LWE 200 LEVIOder

Repair Manual en
LWE140, LWE160, LWE180, LWE200, LWE250

Valid from serial number: 6053221-
Order number: 258944-040

Issued: 2009-10-05 TP
© BT
Document revisions:
Issue date Order Changes

number
2008-08-25 258944-040 Completely new issue.
2009-04-17 258944-040 Update
2009-10-05 258944-040 Chapter 4.4 New table and amendments to text in the chapter
Chapter 5.3 Measures added
Chapter 6 amendments to text and values
Chapter 7 amendments to text and values
Chapter "10.4 Tightening torque drive motor" added
Chapter 16 New descriptions related to the repair of the tiller arm
Chapter "17.3 Lift height limit sensor" added
Chapter 18 New text related to hygiene when working on hydraulics
Chapter "18.8 Tightening torque hydraulic unit" added
Various minor corrections throughout entire document
This manual covers following truck models:
T-code Model Serial number

838 LWE140 6053221-
838 LWE160 6053221-
838 LWE180 6053221-
839 LWE200 6053221-
840 LWE250 6053221-
© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250

Table of contents
Order number Date Valid from serial number T-code
258944-040 2009-10-05 6053221- 838, 839, 840
1 – Table of contents
2 – General introduction ......................................................................... 2-1
2.1 How to use the manual................................................................... 2-1
2.2 Warning symbols ........................................................................... 2-2
2.3 Pictogram....................................................................................... 2-2
2.3.1 Screws/nuts ..................................................................... 2-2
3 – General safety rules .......................................................................... 3-1

3.1 Safety while working ...................................................................... 3-1
3.2 Electrical system ............................................................................ 3-2
3.3 Safe lifting ...................................................................................... 3-3
4 – Installation ......................................................................................... 4-1

4.1 General .......................................................................................... 4-1
4.2 Battery installation.......................................................................... 4-1
4.2.1 Battery installation safety ................................................. 4-1
4.2.2 Install battery ................................................................... 4-2
4.3 Programming PIN codes ................................................................ 4-3
4.3.1 Standards for PIN codes ................................................. 4-4
4.4 Setting the parameters................................................................... 4-5
4.4.1 Adjusting the parameters for collision sensor (option) ..... 4-6
Collision sensor parameters 105 and 106 ....................... 4-6
Programming PIN for resetting the truck ......................... 4-6
4.4.2 Adjusting the parameters for the battery and battery charger
4-7
4.4.3 Parameter 107 - battery size ........................................... 4-9
Table for LWE140, 160, 180, 200 .................................... 4-9
Table for LWE200 with platform and LWE250 .............. 4-10
Verifying the parameter adjustment for free ventilated batter-
ies (Lead/acid batteries) ................................................ 4-11
Verifying the parameter adjustment for valve controlled batter-
ies (Hawker/Exide) ........................................................ 4-11
4.5 Function and safety check ........................................................... 4-12
5 – Maintenance ....................................................................................... 5-1

5.1 General .......................................................................................... 5-1
5.2 Service intervals............................................................................. 5-1
5.3 Maintenance chart ......................................................................... 5-2
6 – Functions and parameters ................................................................ 6-1

6.1 General .......................................................................................... 6-1
6.2 Function description....................................................................... 6-1
Symbols on key pads and display ................................... 6-2
6.3 Principle functions.......................................................................... 6-3
6.4 Timer.............................................................................................. 6-8
© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 1– 1

Table of contents
T-code Valid from serial number Date Order number
838, 839, 840 6053221- 2009-10-05 258944-040
6.5 Parameters .................................................................................... 6-9

6.5.1 General ............................................................................ 6-9
6.5.2 Show parameters ............................................................ 6-9
6.5.3 Enter the parameters ..................................................... 6-10
6.5.4 Driver parameters .......................................................... 6-11
Factory installed driver parameters ............................... 6-12
6.5.5 Service parameters ....................................................... 6-13
6.5.6 Factory parameters ....................................................... 6-17
7 – Troubleshooting ................................................................................ 7-1

7.1 General .......................................................................................... 7-1
Software compatibility ...................................................... 7-1
7.1 Emergency travel mode ................................................................. 7-1
7.2 Troubleshooting methods .............................................................. 7-2
7.2.1 Troubleshooting general introduction .............................. 7-2
7.2.2 Completed troubleshooting .............................................. 7-3
7.3 Error code history........................................................................... 7-4
7.4 Error code system .......................................................................... 7-5
7.5 Error codes .................................................................................... 7-6
7.6 Troubleshooting diagram ............................................................. 7-21
7.6.1 The truck cannot be driven ............................................ 7-22
7.6.2 The truck can only be driven at reduced speed ............. 7-23
7.6.3 The truck can be driven but behaves abnormally .......... 7-24
7.6.4 The truck can be driven but lacks certain functions. ...... 7-24
Software compatibility .................................................... 7-24
Matrix for hardware compatibility ................................... 7-25
7.6.5 Faulty hydraulic functions .............................................. 7-26
7.7 Built-in test function...................................................................... 7-29
7.8 Status of digital inputs/outputs ..................................................... 7-30
7.8.1 Test function “9” – Transistor regulator ......................... 7-30
7.8.2 Test function “10” - Logic card ....................................... 7-33
7.8.3 Test function “12” – Expansion unit SEU (optional). ...... 7-34
7.9 Display test function ..................................................................... 7-35
8 – Chassis 0000 ...................................................................................... 8-1

8.1 General .......................................................................................... 8-1
8.2 Disassemble the drive unit from the fork frame .............................. 8-2
8.3 Removing the platform ................................................................... 8-3
8.4 Change of damper for castor cradle............................................... 8-5
8.5 Changing the springs and cylinder for the castor cradle ................ 8-5
9 – Fork frame 0380 ................................................................................. 9-1

9.1 Components .................................................................................. 9-1
10 – Electrical drive motor 1700 ........................................................... 10-1

10.1 Components ................................................................................ 10-1
10.2 Remove motor from truck............................................................. 10-2
10.3 Fitting the tempreature sensor ..................................................... 10-3
10.4 Tightening torque Drive motor...................................................... 10-4
10.5 Cleaning....................................................................................... 10-5
1– 2 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

Table of contents
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11 – Drive unit/gear 2550 ...................................................................... 11-1

11.1 General ........................................................................................ 11-1
11.2 Components ................................................................................ 11-1
11.3 Remove the gear from the truck................................................... 11-2
12 – Brake 3180 ...................................................................................... 12-1

12.1 Components ................................................................................ 12-1
12.2 Release of brakes ........................................................................ 12-2
13 – Drive wheel 3530 ............................................................................ 13-1

13.1 Changing drive wheel................................................................... 13-1
14 – Castor wheel 3540 ......................................................................... 14-1

14.1 Components ................................................................................ 14-1
14.2 Castor wheel mounting ................................................................ 14-2
14.3 Changing castor wheel................................................................. 14-3
14.4 Changing castor wheel cradle...................................................... 14-3
14.5 Changing springs ......................................................................... 14-3
14.5.1 Removing springs .......................................................... 14-3
14.5.2 Fitting the spring ............................................................ 14-3
15 – Fork Wheel 3550 ............................................................................ 15-1

15.1 Changing climber wheel............................................................... 15-1
15.2 Support arm wheel 3550 .............................................................. 15-2
16 – Tiller arm 4000 ............................................................................... 16-1

16.1 Components in tiller arm .............................................................. 16-1
16.2 Removing tiller arm ...................................................................... 16-2
16.3 Changing gas suspension............................................................ 16-2
16.4 Changing the safety sensor ......................................................... 16-3
16.4.1 Dismantling .................................................................... 16-3
16.4.2 Assembly ....................................................................... 16-3
16.5 Components in tiller arm handle................................................... 16-4
16.5.1 Removing the tiller arm handle ...................................... 16-5
16.5.2 Replacing the logic card ................................................ 16-5
16.5.3 Changing signal button/switch ....................................... 16-6
16.5.4 Changing raising/lowering button. ................................. 16-7
16.5.5 Changing push button ................................................... 16-7
16.5.6 Changing the lifting control lever – from front to back ... 16-8
16.5.7 Changing a switch for safety reversing .......................... 16-9
17 – Electrical components .................................................................. 17-1

17.1 Changing wiring harness.............................................................. 17-1
17.1.1 Changing the wiring harness to the transistor regulator 17-2
17.2 Replacing the transistor regulator ................................................ 17-3
17.3 Lift height limit sensor [B61] ......................................................... 17-4
17.3.1 Replacing sensor [B61] ................................................. 17-4
17.3.2 Adjusting sensor [B61] ................................................... 17-5
18 – Hydraulic system 6000 .................................................................. 18-1

18.1 General ........................................................................................ 18-1
18.2 Hygiene when working on hydraulics ........................................... 18-2
18.2.1 Washing ......................................................................... 18-2
Table of contents
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18.2.2 Packaging ...................................................................... 18-2

