non-configurable options ......... 34
Changing non-configurable options .................. 34
Parameter #16 to 19 configurable optional functions .................................................................. 35
Changing configurable optional functions ......... 36
Parameter 20 .................................................... 40
Parameter 21 .................................................... 40
Recommendation on parameter setting for freely
ventilated batteries ............................................ 41
Instructions for verifying parameter setting ....... 42
Recommendation on parameter setting for valvecontrolled batteries (VRLA) ............................... 43
Instructions for verifying parameter setting ....... 44
Parameter 22 .................................................... 44
Parameter 25 .................................................... 44
Parameter 28 .................................................... 44
Parameter 39 .................................................... 45
Login method and driver parameter access ..... 45

Expanded keypad - General ............................. 45
Expanded keypad - Programming .................... 45
Service indication .............................................. 47

Part number .................................................

50

Transistor panel ...........................................

50
13.8.1 General ............................................................. 50

Troubleshooting ...........................................

51
13.9.1 Error codes and troubleshooting ...................... 51
13.9.2 Reset error ....................................................... 52
13.9.3 Safety ............................................................... 52

Technical specifications – Curtis 1243.........

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53

© BT Europe AB


Table of contents
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

Hydraulic/Pneumatik – 6000

14-1

General .........................................................

1

Hydraulic chart and list of symbols ................

1
14.2.1 List of Symbols ................................................... 1

Adjustments LWE180....................................

2
14.3.1 Adjusting the pressure limit valve ...................... 2
14.3.2 Tools .................................................................. 3

Adjustments LWE200....................................

4
14.4.1 Adjusting the pressure limit valve ...................... 4

Hydraulic chart and list of symbols ................

5
14.5.1 List of Symbols ................................................... 5

Adjusting the pressure limit valve ..................

PowerTrak cylinder – 6680

6

15-1

Component parts...........................................

1

Dismantling of PowerTrak cylinder ................

2

Battery charger (Inbuilt) – 8340

16-1

General .........................................................

1

Charging........................................................

1

Troubleshooting and service .........................

1

Technical data ...............................................

2

Charging settings ..........................................

2
16.5.1 Freely ventilated batteries .................................. 2
16.5.2 Valve regulated batteries ................................... 3

Control/computer equipment – 8700

17-1

General .........................................................

1

Connection ....................................................

1

Layout ...........................................................

2
17.3.1 Main program screen ......................................... 2
17.3.2 Nodes ................................................................. 2
17.3.3 Icons .................................................................. 3

© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

1- 5


Table of contents
T-code
660,661,662

Valid from serial number

723984-

Date
2004-12-16

Order number
221609-040

17.3.4 Tool buttons and menu bar ................................ 3
17.3.5 Information window ............................................ 4
17.3.6 Status bar ........................................................... 4

Connection function .....................................

4

Disconnection function..................................

4

Downloading program function .....................
17.6.1 Normal downloading (truck with key) .................
17.6.2 Normal downloading (truck with keypad) ...........
17.6.3 Emergency downloading (truck with keypad) .....
17.6.4 Downloading in old versions of logic card ..........
17.6.5 Emergency downloading (truck with keypad) .....

5
5
5

6
6
6

Truck report function .....................................

7

Parameters function......................................

8

Diagnostics function......................................

8
17.9.1 Representation of signal colours ........................ 9
17.9.2 “Tiller arm” tab .................................................... 9
17.9.3 “Drive Controller” tab (transistor regulator - travel)
10
17.9.4 “Pump controller” tab (transistor regulator - pump)
11
17.9.5 “EPS” steering servo tab .................................. 12

Other menu functions ..................................

1- 6

17.10.1 Save to file ......................................................
17.10.2 Download from file ..........................................
17.10.3 Reset CAN adapter ........................................

17.10.4 Delete error code log ......................................
17.10.5 Reset hour meter ............................................
17.10.6 Read error code log ........................................
17.10.7 Adjust date and time .......................................
17.10.8 Adjusting the hour meter on older cards ........
17.10.9 Help ................................................................
About the TruckCom application .......................
17.10.10 Exit ...............................................................

13
13
13
13
13
13
13
14
14
14
14
14

Specifications ..............................................

14

Installation ...................................................

15

17.12.1 Installation on a PC with Windows®
95/98 15
17.12.2 Installation on a PC with Windows XP/2000 ..
17.12.3 Installation on a PC with Windows NT ...........
17.12.4 In case of communication problems with CAN
17.12.5 To uninstall .....................................................