18.2.3 Handling ........................................................................ 18-2
18.2.4 Storage .......................................................................... 18-3
18.2.5 Carrying out work .......................................................... 18-3
18.3 Hydraulic system components LWE140, LWE160, LWE180 ....... 18-4
18.4 Hydraulic system components for LWE200 and LWE250............ 18-5
18.5 Fitting the tube connection ........................................................... 18-6
18.6 Hydraulkopplingar 6230 ............................................................... 18-7
18.6.1 Quick change connector ................................................ 18-7
Assembling the quick change connector ....................... 18-7
18.7 Adjusting the pressure-limiting valve............................................ 18-8
18.8 Removing the hydraulic unit......................................................... 18-9
18.9 Tightening the torque for the hydraulic unit ................................ 18-11
19 – Accessories ................................................................................... 19-1

19.1 Spider expansion unit .................................................................. 19-1
19.2 TLS - Truck log system ................................................................ 19-2
19.3 ID unit........................................................................................... 19-2
19.4 Toyota Wireless Information System T.W.I.S. ............................. 19-2
19.5 Intergrated battery charger .......................................................... 19-3
19.5.1 Technical data ............................................................... 19-3
19.5.2 Battery charging ............................................................ 19-4
Main charge ................................................................... 19-4
Uneven charging ........................................................... 19-4
Charging complete ........................................................ 19-4
20 – Appendix ........................................................................................ 20-1

20.1 General ........................................................................................ 20-1
21 – Technical data ............................................................................... 21-1

21.1 LWE140, LWE160, LWE180, LWE200, LWE250 ........................ 21-1
22 – General tightening torques ........................................................... 22-1

22.1 Galvanised, non-oiled bolts.......................................................... 22-1
22.2 Untreated, oiled bolts ................................................................... 22-1
23- Tools ................................................................................................ 23-1

23.1 MQS connectors .......................................................................... 23-1
23.2 AMP connectors........................................................................... 23-3
23.2.1 AMP Connectors, 040 series ......................................... 23-4
23.3 Molex connectors......................................................................... 23-4
23.4 Grease guns ................................................................................ 23-5
23.5 Other tools ................................................................................... 23-6
24 – Oil and grease specification ......................................................... 24-1

24.1 Lubrication schedule .................................................................... 24-2
25 – Electrical components and electrical diagram ........................... 25-1

25.1 Electrical components.................................................................. 25-1

Table of contents
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25.2 Electrical diagram ........................................................................ 25-5

25.2.1 Index of symbols ............................................................ 25-5
25.2.2 Overview diagram .......................................................... 25-6
25.2.3 Electrical diagram .......................................................... 25-7
26 – Hydraulic diagram ......................................................................... 26-1
27 – Destruction instructions ............................................................... 27-1

27.1 General ........................................................................................ 27-1
27.2 Marking of plastics ....................................................................... 27-1
27.2.1 General marking of products and packaging material ... 27-1
27.2.2 Marking according to BT Standard ................................ 27-2
Abbreviations ................................................................. 27-2
Marking examples ......................................................... 27-2
27.3 Pressure vessels.......................................................................... 27-3
27.3.1 Gas dampers ................................................................. 27-3
27.4 Sorting categories ........................................................................ 27-4

Table of contents
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This page is intentionally left blank

General introduction
How to use the manual
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2 – General introduction
2.1 How to use the manual

The service manual is divided into chapters containing the following
information:
• Functions and parameters – This chapter contains a basic descrip-
tion of the main functions of the truck and the control system para-
meters.
• Installation and initial operation – This chapter describes the work
that needs to be done before the truck is used for the first time.
• Maintenance – This chapter contains a general periodic mainte-
nance schedule and a detailed description of the maintenance to be
carried out.
• Troubleshooting – This chapter describes the error codes that ap-
pear in the display when the truck completely or partly stops work-
ing. The chapter also describes the reason why the errors occur and
suggested remedies.
• Step by step – This chapter describes the various parts of the truck,
for example the hydraulic system, including what the parts look like
and the service activities that need to be carried out. The various de-
scriptions are organised according to BT's C-code system.
• Appendixes – The appendixes contain:
- instructions for disposal
- information about electrical components and wiring diagrams
- hydraulics diagrams
- list of required tools
- information about general tightening torques
- oil and grease specifications
- Technical data.

General introduction
Warning symbols
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2.2 Warning symbols

The following warning symbols are used in the service manual:
DANGER!
The word DANGER! means there is a risk of accident potentially lead-
ing to death or serious injury and material loss or damage. Always ac-
companied by the warning symbol.
WARNING!
The word WARNING! means that there are components sensitive for
electro-static discharges.
Follow applicable ESD-routines to protect the device.
NOTE!
The word NOTE means there is a risk of material loss or damage if the
instructions are not followed. Also used to draw attention to a non-
standard torque.
2.3 Pictogram
2.3.1 Screws/nuts
Wherever possible, pictograms have been used to describe certain
working operations.
Pictograms are primarily used for operations that require loosening or
tightening of screws:
×n
s mm
The pictograms contain information about the screw head type and
have arrows that show if the screw should be loosened or tightened.
Text beneath the pictogram provides additional information about
's': tool dimension, 'n': number of screws and, where necessary, 'T':
recommended tightening torque.

General safety rules
Safety while working
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3 – General safety rules

Only personnel trained in servicing and repairing this type of truck are
authorised to carry out service and repair activities.
3.1 Safety while working

To ensure that you work safely and to prevent accidents while working
on a truck, remember the following:
• keep the area where servicing activities are performed clean. Oil or
water will make the floor slippery.
• use the correct working position. Service activities often involve
kneeling or bending forward. Try sitting on a toolbox, for example, to
relieve the strain on your knees and back.
• loose articles and jewellery may become trapped in the moving parts
of the truck. So never wear loose articles or jewellery while working
on the truck.
• use the correct tools for the work you are carrying out.
• keep all tools well maintained.
• store and transport old oil according to applicable local regulations.
• do not flush solvents, etc. down the drain unless they are intended to
be disposed of in this way.
Follow the local disposal regulations.
• heated paint gives off harmful gases. So use sanding or a paint strip-
per to remove the paint at least 100 mm around an area where any
welding/grinding is to take place.

Electrical system
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3.2 Electrical system

When working on the electrical system of the truck, remember the fol-
lowing:
• a short circuit may occur if metal objects come into contact with live
connections. This can result in burns. So remove watches, rings and
other metal jewellery before starting work.
• always use insulated tools while working on the electrical system.
• always switch off the truck's power supply before opening the hoods
to the drive assembly and the electrical system.
• disconnect the battery when using electric welding equipment. The
welding current may damage the battery.
• always remove the battery plug when carrying out maintenance on
the truck, unless the instructions in this service manual state other-
wise.
• blow electric motors clean using compressed air.
• clean electrical panels, electronic cards, connectors, contactors, so-
lenoid valves, etc. with a moist cloth and a cleaning agent that will
not damage the part.
NOTE!
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the electronic cards.

Safe lifting
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3.3 Safe lifting
All lifting must be carried out on a flat, nonslip and stable surface.
Asphalt floors must be avoided if possible.
• To prevent the truck moving while it is being lifted, it must not be lift-
ed with anyone on the platform or with the tiller arm in the lowered
position.
• If the drive wheel, which is braked, is being lifted the other wheel
must be chocked to stop the truck moving.
• Select the lifting point so that the lift is as light as possible, for exam-
ple one corner at a time. If the truck has marked lifting points on the
lower part of the chassis, these should be used for a well-balanced
lift.
• Ensure the area where you place the jack is clean and free of oil and
grease.
• Ensure there is no grease or oil on your hands or the jack lever.
• Use the lever supplied with the jack. If the lever is too short, it will re-
quire more effort than is necessary. If the lever is too long there is a
risk that the jack will be overloaded.
DANGER!
Risk of crushing – a poorly chocked truck may fall.
• Never work under a truck that is not blocked with supports or secured
by a lifting device.

Safe lifting
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• Place supports:
- as close to the raised part of the chassis as possible to reduce the
falling height if the truck tips over
- so that the truck cannot roll.
• Never place a support under the jack to increase the lifting height.
• Never work under a lifted truck without appropriate supports.

Installation
General
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4 – Installation
4.1 General
The chapter describes the work that has to be done before the truck is
put into operation.
4.2 Battery installation

4.2.1 Battery installation safety
Remember the following safety regulations before you begin working
with the battery:
• Always use pprotective equipment to protect the eyes, face and skin
when you are inspecting, handling or filling batteries.
DANGER!
Battery acid causes burns. If your skin or clothing comes into contact
with battery acid, rinse the area immediately with cold water. If your
face or eyes come into contact with battery acid, rinse the area with
cold water and seek immediate medical attention.
• Ensure that there is a shower and an eye bath nearby in case an ac-
cident occurs.
• A battery emits explosive gases. Never use naked flames or any-
thing else that could cause sparks close to a battery.
• Do not put tools or other metal objects on the battery. This can lead
to a short circuit or explosion.