16
21
21
21

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Technical data – M4
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code

660,661,662

2- Technical data – M4
Model

LWE180

LWE200,
LPE200-6

LPE200-8

Type

TSL140S-DS20

TSL140S-DS30

TSL140S-DS40

Output, kW

1.0

1.2

1,7

Duty cycle

S2, 60 min

S2,60 min

S2,60 min

Minimum carbon brush length, mm

13

13

13

Nominal commutator diameter, mm

47

47

60

Minimum commutator diameter, mm

47

47

60

Resistance, shunt field winding, Ω at 25 C°

0,55

0,55

0,55

Resistance armature winding, Ω at 24 °C

0.0156

0,0156

0,0161

Insulation resistance between the windings and motor casing

>=1 Mohm

>= 1Mohm

>= 1Mohm

Weight, kg

14

14

17

Type

BFK457-08

BFK457-08

BFK458-12

Braking force, Nm

16

16

32

Output, W

25

25

40

Resistance coil, Ω

23

23

14.4

Nominal play in actuated position, mm

0.2-0.4

0.2-0.4

0.3-0.5

Minimum thickness brake disc, mm

5.5

5.5

8.8

Thickness of a new brake disc, mm

7.0

7.0

10.0

Type

2-stage angle
transmission

2-stage angle
transmission

2-stage angle
transmission

Gear ratio

19,14:1

19,14:1

16,29:1

Oil volume, litre

1.0

1.0

1.0

Oil type
at normal temperature
at temperature < -15oC

Hypoid oil

SAE 80W/90
SAE 75W

Hypoid oil
SAE 80W/90
SAE 75W

Hypoid oil
SAE 80W/90
SAE 75W

Drive motor

Broms

Transmission/drive gear

© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

2- 1


Technical data – M4
T-code
660,661,662

Valid from serial number
723984-

Model

Date
2004-12-16

Order number
221609-040

LWE180

LWE200,
LPE200-6

LPE200-8

Drive wheel, mm

Dia 215x70

Dia 215x70

Dia 215x70

Axle pressure without load, kg

200

374

374

Axle pressure at rated load, kg

650

565

565

Tightening torque for wheel bolts, Nm

65 Nm

65 Nm

65 Nm

Fork wheel, mm

Dia 85x75

Dia 85x75

Dia 85x75

Axle pressure without load, kg

2x40 (240)

2x65 (240)

2x65 (240)

Axle pressure at rated load, kg

2x710 (240)

2x790 (240)

2x790 (240)

Support castors, mm

Dia 125x40

Dia 125x40

Dia 125x40

Axle pressure without load

2X70 (240)

2X75 (240)

2x75 (240)

Axle pressure at rated load, kg

2x80 (240)

2x210 (240)

2x210 (240)

Output, kW

1.2

2.2

2.2

Duty cycle,%

10

10

10

Minimum carbon brush length, mm

7.5

12

12

Minimum commutator thickness/diameter, mm

4.75

4.7

4.7

Pressure at rated load, bar

110

150

150

Overflow pressure, bar

130

170

170

Pump flow, litre/minute

4.7

4.6

4,6

Tank volume, litre

0,5

1,0

1,0

Oil type:
at normal temperature
at temperature < -15oC

Hydraulic oil
ISO-L-HM32
ISO-L-HV32

Hydraulic oil
ISO-L-HM32
ISO-L-HV32

Hydraulic oil
ISO-L-HM32
ISO-L-HV32

Drive motor circuits, A

125

125

125

Pump motor circuits, A

125

125

125

Control circuits, A

7,5

7,5

7,5

Wheels

Hydraulic system

Fuses

2- 2

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Technical data – M4
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

Model

T-code
660,661,662

LWE180

LWE200,
LPE200-6

LPE200-8

Dimensions LxWxH, mm

193x642x450

193x642x450-510

193x642x450-510

Capacity, Ah

160-320

240-320

240-320

Weigh, kg

165-250

210-250

210-250

Without load, km/t
Without load, m/s

6,0
1.7

6,0

1.7

8,0
2.22

With rated load, km/t
With rated load, m/s

6,0
1,7

6,0
1,7

7.2
2.0

Lift without load, s

2.2

1.7

1.7

Lift with rated load, s

3.4

2.3

2.3

Lowering without load, s

2.6

1.4

1.4

Lowering with rated load, s

3.1

1.5

1.75

Driving without load, A

38

28

46

Driving with rated load, A

45

46

65

Lift without load, A

39

49

49

Lift with rated load, A

80

52

52

8%

9%

9%

Short
Medium
Lång

519
565
613

519(LWE200)
660
1008

660
1008

Turning radius WA

1466

1960

1960

Lift height

205

205

205

295

420

440

Battery compartment, Batteries

Driving speed

Lift/lowering speed

Power consumption

Incline climbing ability
With rated load

Measurement, L2

Weight
Truck without battery, Medium

© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

2- 3


Technical data – M4

T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

This page is intentionally left blank

2- 4

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Introduction Maintenance – P1
Safety regulations with maintenance work
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