Installation
Battery installation
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4.2.2 Install battery

The battery that is to be installed in the truck must be of the right size. A
battery that is too small in terms of size and weight can seriously affect
the truck's braking ability and stability when lifting. See the truck's data
plate for correct information about the battery.
1. Lift the battery into place using an approved lifting device and a
suitable battery yoke or lifting straps.
DANGER!
The battery may fall when the lifting device is loosened if it has not
been secured with an axle stand or other similar suspension gear of
the right height. Check the height of your suspension gear before
loosening the lifting yoke.
2. Check the electrolyte level in the battery. This should normally be
10-15 mm above the cell plates.
3. Connect the battery cables/battery sleeve.
DANGER!
Always check that you have the right polarity when connecting the
battery cables. Compare the markings on the cables with the mark-
ings on the battery terminals. A wrongly connected battery may
cause a short circuit.
4. Close the battery lid.
5. Put the battery front partition back.
6. Check or enter the parameters for the battery and battery charger.
See the section Adjusting battery and battery charger parameters
in this chapter.
7. Carry out a function test on the truck and check that the lift height
limit sensor is correctly set before using the truck. See section
“17.3.2 Adjusting sensor [B61]”.

Installation
Programming PIN codes
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4.3 Programming PIN codes

A majority of PIN codes can be made available by activating the so-
called block. Block 0 (zero) is activated as standard, which means that
3 driver profiles can be used from the start. Activating the second block
makes all PIN codes for that block accessible. If all 10 blocks are acti-
vated, 10 PIN codes become available for the driver profile.
The truck programme stores a standard set PIN code according to the
table “Standard assignment of PIN codes”. These PIN codes may be
changed to a chosen value, but PIN codes that exist for other driver
profiles should be avoided.
Carry out the following to start the programming:
1. Connect the CAN service key to socket [X41].
2. State code 341671 and press the ON button.
3. Choose the programming code from the table below:
Function Programming Remark

Return to factory settings. Press 1 + ON button Block 1-9 is deacti-
vated. The original
PIN codes are reset
according to the
table for standard
assignment of PIN
codes.
PIN codes in the block can Press 2 + b + ON button B = Block 0-9
be used.
PIN codes in the block Press 3 + b + ON button B = Block 0-9
cannot be used.
Programming new PIN Press 4 + b + P + NNNN + ON button B = Block 0-9
codes NOTE! P = Driver profile 1-10
The block that applies must be activated NNNN = PIN code
first (see function 2 above in the table). NOTE!
You may only state
one number for
driver profiles. Driver
profile 10 must
therefore be stated
as 0 (zero).
4. Turn off the truck by pressing the OFF button.

Programming the PIN codes is now finished. Verify that the pro-
gramming is correct by logging in with some of the new PIN codes.
NOTE!
It is important to establish that the correct driver profiles are activated
when a certain PIN code is stated. This especially applies when a driv-
er profile is set up for a specific application.

Installation
Programming PIN codes
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4.3.1 Standards for PIN codes

The table below shows the PIN codes that are found as standard in the
programme. The PIN codes can be activated or changed according to
the driver's wishes. A driver profile is activated with the normal log in of
all PIN codes, whose block number is activated.
The truck programme does not permit a login using the PIN code 0000.
NOTE!
It is recommended that service personnel keep notes about activated
blocks, changed PIN codes and specially adjusted driver profiles.
Standard assignment for PIN codes

Driver 1 2 3 4 5 6 7 8 9 10
profile NOTE!
no. Stated
as 0
Block 0 0001 0002 0003 0000 0000 0000 0000 0000 0000 0000
Block 1 7901 1437 3731 1049 9439 7265 1322 2869 1574 5421
Block 2 4854 2907 9175 5799 1490 3031 7392 5622 5023 1787
Block 3 3174 1026 3815 6703 1179 5152 7514 5668 3215 4659
Block 4 7110 5477 3846 9491 5918 8222 6923 8139 7025 9197
Block 5 6276 9879 9658 1690 4042 5201 9807 4332 9715 2549
Block 6 4142 8620 3754 8432 8788 7430 1948 2595 8527 7474
Block 7 1482 7135 2395 7365 7092 4611 2831 4185 6067 1930
Block 8 4731 1022 5377 3257 7334 9009 7881 8843 7436 2876
Block 9 3162 5878 2828 1910 6907 2136 5730 2957 7691 3242

Installation
Setting the parameters
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4.4 Setting the parameters

The parameters that are handled in this chapter are only the parame-
ters that need to be adjusted when putting the truck into operation and
that require more detailed description. For information about other
parameters, see the chapter Functions and parameters.
Check that parameters are adjusted to desire values with regards to
• maximum speed, driver parameter - see chapter Functions and pa-
rameters
• acceleration, driver parameter - see chapter Functions and parame-
ters
• internal braking, driver parameter - see chapter Functions and pa-
rameters
• Collision sensor (option)
• battery
• battery charger (option)
NOTE!
When you check or adjust parameters, remember to write down, in a
truck report for example, the truck's specific parameter values. Sepa-
rate information about the truck specific parameters are good to have
e.g. truck condition, since the information cannot be received in an-
other way.

Installation
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4.4.1 Adjusting the parameters for collision

sensor (option)
This parameters for collision sensitivity must be adjusted on truck
installation.
If a collision sensor is installed on the CAN bus, this registers when the
truck knocks against something. If a knock exceeds a certain level, indi-
cated by parameters 105 and 106, this is calculated as a collision and
the truck's speed is reduced to creep speed, a signal sounds and error
code 8.001 is shown on the display.
Information about the collision is stored in the truck's internal memory.
The last ten registered collisions can be read directly on the display and
the driver's identity can also be read via the PIN code. Other informa-
tion is received via TruckCom where the collision levels and times can
also be seen.
Collision sensor parameters 105 and 106

See the table below for information about the values that can be stated:
Service parameters
Parameter Name/unit Min/ Step Std Description
Max
105 Collision sen- 0/100 1 0 States the degree of
sor sensitivity for what
X level should be interpreted as
a collision for a shock to
the side.
106 Collision sen- 0/100 1 0 States the degree of
sor sensitivity for what
Y level should be interpreted as
a collision for a shock to
the front and back.
NOTE!
If you set the parameter value for the collision sensor at 0 (zero) this
means that the collision sensor and the log function are turned off.
Programming PIN for resetting the truck

When the truck has stopped after a collision, the truck must be reset by
entering a special PIN code. This PIN code must be programmed by
service technicians at installation.
The PIN that is activated is found in driver profile 1 and special block
10. The PIN code has a standard value 0000, which must be changed
to PIN code chosen by service technicians.
NOTE!
The PIN code must not contain the same number combination as any
of the preprogrammed PIN codes.

Installation
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4.4.2 Adjusting the parameters for the battery

and battery charger
The following parameters must be adjusted or checked on battery
installation.
NOTE!
Even if the battery comes with the truck from the factory, the parame-
ters must be adjusted or checked.
NOTE:
Ensure that service parameter 109 is set to the value of the battery
fitted, and that the correct battery capacity has been set in parameter
110.
NOTE:
Only 134 Ah, 174 Ah and 201 Ah battery sizes may be used when
using a Hawker Evolution battery.

Installation
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Parameter Name/unit Min/Max Step Std Description

107 service Battery 1/20 1 8 LWE140/160/180/200:
parameter adjustment, 8 = Large battery
Ah 12 = Medium battery
17 = Small battery
For more information, see text
according to the table. See section
“4.4.3 Parameter 107 - battery size”.
10 LWE250 and LWE200 with platform:
10 = Large battery
14 = Medium battery
19 = Small battery
For more information, see text
according to the table. See section
“4.4.3 Parameter 107 - battery size”.
109 service Intergrated 0/3 1 0 State battery type
parameter battery 0 = No charge. Standard type. Error
charger, bat- code is displayed if this parameter is
tery type set at 0 when there is a battery
charger and factory parameter 1101
is set at 1.
1 = Lead/acid battery
2 = Hawker Evolution battery. Sizes
134 Ah, 174 Ah, 201 Ah
3 = Exide GEL battery
110 service Intergrated 0/300 1 0 State battery capacity.
parameter battery (100/300) (100) 0 (100) = No charge. Standard type.
charger, bat- Error code is displayed if this param-
tery capac- eter is set at 0 (100) when there is a
ity, Ah battery charger and factory parame-
ter 1101 is set at 1.
The values in brackets () apply if the
truck has software version -006 or
later.
1101 factory Intergrated 0/1 1 0 0 = No battery charger
parameter battery 1= Battery charger present
charger
NOTE!
If factory parameter 1101 has a value of 0 (zero), service parameters
109 and 110 must also have a value of 0 (zero). If the truck has softwa-
re version -006 or later, and if the factory parameter 1101 has the va-
lue 0 (zero), service parameter 109 must have the value 0 (zero) and
110 must have the value 100 (one hundred). The value in service pa-
rameter 109 and 110 only needs to be changed if the truck is equipped
with an integrated charger and the value of factory parameter 1101 is
set at 1.

Installation
258944-040 2009-10-05 6053221- 838, 839, 840
4.4.3 Parameter 107 - battery size

You must state which type of battery the truck is equipped with. To
adjust the meter for battery charge level, consideration must be given
to the following:
• Acid concentration when the battery is fully charged, in order to
check the battery's quality. The value should lie between 1.27-1.29.
NOTE that the acid concentration can vary depending on the type of
battery.
• When the lifting capability is disconnected (the battery discharged to
80 %) the value should be close to 1.14 but no lower.
Table for LWE140, 160, 180, 200
See the table below for the recommended parameter settings.
Parameter 107 Battery size Battery size Battery size
Lead/acid Hawker Evolution Exide
battery
1
2
Lower dis- 3
charge
4
5
6
7 311-330 Ah 261-280 Ah 271-290 Ah
8 291-310 Ah 241-260 Ah 251-270 Ah
9 271-290 Ah 221-240 Ah 231-250 Ah
10 251-270 Ah 201-220 Ah 211-230 Ah
11 231-250 Ah 181-200 Ah 191-210 Ah
12 216-230 Ah 161-180 Ah 171-190 Ah
13 201-215 Ah 141-160 Ah 151-170 Ah
14 186-200 Ah 120-140 Ah 131-150 Ah
15 171-185 Ah 110-130 Ah
16 156-170 Ah
17 141-155 Ah
Deeper dis- 18 125-140 Ah
charge 19
20

Installation
838, 839, 840 6053221- 2009-10-05 258944-040
Table for LWE200 with platform and LWE250

See the table below for the recommended parameter settings:
Battery size Battery size Battery size
Lead/acid Hawker Evolution Exide
battery
1
Lower dis- 2
charge
3
4
5
6
7
8
9 311-330 Ah 261-280 Ah 271-290 Ah
10 291-310 Ah 241-260 Ah 251-270 Ah
11 271-290 Ah 221-240 Ah 231-250 Ah
12 251-270 Ah 201-220 Ah 211-230 Ah
13 231-250 Ah 181-200 Ah 191-210 Ah
14 216-230 Ah 161-180 Ah 171-190 Ah
15 201-215 Ah 141-160 Ah 151-170 Ah
16 186-200 Ah 120-140 Ah 131-150 Ah
Deeper dis-
charge 17 171-185 Ah 110-130 Ah
18 156-170 Ah
19 141-155 Ah
20 125-140 Ah
DANGER!
The battery's life-span will be reduced if the value of parameter 107 is
adjusted to a value that is too high. The standard adjustment of pa-
rameter 107 is set for normal handling of the truck. Other applications
may require a different adjustment of parameter 107. Check that the
parameter adjustment is right using the instructions below.
4 – 10 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

Installation
258944-040 2009-10-05 6053221- 838, 839, 840
Verifying the parameter adjustment for free ventilat-

ed batteries (Lead/acid batteries)
1. Charge the battery
2. Use the truck in its normal application unitl the battery indicator
shows an empty battery (0 % on the display).
3. Disconnect the battery from the truck and let the battery rest for at
least two minutes.
NOTE!
Do not charge or discharge during this time.
4. Measure the acid weight of the battery at room temperature.
If the acid weight is under 1.15 g/cm3, the parameter must be re-
duced. A value substantially above 1.15 g/cm3 reduces the risk of
damage to the battery. At the same time the operating time of the
truck is reduced. If a longer operating time is desired, the parame-
ter value can be increase by up to one unit.
NOTE!
Each change must be followed by a new verification of the parameter
adjustment.
Verifying the parameter adjustment for valve con-

trolled batteries (Hawker/Exide)
1. Charge the battery
2. Use the truck in its normal application until the battery indicator
shows an empty battery (0 % on the display).
3. Disconnect the battery from the truck and let the battery rest for at
least two minutes.
NOTE!
Do not charge or discharge during this time.
4. Measure the voltage of the battery at room temperature.
If the voltage is under Uend (see table below) the parameter value
must be reduced. A value substantially above Uend reduces the
risk of damage to the battery. At the same time the operating time
of the truck is reduced. If a longer operating time is desired, the pa-
rameter value can be increase by up to one unit.
NOTE!
Each change must be follwoed by a new verification of the parameter
adjustment.
Battery type Battery voltage at rest, Uend

Hawker Evolution/Exide 24.24 V
© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 4 – 11

Installation
Function and safety check
838, 839, 840 6053221- 2009-10-05 258944-040
4.5 Function and safety check

2
3
1, 5 4
12 6
11
10
9 8
13
Before the truck is put into operation, the following points must be
checked.
Pos. Inspection point Measure Duration scale

1 Operating control Check function 2:25 minutes
2 Safety reversing Check function
switch
3 Horn Check function
4 Steering Check function
5 Brake Check function
6 Emergency switch Check function
7 Hydraulic system Check all components
8 Drive unit Investigate possible noises and oil leaks
9 Wheel Investigate damage, remove dirt etc.
10 Chassis Investigate damage, remove dirt etc.
11 Battery cover and lock Check function
12 Battery Check acid and charging level
13 Fork carriage Investigate damage, remove dirt etc.

Maintenance
General
258944-040 2009-10-05 6053221- 838, 839, 840
5 – Maintenance
5.1 General
This chapter includes a survey diagram for regular maintenance fol-
lowed by detailed descriptions of required maintenance procedures.
5.2 Service intervals

The service intervals are merely a guideline and need not be strictly fol-
lowed. The service technician should adapt these to local require-
ments, however, it is important that the intervals coincide with the mini-
mum BT requirements.
The service intervals are based on truck operating hours and can be
adapted to most normal 8-hour shifts. The following operating hours
have been used when calculating the intervals.
Day time: 08.00-17.00 (20 h/week)
2 shifts: 06.00-14.00, 14.00-22.00 (40 h/week)
3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 h/week)
Make sure the truck is subjected to regular maintenance at intervals of
750 operating hours. The truck's safety, efficiency and service life
depend on the service and maintenance it receives.
Following completed service intervention, test drive the truck and per-
form an operational inspection. See the Installation chapter under the
heading Function and safety checks.
Only use BT approved spare parts during service and repairs

Maintenance
Maintenance chart
838, 839, 840 6053221- 2009-10-05 258944-040
5.3 Maintenance chart

Service maintenance should be performed in intervals of 750 operating
hours or every 12 months, whichever occurs first.
The sequence shown in the maintenance chart is not the optimised
working plan and is only sorted according to ‘C’ codes.
Truck area Pos. Action 750h/12m Estimated

time
0000 Chassis 1 Inspect cover mountings. X 5:20 minutes
2 Inspect signs and stickers X including
removal of
3 Inspect for cracking and X covers.
other damage
4 Inspect cylinder mounting X
in the fork carriage.
5 Inspect the locking screw in X
the castor wheel suspen-
sion.
6 Inspect the motor plate for X
cracks and other damage.
7 Tighten the paper holder X
tensioner if necessary
2 7
4
1
1
2
2
2
2
2 2
5
*M-plate to be fixed to specially manufactured trucks only.

Maintenance
Maintenance chart
258944-040 2009-10-05 6053221- 838, 839, 840
Truck area Pos. Action 500h/12m 750h/12m Estimated

time
0380 Fork 1 Inspect for cracking and X 1:30 minutes.
frame other damage
2 Inspect the play in bush- X
ings and links
3 Inspect the push rods and X
welds for cracks and other
damage.
4 Check the function and X
attachment of the battery
holder. Check the moun-
ting bracket on the battery
tray.
(Optional)
5 Insert grease in the nip- X
ples (6 pcs.) of the push
rods and fork wheels.
Applies to LWE140/160.
4
2

Maintenance
Maintenance chart
838, 839, 840 6053221- 2009-10-05 258944-040
2
1

time
0560 Platform and 1 Check crack formation and X 1:30 minutes
brackets (option) damage
2 Check the spring and that X
the platform returns to fol-
ded position from lowered
position

Maintenance
Maintenance chart
258944-040 2009-10-05 6053221- 838, 839, 840

time
1700 Drive motor 1 Inspect drive motor mount- X 4:30 minutes
ing.
2 Clean the drive motor X
3 Inspect the drive motor X
bearing for abnormal noise.
2550 Driving gear 4 Inspect for abnormal noise X
5 Inspect the steering bear- X
ing for correct mounting
and play, 23±3 Nm.
3180 Brakes 6 Clean the brake. X
7 Inspect play in the neutral X
position, 0,2 +0,1 mm.
6, 7
1, 2, 3
4
Maintenance
Maintenance chart
838, 839, 840 6053221- 2009-10-05 258944-040

time
3500 Wheels 1 Inspect drive wheel wear. X 2 minutes
2 Inspect the nuts, 81 ±19 Nm. X
3 Inspect castor wheel wear X
4 Inspect fork wheel wear. X
5 Check whether the castor wheel X
swings freely
4
1 3
Wheels Normal dimensions, Minimum

mm (H) dimensions, mm
Drive wheel 30 15
Castor wheels 20 10
Fork wheels 11 5,5

Maintenance
Maintenance chart
258944-040 2009-10-05 6053221- 838, 839, 840

time
4110 Tiller arm 1 Check the mounting. X 1:45 minutes
2 Inspect the steering con- X
sole for correct mounting
(4 pcs.)
23 ±3 Nm.
3 Inspect the handle for cor- X
rect mounting.
4 Inspect the strength of the X
gas suspension and the
locking performance.
The tiller arm should
return to the top position
both from the bottom
position and the lower
position in which the
brake is applied.
3
1

Maintenance
Maintenance chart
838, 839, 840 6053221- 2009-10-05 258944-040
Truck area Pos. Action 750h/12m Esti-

mated
time
5000 Electrical 1 Check the contacts, wiring har- X 4:30
system ness (including battery cables),
cable insulation and that all
cables are running freely.
2 Inspect the contactors for correct X
operation.
3 Inspect the error code log, truck X
operating hours and all display
segments.
4 Clean and check for possible play X
between the controller box and
the heat deflection plate.
5 Retighten all cable connections. X
6 Inspect all switches and sensors. X
5
5
2
4