3- Introduction Maintenance – P1
All points in the service program should be carried out to attain the highest safety and the least possible downtime. The service intervals are
only a guide and do not need to be followed to the letter. The operator
may adapt them to local conditions, but it is important that the intervals
comply with BT’s minimum requirements.
The service intervals are based on the running times and can be adapted to most normal 8 hour shifts. The service interval may be shortened
if the truck is used more frequently or in more demanding situations, e.g
cold store, dusty or corrosive situations. The following running times
have been used when calculating the intervals:
- Day time: 08.00-17.00 (20 hr./week)
- 2-shifts:
06.00-14.00, 14.00-22.00 (40 hr./week)
- 3-shifts:
06.00-14.00, 14.00-22.00,22.00-06.00 (60 hr./week)
Ensure the truck is given a regular maintenance service after every 500
driving hours. The truck’s safety, efficiency and service life is dependent on the service and maintenance it is given.
Only use BT approved spare parts when service and repair work are
carried out.

3.1 Safety regulations with
maintenance work
Only personnel that have been trained in the service and repair of this
type of truck are authorised to carry out service and repair work.

• Do not carry out any maintenance work on the truck unless you have
the correct training and knowledge to do so
• Keep the area where you carry out the service clean. Oil or water
makes the floor slippery
• Never wear loose objects or jewellery when working on the truck
WARNING!
Short-circuiting/Burns.
When working with the truck’s electrical system, short-circuiting/
burns can occur if a metal object comes into contact with live electrical connections.
Remove watches, rings or other types of metal jewellery.

• Always disconnect the battery by pulling out the battery isolator
when carrying out maintenance work on the truck unless otherwise
stated in this Service Manual
• Always switch off the truck’s power supply before opening the covers on the drive unit or electrical system
• Relieve the system pressure slowly before starting work on the
truck’s hydraulic system
© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

3- 1


Introduction Maintenance – P1
Cleaning and washing
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

• Use paper or a rigid sheet of cardboard when checking for oil leakage. Never use your hand
• Bear in mind that the oil in the transmission or the hydraulic system
can be hot
WARNING!
Risk of burns.
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.

• Only fill the hydraulic system with new and clean oil
WARNING!
The hydraulic system can be damaged.
If the oil is contaminated hydraulic components can be damaged.
Always use new and clean oil in the hydraulic system.

• Store and dispose of changed oil in accordance with local directives
• Do not release solvents and the like, which are used for cleaning/
washing, into drains that are not intended for this purpose. Follow
the local directives that apply for disposal
• Disconnect the battery when welding on the truck
NOTE!

The battery can be damaged.
When welding using an electric power source the welding current can
enter the battery.
The battery should therefore be disconnected.

• Remove at least 100 mm of paint around the welding/grinding area
through sand-blasting or the use of a paint stripper when welding or
grinding on painted surfaces
CAUTION!
Harmful gases.
Paint that is heated gives off harmful gases.
Remove 100 mm of paint from the work area.

3.2 Cleaning and washing
Cleaning and washing of the truck is important to ensure the truck’s reliability.
• Carry out general cleaning and washing weekly
NOTE!
Risk of short-circuiting.
The electrical system can be damaged
Disconnect the battery before washing by pulling out the battery connector.

3- 2

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB

Introduction Maintenance – P1
Cleaning and washing
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

3.2.1 External cleaning
• Remove rubbish, etc. from the wheels daily
• Use a well-known degreasing agent, diluted to a suitable concentration
• Rinse off loose grime using tepid water
NOTE!
Jamming, corrosion.
Mechanical components can be damaged.
After washing, the truck should be lubricated as set out in the chapter
Maintenance and lubrication chart.

3.2.2 Cleaning the motor compartment
• Cover the electric motors, connections and valves before washing
NOTE!
Risk of short-circuiting.
The electrical system can be damaged.
Electrical components must not be cleaned with a high pressure

washing unit.

• Clean the motor compartment using a well-known degreasing agent,
diluted to a suitable concentration
• Rinse off loose grime using tepid water

3.2.3 Electrical components
• Blow electric motors down using compressed air
• Clean the electrical panels, electronic boards, contactors, connections, solenoid valves, etc. using a damp cloth and a cleaning agent
NOTE!
Risk of short-circuiting.
Electrical components can be damaged.
Do not break the guarantee seal on the electronic board.

© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

3- 3


Introduction Maintenance – P1
Safe lifting
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

3.3 Safe lifting
All lifting must be carried out on a flat, non-slip and firm surface. Avoid
new laid asphalt or asphalt on a hot summer’s day.
• Activate the parking brake to prevent the truck from moving during
the lift. If the lift applies to the brake wheel, chock the other wheels
so that the truck stands still
• Select a lifting point so that the lift is as easy as possible (one corner
at a time). If the truck has marked lifting points on the under side of
the chassis these can be used to obtain a well balanced lift
• Ensure that the surface under the jack is clean and free from oil and
grease
• Ensure that your hands and the jack’s lever are free from oil and
grease
• Use the lever that belongs to the jack. A lever that is too short requires more force than is necessary. If the lever is too long there is a
risk of the jack being overloaded
• Support the truck:
- as close as possible to the part of the chassis that is to be lifted.
This reduces the risk of the truck tipping over
- so that the truck cannot roll
• Never lift up the jack in order to lift higher
• Never work under a lifted truck unless it is well supported
WARNING!
Risk of crushing.

A badly supported truck can fall.
Never work under a truck that is not supported on trestle-blocks and
secured by a lifting device.

3- 4

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Preventive maintenance – P2
Maintenance schedule
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

4- Preventive maintenance – P2
4.1 Maintenance schedule
I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.

M: Control measurement, rectify if necessary

Pos.
No.

Work to carry out
Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

0000

Chassis

0000.1

Check all links and locking pins

l

0000.2

Check wear on cover/battery locking

l

0000.3

Check of cracking and damage

l

0000.4

Check the cover locks

I

0000.5

Check finger guard

I

0000.6

Check signs and stickers

I

0000.7

Press grease into grease nipples

0380

Fork carriage

0380.1

Check for crack formation and damage

l

0380.2

Check clearance in bushes and links

I

0380.3

Press grease into grease nipples (Option)

0380.4

Check the lift limit switch

0560

Platform and mountings

0560.1

Check for any cracks or damage

l

0560.2

Check gas damper and cup springs

l

1700.

Drive motor

1700.1

Check clearance in connections

1700.2

Check the carbon brushes in the drive motor

M

1700.3

Clean the drive motor

C

1700.4

Re-tighten the attachment bolts

1700.5

Check for abnormal noise in bearing

© BT Europe AB

Service Manual

I/L6

I/L6
l

I/T1

I/T

T2
l

LWE180, LWE200, LPE200-6/8

4- 1


Preventive maintenance – P2
Maintenance schedule
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary

Pos.
No.

Work to carry out
Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

2550

Drive gear

2550.1

Check for leakage

2550.2

Check the oil level

I

2550.3

Check for abnormal noise

I

2550.4

Check the attachment and clearance in
steering bearing

I

2550.5

Change the oil in the drive gear

3100.

Brake

3100.1

Clean

3100.2

Check for wear on the brake disc

M

3100.3

Check the clearance in disengaged position

M

3500

Wheels

3500.1

Remove string and other rubbish

3500.2

Check the drive wheel for wear and the tightening torque on bolts

I/T

3500.3

Check that the support wheel turns and
rotates freely

I

3500.4

Check for wear on the support wheel

I

4110

Tiller arm

4110.1

Check the mountings

4110.2

Check the power in the gas damper

5000

Electrical functions

5000.1

Check the operation of the brake microswitch in the upper and lower brake positions. Lubricate the switch head.

I

5000.2

Check the function of the collision safety
switch

I

5000.3

Check the function of the gate switches

I

I

5000.4

Check the function of platform switch

I

I

5000.5

Check the function of the horn

I

I

4- 2

I

I3

L

L4

C

Service Manual

I

I
I

LWE180, LWE200, LPE200-6/8

I/L

© BT Europe AB


Preventive maintenance – P2
Maintenance schedule
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary

Pos.
No.