Maintenance
Maintenance chart
258944-040 2009-10-05 6053221- 838, 839, 840

time
6000 Hydraulic 1 Inspect hoses and pipes for wear X 16 minutes
system 2 Inspect the oil level X
(Permitted range for oil level with
lowered forks, see picture)
3 Inspect the hydraulic unit for correct X
mounting.
4 Inspect the hydraulic system for pos- X
sible leakage.
5 Clean or replace the oil and clean the X
oil tank.
NOTE: Initially after 750 h/12 m, then
every 4500 h/36 m.
6 Clean the oil filter. X
NOTE: Initially after 750 h/12 m, then
every 4500 h/36 m.
6600 Lifting 7 Check the lifting cylinder and “Power- X
cylinder link-cylindern”(option) for leakage.
20 mm 2
30 mm 1, 3, 4, 5, 6
LWE140, LWE160,
LWE180
2
10 mm
LWE200, LWE250

Maintenance
Maintenance chart
838, 839, 840 6053221- 2009-10-05 258944-040

Functions and parameters
General
258944-040 2009-10-05 6053221- 838, 839, 840
6 – Functions and parameters
6.1 General
The chapter “Functions and parameters” provides a basic description
of the truck's main functions and the control system's parameters.
6.2 Function description

The section Function description gives a basic description of the truck's
main functions.
• Event – the use of any of the truck's main functions are called
events. All events are indicated using a figure.
• Preceding event – Indicates an event that must have happened im-
mediately before the current event in order for this to be carried out
correctly.
• Action(s) – An action that the driver must perform in order for an
event to happen.
• Influencing factors – Conditions that must be fulfilled in order for an
event to happen. Certain parameter settings also influence the
event's outcome.
• Resulting conditions - Describe the key events that can be checked
in order to confirm a function.
NOTE that the resulting conditions are showing what is assumed to
happen when there are no errors.
Text within square brackets [ ] refer to the electrical component names
in the truck's electrical diagram.
{High} means ≈ 24 V and {low} ≈ 0 V unless otherwise stated.

Function description
838, 839, 840 6053221- 2009-10-05 258944-040
Symbols on key pads and display
Symbol Description
ON button
This button is used to both start the truck
and to confirm settings
OFF button
Error code
Battery charge as a percentage
Parameter
Timer

Principle functions
258944-040 2009-10-05 6053221- 838, 839, 840
6.3 Principle functions
Event: 1. The battery is connected

Action(s) Connect the truck battery [G1]
Influencing factors Main fuse OK [F1]
Working fuses OK [F50, F51]
Resulting condi- The status LED for the transistor regulator is lit permanently [T1].
tions
Event: 2. Start truck
Preceding event(s) The battery is connected.
Action(s) Enter a valid PIN code and press the ON button on the keypad [S223].
Influencing factors Emergency stop [S21] is not active [T1:INP. SUPPLY+24V DC] {high}.
Sensor for tiller arm in drive position is not activated [B60] [T1:INP.TILLER
ARM IN DRIVE POS] {low}.
Resulting condi- The current lamp shines. The main display show the hour meter for 4 sec-
tions onds and then shows the battery's charge condition as a percentage of its
full charge.
The mechanical brakes remain connected [Q1] [T1:OUT.BRAKE
RELEASE] {high}.
Event: 3. Fold down tiller arm to drive position
Preceding event(s) Start truck.
Action(s) Lower the tiller arm.
Influencing factors Sensor for tiller arm in drive position [B60].
Resulting condi- Sensor for tiller arm in drive position is activated [B60] [T1:INP. TILLER
tions ARM IN DRIVE POS] {low}.
The main contactor output voltage becomes {low} [T1:OUT. MAIN CON-
TACTOR]
The main contactor is closed [Q10].

Principle functions
838, 839, 840 6053221- 2009-10-05 258944-040
Event: 4. Running in fork direction

Preceding event(s) Fold down tiller arm to drive position.
Action(s) Turn the speed control in the fork direction
Influencing factors Speed control with Hall-sensor [A5:S10-18].
Settings in the driver parameters 4, 5 and 6 affect the drive performance
Resulting condi- [T1:OUT.BRAKE RELEASE] becomes {low}.
tions The brake [Q1] is activated, the mechanical brake is released.
The current feed to the propulstion motor's field winding (S2 +ve and S1 -ve).
The pulse current feed to the drive motor's rotor is proportional to the
speed control's torsion.
Event: 5. Running in the castor wheel's direction
Preceding event(s) Fold down tiller arm to drive position.
Action(s) Turn the speed control in the castor wheel's direction
Influencing factors Speed control with Hall-sensor [A5:S1-9].
Settings in the driver parameters 4, 5 and 6 affect the drive performance
Resulting condi- [T1:OUT. BRAKE RELEASE] becomes {low}.
The current feed to the propulstion motor's field winding (S2 -ve and S1 +ve).
speed control's torsion.
Event: 6. Neutral braking
Preceding Running in the fork or castor wheel direction
event(s)
Action(s) Let the speed control go back to the free position.
Influencing fac- Adjust driver parameter 5.
tors
Resulting condi- The drive motor [M1] works as a generator and via the transistor regulator
tions [T1] converts the truck's kinetic energy into electricity, which causes the
truck to brake. The excess energy is fed back to the battery [G1] in the
form of electricity which is then charged. The mechanical brake [Q1] is
activated when the truck stops. [T1:OUT.BRAKE RELEASE] becomes {high}.

Principle functions
258944-040 2009-10-05 6053221- 838, 839, 840
Event: 7. Reverse braking

Preceding event(s) Running in the fork or castor wheel direction
Action(s) The speed control is turned to the other driving direction.
Influencing factors Parameter 201.
Resulting condi- The drive motor [M1] works as a generator and via the transistor regulator
tions [T1] converts the truck's kinetic energy into electricity, which causes the
truck to brake. The excess energy, in the form of electricity, is fed back to
the battery [G1] which is then charged. The braking effect increases the
more the speed control is turned.
The mechanical brake [Q1] [T1:OUT. BRAKE RELEASE] is activated
when the truck stops.
Event: 8. Mechanical internal braking
Preceding event(s) Running in the fork or castor wheel direction
Action(s) The tiller arm is folded completely up or down.
Influencing factors Sensor for tiller arm in drive position [B60].
Resulting condi- Sensor for tiller arm in drive position [B60] deactivated [T1:. INP. TILLER
tions ARM IN DRIVE POS] {low}.
When the tiller arm is folded completely up or down, this applies the high-
est permitted braking reduction at 200 ms or until the drive speed is lower
than 0.8 m/s. Then the mechanical brakes are activated [Q1].
[T1:OUT.BRAKE RELEASE] {high}.
Event: 9. Anti-collision safety switch
Preceding event(s) Running in the castor wheel's direction.
Action(s) When running in the castor wheel's direction, press in the anti-collision
safety switch [A5:S17].
Influencing factors Safety switch [A5:S17].
Resulting condi- The hall sensor [A5:S17] is activated directly. The logic card [A5] interprets
tions this signal as a command to the transistor regulator [T1] to run the drive
motor at reduced speed in the fork direction as long as the anti-collision
safety switch [A5:S17] is depressed. The command signal for normal run-
ning of the drive motor from the speed control is blocked until the speed
regulator is released and returnes to the neutral position.

Principle functions
838, 839, 840 6053221- 2009-10-05 258944-040
Event: 10. Fork lift

Preceding event(s) Start truck.
Action(s) Press in the fork lift button [A5:S19].
Influencing factors Main contactor [Q10].
Fuse [F1].
Fork lift button [A5:S19].
Battery status OK (battery's discharge indicator > 0 or
battery charge > 20 %).
Resulting condi- [T1:OUT. PUMP CONTACTOR] become {low}.
tions The pump contactor [Q25] are activated, the pump motor [M3] starts.
Event: 11. Fork lower
Preceding event(s) Start the truck or fork lift.
Action(s) Press the button for fork lowering [A5:S20].
Influencing factors Main contactor [Q10].
Button for fork lowering [A5:S20].
Resulting condi- [T1:OUT. LOWER VALVE] becomes {low}, hydraulic lowering valve [Q4] is
tions activated.
Event: 12. Click-2-Creep
Preceding Start truck.
event(s)
Action(s) Quick double operation of speed control in order to activate the function.
Put the tiller arm in the upright position and drive the truck at low speed
(2.5 km/h).
Influencing fac- Main contactor [Q10].
tors Adjsuting factory parameter 1002.
Resulting condi- [T1:OUT.BRAKE RELEASE] becomes {low}.

The current feed to the propulsion motor's field winding (S2 +ve and S1 -ve).
speed control's torsion. “SLO” is shown on the display (blinking).

Principle functions
258944-040 2009-10-05 6053221- 838, 839, 840
Event: 13. Turtle function (option)

Preceding Fold down tiller arm to drive position.
event(s)
Action(s) Press [S206] to activate the function.
Turn the speed control in one direction.
Influencing fac- Option button 1 [S206].
tors Adjusting driver parameter 7 and service parameter 202.
Resulting condi- [T1: OUT. BRAKE RELEASE] becomes {low}.