Work to carry out
Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

5000.6

Check for wear on cabling

5000.7

Check the function of the driver’s control

I

I

5000.8

Check the error code log and operating times

I

I

5110

Battery

5110.1

Check the electrolyte level, 10-15 mm over
the cell plates

M

5110.2

Check connections to battery, truck and
charger

I

5110.3

Check that the cell and pole guards are
undamaged

I

5110.4

Check the fluid density and temperature

M

5110.5

Remove overflow fluid from the battery trough

C

5110.6

Check the battery locking

5400

Power system

5400.1

Cleaning and checking of mounting in chassis

C/T1

5400.2

Re-tighten cable connections

T1

5400.3

Check the contactor points on K10 and K30

I

5400.4

Check the movement of the contactors

I

5400.5

Check the cable insulation

I

5700

Electronic circuit board

5700.1

Check connectors and cables

5700.2

Check all segments on the display

© BT Europe AB

Service Manual

I

I

T1

I

C/T

I
I

LWE180, LWE200, LPE200-6/8

4- 3


Preventive maintenance – P2
Maintenance schedule
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary

Pos.
No.

Work to carry out
Interval in hours

5

20

80

500

1000

3000

Interval in days/weeks/months

1d

1w

1m

6m

12m

36m

6100

Hydraulic system

6100.1

Check hoses and connections for wear

I

6100.2

Check hoses for wear and damage

I

6100.3

Check the oil tank for cracks, leakage and
damaged mountings

I

6100.4

Check that the oil level is correct

6100.5

Change the oil and clean the filter

6600.

Lift cylinder

6600.1

Check for leakage

I

6600.2

Check the mountings

I

6680

Power Trak

6680.1

Check if there is any damage or cracks on
the PowerTrak spring

6680.2

Grease in the contact pressure spring’s
guides

I
L

L5

I
C/L

1 = The connections are re-tightened for the first time after 80 h, and
then every 1000 h/12 months.
2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm.
3 = Check for leakage in conjunction with the first oil change.
4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months
5 = The oil is changed and the filter cleaned for the first time after 80 h/
1 month, and then every 1000 h/12 months.
6 = If the truck goes into a refrigerated environment or other harsh environment, the point is addressed at more frequent intervals.
When points with higher hour intervals are carried out the points with
lower hour intervals should also be carried out unless otherwise specified above.

4- 4

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Preventive maintenance – P2

Maintenance schedule
Order number
221609-040
5000

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

5000

6680
4110
5110
5700

5000

6600
5400
3100
1700
0380

6100

0560

0000

2550
5000
3500

© BT Europe AB

Service Manual

LWE180, LWE200, LPE200-6/8

4- 5


Preventive maintenance – P2
Lubrication schedule
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number

221609-040

4.2 Lubrication schedule
Pos.
No.

Service point

Interval/Operating hours

0380

Lubricating nipples (Option)

2550

Drive gear

O4

C

6100

Hydraulic system

O5

O

80 h

L = Lubrication

500

1000 h

3000 h

L

C = Check

Type of
lubricant
E

O

C
B

O = Oil change

4 = The oil is changed for the first time after 80 h/1 month, and then every 3000 h/36 months
5= The oil is changed and the filter cleaned for the first time after
80 h/1 month, and then every 1000 h/12 months.

6100

0000
2550

0380

4- 6

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Oil and grease specifica tion – P3
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

5- Oil and grease specifica tion – P3
Pos.

Type of lubricant

Specification
> -15° C

< -15o C

A

Grease

BT 26777
(Spray)

BT 26777
(Spray)

Bearings and bushes

B

Hydraulic oil

ISO-L-HM32

ISO-L-VG 32

Hydraulic system

C

Transmission oil

Hypoid oil SAE
80W/90

Hypoid oil SAE
75W

Gears

D

Grease

Staburags
NBU 8EP

Staburags
NBU 8EP

Guide bearing

E

Grease

BT 73942XX5
TOTAL N3942

BT 73942XX5
TOTAL N3942

Lubricating nipples,
Contact pressure spring

© BT Europe AB

Service Manual

Application

LWE180, LWE200, LPE200-6/8

5- 1


Oil and grease specifica tion – P3
T-code
660,661,662

Valid from serial number
723984-

Date
2004-12-16

Order number
221609-040

This page is intentionally left blank

5- 2

Service Manual

LWE180, LWE200, LPE200-6/8

© BT Europe AB


Tools – P4
Super Seal connectors
Order number
221609-040

Date
2004-12-16

Valid from serial number
723984-

T-code
660,661,662

6- Tools – P4
6.1 Super Seal connectors
1
3

3
2

Figure

© BT Europe AB

Number

Application

159232

Tools for fitting pins/sleeves

159229

Tools for loosening locks (1)

159230

Tool for fitting secondary locks
1-2 poles (2)

159231

Tool for fitting secondary locks
3-6 poles (2)

159228

Tools for removing pins/sleeves (3)

Service Manual

LWE180, LWE200, LPE200-6/8

6- 1