The current feed to the propulsion motor's field winding (S2 +ve and S1 -ve).
speed control's torsion. The maximum speed is limited by driver
parameter 7. “SLO” is shown on the display (shines constantly).

Timer
838, 839, 840 6053221- 2009-10-05 258944-040
6.4 Timer
When the truck is started, the timer on the display and the time meas-
urement symbol shines for 4 seconds.
The truck's control system stores five different time values. The time
values are controlled by parameter 103. To choose which value should
be shown, follow the instructions below.
1. Ensure that the battery is connected.
2. Ensure that the truck is turned off. Press the OFF button.
3. Punch in the chosen PIN code. NOTE! Without pressing the ON
button.
4. Keep the horn button pressed down until “H” appears, and then re-
lease the button. The time measurement symbol shines.
The different time measurement symbols are shown when you press
repeatedly on the speed control. The current time values are shown for
a short time after the setting has been chosen.
Time measurement value Display

Value 1 = Key time
The total time that the truck has been in use.
Value 2 = Operating time

The combined time whether the pump or drive motor has been
in operation.
Standard display.
Value 3 = Drive motor time
The total time that the drive motor has been in use.
Value 4 = Pump motor time

The total time that the pump motor has been in use.
Value 5 = Time remaining until service.

Parameter 101 controls the output value.

Parameters
258944-040 2009-10-05 6053221- 838, 839, 840
6.5 Parameters
6.5.1 General
The truck's control system stores a number of parameters. These
parameters are used to configure the truck for the right function with
regards to environment and application. The parameters are divided up
into three groups.
• Driver parameters – Adjusts the driving properties in the truck to a
certain driver or application. Driver parameters can be changed di-
rectly without a CAN service key.
• Service parameters – Used to adjust the truck's function proper-
ties. Service parameteters can only be adjusted using a suitable
CAN service key that is connected to the truck. NOTE that the serv-
ice parameters can be checked without a CAN service key having to
be connected, but the values cannot be changed.
• Factory parameters – Parameters that are entered during produc-
tion in the factory and may, if specific needs arise, be changed by
service technicians. The parameters state e.g. the truck model and
which controls to use for the hydraulic function. The factory parame-
ters cannot be changed via the CAN service key.
All parameters can be changed via PC/PDA and TruckCom.
6.5.2 Show parameters

If you only want to see the truck's different settings, use the following
instructions:
1. Connect the CAN key or press in the PIN code and then press on
the horn button and keep it pressed in.
The display shows:
- Operating times and remaining time to the next service (H)
- Error codes (E)
- Parameters (P)
- The hardware and software numbers (Pn)
- Display test function (d)
- Collision sensor log (c)
- Emergency (limp home) mode (ed)
2. Release the horn button to selected what you wish to view.
3. Turn the speed control to move between the different positions in
the function above.

Parameters
838, 839, 840 6053221- 2009-10-05 258944-040
6.5.3 Enter the parameters

To enter the parameters, use the following instructions:
1. Connect the CAN key or press in the PIN code and then press on
the horn button and keep it pressed in.
Release the horn button when the display shows “P”.
The parameter symbol remains lit.
2. Turn the speed control to move between parameters. Release the
control when the display shows the correct parameter number.
3. Press once on the horn button to change the value.
The parameter symbol starts blinking.
4. Change the value by turning the speed control.
5. Confirm the setting by pressing once more on the horn button.
The parameter symbol lights again, and stays on.
6. Complete the programming by pressing the OFF button.

Parameters
258944-040 2009-10-05 6053221- 838, 839, 840
6.5.4 Driver parameters

NOTE!
Changing specific truck parameters changes the trucks driving prop-
erties. Do not change any parameter values without the relevant prior
knowledge.
Parameter Name/unit Min/Max Step Std Description

4 Acceleration, % 10/100 5 80 States the truck's acceler-
ation capacity. NOTE that
the lower the parameter
value, the less time it takes
for the truck to reach its
maximum speed.
5 Internal brak- 10/100 5 90 States the motor's internal
ing, % braking force when the
speed control is in neutral.
The lower the parameter
value, the lower the inter-
nal braking time.
6 Maximum 30/100 5 100 States the trucks maxi-
speed, % mum speed.
7 Maximum 30/100 5 50 States the truck's maxi-
speed turtle mum speed when the tur-
function, % tle function is activated.

Parameters
838, 839, 840 6053221- 2009-10-05 258944-040
Factory installed driver parameters

Different driver profiles have different values input from the factory for
driver parameters 4, 5 and 6. See the table below.
The values for driver profiles 1 and 4-10 apply as standard values.
Driver pro- Parameter Factory set- PIN

file ting code
Driver profile 1 4 80 1
5 90
6 100
5 90
6 90
5 100
6 100
NOTE!
When changing software, the factory settings for driver profiles 2 and
3 disappear. All driver profiles are then given the same standard val-
ues, i.e. the standard values for driver profiles 1 and 4-10. If you want
to restore the factory settings, the values must be stated again, either
manually or via PC/PDA.

Parameters
258944-040 2009-10-05 6053221- 838, 839, 840
6.5.5 Service parameters

NOTE!
Changing specific truck parameters changes the trucks driving prop-
erties. Do not change any parameter values without the relevant prior
knowledge.
NOTE!
Parameter 201 must be set at a value that is as great or greater than
the value in parameter 5. If the value in any of the parameters is
changed so that the value in parameter 201 becomes less than the
value in parameter 5, the value in parameter 201 is automatically set
at 100. When the parameter value changes automatically, the error
code 2.002 is generated.
NOTE!
Ensure that service parameter 109 is set to the value of the battery
fitted, and that the correct battery capacity has been set in parameter
110.
NOTE!
Only 134 Ah, 174 Ah and 201 Ah Hawker Evolution battery sizes may
be used.
The CAN service key must be connected to the contact [X41] before
adjustment of the service parameters can be carried out.
Para- Name/unit Min/ Step Std Description

meter Max
101 Service interval, 0/ 50 0 States a limit when the next service
hours 2000 should take place. When it is time
for service, the error code 2.003 is
shown in the display.
0 = Service indicator off.
102 Driver access 1/10 1 3 States which login method should
be used and if the driver will have
the possibility to change the driver
parameter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad using 100
PIN codes
Values 5 and 6 = Keypad using
DHU[K110]
Values 7 and 8 = ID unit
Values 9 and 10 = ID unit using
DHU[K110]
Odd values = Open driver parame-
ters
Even values = Driver parameters
must be changed using the CAN
key.

Parameters
838, 839, 840 6053221- 2009-10-05 258944-040

meter Max
103 Timer option 1/5 1 2 States a time value for the timer.
For more information, see the sec-
tion about the Timer in this chapter.
104 Automatic log 0/20 1 20 States the time it takes before the
out, minutes truck is turned off when the keypad
is used. The time is calculated from
when the last power consuming unit
is used. Value 0 gives 4 hours.
105 Collision sen- 0/255 1 0 Option. States the degree of sensi-
sor X level tivity for what should be interpreted
as a collision for a shock to the side.
This parameter should be set on
truck installation. For more informa-
tion see the chapter Installation.
106 Collision sen- 0/255 1 0 Option. States the degree of sensi-
sor Y level tivity for what should be interpreted
as a collision for a shock to the front/
back. This parameter should be set
on truck installation. For more infor-
mation see the chapter Installation.
107 Battery adjust- 1/20 1 8 LWE140/160/180/200:
ment, Ah 8 = Large battery
12 = Medium battery
17 = Small battery
For more information, see the chap-
ter Installation.
10 LWE250 and LWE200 with platform:
10 = Large battery
14 = Medium battery
19 = Small battery
ter Installation.
109 Intergrated bat- 0/3 1 0 States what type of battery is to be
tery charger, charged.
battery type 0 = No charge. Standard type. Error
code is displayed if this parameter is
set at 0 when there is a battery
charger and factory parameter 1101
is set at 1.
1 = Lead/acid battery
2 = Hawker Evolution battery. Sizes
134 Ah, 174 Ah, 201 Ah
3 = Exide GEL battery
ter Installation.

Parameters
258944-040 2009-10-05 6053221- 838, 839, 840

meter Max
110 Intergrated bat- 0/300 1 0 States battery capacity
tery charger, (100/ (100) 0 (100) = No charge. Standard type.
battery capac- 300) Error code is displayed if this param-
ity, Ah eter is set at 0 (100) when there is a
battery charger and factory parame-
ter 1101 is set at 1.
The values in brackets () apply if the
truck has software version -006 or
later
ter Installation.
111 Resetting fol- 0/1 1 0 0 = Special pincode required for
lowing a colli- resetting after a collision.
sion 1 = The truck can be reset using all
activated pincodes.
2 = The horn sounds once every five
seconds.
3 = Alternatively, 1 and 2 combined.
201 Reverse brak- 70/ 5 100 States how powerful the truck
ing 100 brakes when the speed control is
turned in completely the opposite
direction
NOTE: This value must not be set
less than the value of parameter 5. If
it is lower error code 2.002 will be
displayed when start-up and the
value will not be changed.
202 Creep speed -200/ 5 0 States the speed that the truck has
200 when it reaches the first speed sen-
sor.
-200 = low speed at the first speed
sensor.
200 = high speed at the first speed
sensor.

Parameters
838, 839, 840 6053221- 2009-10-05 258944-040
6.5.6 Factory parameters

Adjsuting the truck's factory parameters is done during production in
the factory. You can only change the factory parameters via the soft-
ware TruckCom in a PC or PDA.
NOTE!
Remember that a change of specific truck parameters changes the
truck's properties. Do not change any parameter values without the
relevant prior knowledge. Only authorised service technicians with
personal TruckCom user identities have the rights to change factory
settings. This must only be done if specific needs arise.
The user identity and the time of parameter change is logged in the
handle's circuit board.

meter Max
1001 Truck type 0/6 1 0 0 = Unknown truck type
1 = LWE140
2 = LWE160
3 = LWE180
4 = LWE200
5 = LWE250
1002 Non-configurable 0/3 1 1 You have access to 3 func-
option tions via parameter 1002.
These functions are either
activated or deactivated.
The functions require no fur-
ther adjustment and are
therefor called non-config-
urable options.
0 = No option function
1= Click-2-Creep
2= Turtle function
3 =Both Click-2-Creep and
turtle function.
1003 ConfOption Func1 0/6 1 0 Requires SEU
1004 ConfOption 0/255 1 0 Requires SEU
Func1Arg1
Func1Arg2
Func1Arg3
Func1Arg4
Func2Arg1

Parameters
258944-040 2009-10-05 6053221- 838, 839, 840

meter Max
Func2Arg2
Func2Arg3
Func2Arg4
Func3Arg1
Func3Arg2
Func3Arg3
Func3Arg4
Func4Arg1
Func4Arg2
Func4Arg3
Func4Arg4
1023 Control for hydraulic 1/3 1 1 1 = Rear lift and lowering
function control connected to the first
hydraulic function and for-
ward control connected to
second hydraulic function.
2 = Rear lift and lowering
control connected to the
second hydraulic function
and forward control con-
nected to first hydraulic func-
tion.
3 = Both lift and lowering
control connected to the first
hydraulic function. There is
no second hydraulic func-
tion.
1101 Intergrated battery 0/1 1 0 0= Battery charger missing
charger 1= Battery charger present

Parameters
838, 839, 840 6053221- 2009-10-05 258944-040

Troubleshooting
General
258944-040 2009-10-05 6053221- 838, 839, 840
7 – Troubleshooting
7.1 General
The chapter Troubleshooting describes the error codes that are shown
on the display when the truck is completely or partly not working. The
causes of faults and actions for rectifying them are also described here.
The truck's electronic control system has an integrated error code dis-
play and log. When a fault occurs, the error code is shown on the dis-
play and the error code lamp blinks.
The first time that an error code is shown on the display, it can be good
to check if the error persists by restarting the truck.
NOTE!
The request to Restart the truck always means that the battery sleeve
should be pulled out before the truck is started again.
Software compatibility
Ensure that the logic card ICH [A5] and transistor regulator ACT [T1],
and battery charger BCU [A30], has software from the same software-
package.
In order to guarantee all truckfunctions make sure to have last software
package downloaded.
Emergency travel mode

If the truck for some reason stops operating and remains immobile in
an unsuitable place, it is possible to activate the emergency travel
mode to move the truck out of the way.
1. Enter your PIN code.

2. Press the horn button and keep it depressed.
“Ed” is displayed.
3. Relase the horn button.
All lamps blink and “SLO” is displayed.
It is now possible to drive the truck, but exercise extreme caution. It is
not possible to brake by raising the tiller arm.
If the truck is on an incline, be even more careful when using the
emergency travel mode. If too much acceleration is used, there is a
risk the truck can roll away. To stop the truck, change the travel direc-
tion to the opposite direction.
With some errors, the emergency travel mode will not operate. In this
case, it is not possible to receive information about the error.

Troubleshooting
Troubleshooting methods
838, 839, 840 6053221- 2009-10-05 258944-040
7.2 Troubleshooting methods
7.2.1 Troubleshooting general introduction

Begin troubleshooting
Has an error code Follow the instructions

Eliminate unlikely causes
been displayed? in the chapter
Yes “Troubleshooting”
No
Are the symptoms in Follow the instructions Choose and prioritise

the troubleshooting in the troubleshooting the most likely causes
diagram? Yes diagram
No
Collect as much When you have identified

information about the Where in the workplace
did the problem occur? the error, see the
problem as possible instructions in the
chapter “Actions”
When did the problem
occur?
What functions are

affected?
What circumstances
triggered the problem?
Identify all parts which

may cause the problem.
Use the wiring diagram
when needed.

Troubleshooting
Troubleshooting methods
258944-040 2009-10-05 6053221- 838, 839, 840
7.2.2 Completed troubleshooting

Drive the truck in the same way
Conclude troubleshooting it was being driven when the
problem first occurred. Verify
that the problem does not
occur again
Ensure that all cables and

hoses are placed back in Let the driver drive the truck.
the correct way. Verify that the problem does
not occur again
By giving feedback,
If you have contacted the you can contribute to a shared
Ensure that all parts that technical support department knowledge database. This is important
have been emptied of liquids to discuss the problem, speak for continually improved support to
have been refilled to the to them again and tell them service technicians in the field
correct level that you have solved the
problem
Recreate the
circumstances that existed
when the problem first
occurred

Troubleshooting
Error code history
838, 839, 840 6053221- 2009-10-05 258944-040
7.3 Error code history

Up to 50 of the last error code events can be stored together with the
timer values for when the error occurred. In the error code log, the error
codes are shown chronologically with the most recent error code first.
To show the error code log, work according to the following instruc-
tions:
1. Ensure that the battery is connected.
2. Ensure that the truck is turned off. Press the OFF button.
3. Punch in the chosen PIN code. NOTE! Without pressing the ON
button.
4. Keep the horn button pressed down until “E” appears, and then re-
lease the button. The error code symbol is lit.
The most recent error is shown The display alternates between the
error code and the timer value when the error occurred. If the error code
log contains more than one code, these codes can be shown by press-
ing repeatedly on the speed control.

Troubleshooting
Error code system
258944-040 2009-10-05 6053221- 838, 839, 840
7.4 Error code system

See the tables below for an explanation of the error code system.
Structure Description
G.ANN Example 3.510
G (3) Group. States which system is affected by the error.
A (5) Error category. Describes the type of fault that occurred and
what happened.
NN (10) Error code
Group Description
1 Do not use
2 Transistor regulator and logic card
3 The drive system
4 The hydraulic system
5 Do not use
6 Do not use
7 Do not use
8 Option
Error cate- Description

gory
0 Use caution. Mainly an information code, which indicates that
certain of the truck's functions are reduced or do not work.
1-2 Lifting errors. Raising and lowering of the forks is impaired or
not working and the truck's speed is reduced to safety speed.
3 Do not use.
4 Critical error. The main contactor opens. The truck stops.
5 Critical error. The main contactor opens. The truck stops.
Code Description
00-09 Diverse error codes.
10-19 CAN related error codes.
20-39 Error codes regarding specific units.
40-59 Error codes for short-ciruited outputs.
60-79 Error codes for open electrical circuits.
80-99 Faulty signals from sensors.

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040
7.5 Error codes

NOTE that certain error codes are stored in the programme and disap-
pear from the display while other error codes remain on the display and
require that the truck is first stopped and then restarted for the error
code to disappear.
Code Event Possible cause

Measure
Transistor regulator and logic card
E141 Software download interrupted Transfer cable disconnected.
Restart the download in “Emergency
download” mode
2.001 The transistor regulator stops all functions. Emergency switch pressed.
Check:
• that the emergency switch is unaf-
fected
• cable 24.
• Fuse [F51]
2.002 No event. The truck can be driven. Certain parameter values may be out-
side the predefined values. Reset the
parameters to standard values.
• Check the parameter settings.
• If the code is immediately followed
by error code 2.004, copy configura-
tion via TruckCom to transistor regu-
lator[T1].
2.003 No event. The truck can be driven. Time for service.
Check the service meter (timer S). This
may not have been reset after the last
service.
2.004 No event. The truck can be driven. The values in the transistor regulator's
backup file is different from the values
in the handle's logic card with regards
to parameters, timers and/or machine
number.
Check via TruckCom where the correct
data is. See table 7.6.4.
2.101 Safety speed, raising and lowering the The truck type has not been indicated.
forks not working.
State the truck type by adjusting factory
parameter 1001 (Truck type) or see
table 7.6.4

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
2.102 Safety speed, raising and lowering the The stated truck type does not support
forks not working. the analogue raising and lowering func-
tions.
Check the factory parameter settings
1001 (Truck type) and 1023 (Hydraulic
function control).
2.501 The main contactor opens. Low battery voltage <16.8 V> for more
than 2 seconds
Charge the battery. Inspect all cables
and connectors
2.511 The main contactor opens. CAN communication error.
Check:
• connections and wiring harness
• cables 119 and 120
• logic card in the handle.
2.514 The main contactor opens. CAN communication error.
Check:
• cables 119 and 120.
• logic card in the handle.
2.515 The truck does not start CAN communication error.
Check:
• connections and cabling between
DHU [K110] and logic card ICH [A5]
2.520 The main contactor opens. Fault in the software for the control
handle or microprocessors.
Download new software.
2.521 The main contactor opens. The safety reversing function is faulty.
Mechanical fault of fault with the hall
sensor that controls the safety revers-
ing function.
Check via TruckCom that the hall sen-
sor works.
2.522 The main contactor opens. Faulty power supply to the hall sensor.
Check via TruckCom that the hall sen-
sors work.

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
2.523 The main contactor opens. The main contactor is not activated.
• Check that the main contactor
works.
• Open the main contactor.
Drive system
3.001 Driving is prevented until the speed con- • The speed control is not in neutral
trol is in neutral. when starting.
• Faulty hall sensor.
Check:
• speed controller's function
• via TruckCom that the hall sensors
work.
3.002 The transistor regulator reduces the maxi- The transistor regulator's temperature
mum current to 50 %. exceeds +85°C. The driving may be
too intensive.
• Drive the truck less intensively.
• Check for dirt around the transistor
regulator. Too much dirt means that
the transistor regulator does not cool
down properly.
3.003 The transistor regulator reduces the maxi- The motor's temperature exceeds
mum current to 50 %. +150°C. The driving may be too inten-
sive.
• Drive the truck less intensively.
• Check for dirt around the motor. Too
much dirt means that the motor does
not cool down properly.
3.040 No event. The truck can be driven. Faulty energy saving function in the
holding position.
• Internal fault in the transistor regulator.
• Restart the truck.
• If the error persists, change the tran-
sistor regulator.
3.080 The transistor regulator reduces the maxi- The temperature sensor for the transistor
mum current to 50 %. regulator shows abnormal values.
sistor regulator.

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
3.081 The transistor regulator reduces the maxi- The temperature sensor for the motor
mum current to 50 %. shows abnormal values. The sensor
may be faulty.
Check cables (63/64) to the tempera-
ture sensor in the motor.
3.101 Safety speed, raising and lowering the The transistor regulator is using prede-
forks not working. fined current gain. Internal fault
sistor regulator.
3.120 Safety speed, raising and lowering the Faulty control total for parameters in
forks not working. the transistor regulator.
• Reprogramme the truck.
sistor regulator.
3.121 Safety speed, raising and lowering the The transistor regulator cannot use the
forks not working. internal memory.
• Reprogramme the truck.
sistor regulator.
3.140 The horn does not work. The safety The horn output has short-circuited.
speed.
Check:
• cable 50
• the horn.
3.501 The main contactor opens. Faulty transistor regulator.
Check:
• the transistor regulator
• factory parameter 1001 (Truck type).
If the error persists, change the transis-
tor regulator.

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
3.502 The main contactor opens. The control handle's logic card cannot
download parameters to the transistor
regulator.
• Change logic card in the handle.
sistor regulator.
3.510 The main contactor opens. CAN communication problem with the
transistor regulator when starting.
Check:
• make sure that the ICH [A5] and
ACT [T1] have compatible software.
See Section "7.1 General".
• logic card in the handle and possibly
change the card.
tor regulator.
3.511 The main contactor opens. The handle's logic card does not see
CAN data from the transistor regulator.
Check:
change the card.
tor regulator.
3.512 The transistor regulator stops all functions. The transistor regulator does not see
CAN data from the control handle's
logic card.
Check:
change the card.
tor regulator.

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
3.514 The main contactor opens. The logic card in the control handle
cannot send CAN data to the transistor
regulator.
Check:
change the card.
tor regulator.
3.515 The transistor regulator stops all functions. The transistor regulator discovers CAN
communication error.
Check:
change the card.
tor regulator.
3.520 The transistor regulator stops all functions. The transistor regulator discovers
short-circuit in the output step.
Check:
• motor cables
• motor
• the transistor regulator.
3.521 The transistor regulator stops all functions. The transistor regulator discovers low
motor voltage.
Check:
• motor cables
• motor
3.522 The transistor regulator stops all functions. The transistor regulator discovers high
motor voltage.
Check:
• motor cables
• motor

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
3.523 The transistor regulator stops all functions. The transistor regulator discovers inter-
nal problems with its own software or
hardware.
Internal fault in the transistor regulator.
Reprogramme the truck both in the
handle and the transistor regulator.
3.524 The transistor regulator stops all functions. The transistor regulator discovers inter-
nal problems with its own software or
hardware.
Reprogramme the truck both in the
handle and the transistor regulator.
3.525 The transistor regulator stops all functions. The transistor regulator discovers that
the motor phase is always 0 (zero).
Check:
• motor cables
• motor
3.526 The transistor regulator stops all functions. The transistor regulator's voltage feed
is wrong.
Change transistor regulator.
3.527 The transistor regulator stops all functions. Faulty transistor regulator software.
Check that the last software for the
transistor regulator exists.
3.528 The transistor regulator stops all functions. Internal problem for the transistor regu-
lator's microprocessor.
Check that the last software for the
transistor regulator exists.
sistor regulator.
3.529 The transistor regulator stops all functions. The transistor regulator discovers an
internal problem.
• Internal fault in the transistor regula-
tor. Check the software.
sistor regulator.

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
internal problem.
sistor regulator.
internal problem.
sistor regulator.
3.532 The transistor regulator stops all functions. The transistor regulator has an internal
problem in the AD transformer.
tor.
• Change transistor regulator.
3.533 The transistor regulator stops all functions. The charging voltage for the transistor
regulator's capacitor shows abnormal
values.
Check:
• cable 20
• pump contactor
tor regulator.
3.534 The transistor regulator stops all functions. The transistor regulator discovers a
problem with the speed sensor. The
jump in frequency is too great.
Check:
• the speed sensor and possibly
change it.
3.535 The transistor regulator stops all functions. Faulty control total for parameters in
the transistor regulator.
Download new programme in the han-
dle and transistor regulator.

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
3.536 The transistor regulator stops all functions. The transistor regulator's current sen-
sor is outside valid intervals.
3.537 The transistor regulator stops all functions. Multiple direction commands from the
handle.
Internal fault in the handle.
3.538 The main contactor opens. Unknown fault in the transistor regula-
tor.
tor. Reprogramme the transistor reg-
ulator.
sistor regulator.
3.539 The transistor regulator stops all functions. The transistor regulator discovers that
the battery voltage value is not
between 18 V - 28.8 V.
Check:
• the cables between the battery and
transistor regulator.
• the battery.
3.540 The transistor regulator stops all functions. The transistor regulator's output to the
main contactor has short-circuited.
Check:
• the main contactor.
parking brake has short-circuited.
Check:
• the parking brake.

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
3.542 The transistor regulator stops all functions. One of the transistor regulator's circuits
to the main contactor, parking brake or
lowering valve has shortcircuited
at+24 V when starting.
Check
• main contactor
• parking brake
• lowering valve.
main contactor is short-circuited.
Check:
3.561 The transistor regulator stops all functions. The circuit between the transistor regu-
lator and the coil in the main contactor
is open.
Check:
3.562 The transistor regulator stops all functions The transistor regulator's output to the
parking brake is open.
Check:
• parking brake.
3.563 The transistor regulator stops all functions. The transistor regulator's coil circuit to
the parking brake is open.
Check:
• parking brake.
3.580 The transistor regulator stops all functions. Main contactor closed.
Check:

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
3.581 The transistor regulator stops all functions. Main contactor closed.
Check:
• main fuse [F1]
3.582 The transistor regulator stops all functions. The transistor regulator's output for
power supply has the wrong voltage
level.
Check:
• the main contactor
• lowering valve
• brake
• pump contactor.
3.583 The transistor regulator stops all functions. The transistor regulator's internal
power supply does not increase.
Hydraulic system
4.001 Lifting is prevented until the analogue con- The analogue control for lifting and low-
trol of lifting and lowering is back in the ering is not in the neutral setting when
neutral setting. starting. (Applies to SWE trucks).
Speed control not affected when start-
ing the truck.
Check:
• cable in the handle
• potentiometer. For fault, change po-
tentiometer.
4.101 Safety speed, raising and lowering the Analogue control signals for lifting and
forks not working. lowering shows abnormal values.
Speed control not affected when start-
ing the truck.
Check:
• cable in the handle
• potentiometer. If broken, change po-
tentiometer.

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
4.102 Safety speed, raising and lowering the The handle type does not correspond
forks not working. with the adjustment for factory parameter
1023 “Control for hydraulic function”.
Check the adjustment for factory
parameter 1023 and compare with the
truck's handle.
4.125 Safety speed, raising and lowering the The pump motor's current feedback is
forks not working. always zero when the pump motor is in
operation.
The current sensor in the transistor
regulator is faulty. Change transistor
regulator.
4.126 Safety speed, raising and lowering the The pump motor's current feedback is
forks not working. too high when starting and in holding
position.
The current sensor in the transistor
regulator is faulty. Change transistor
regulator.
4.521 The main contactor opens. The pump motor's voltage is too low.
Check:
• the cable between the transistor reg-
ulator and pump motor.
• the pump motor.
4.522 The main contactor opens. The pump motor's voltage is too low.
Check:
• the cable between the transistor reg-
ulator and pump motor.
• the pump motor.
4.540 The transistor regulator stops all functions. • The transistor regulator's output to
the lowering valve has short-
circuited.
• Internal short-circuit in the transistor
regulator.
• Check connections and wiring har-
ness
• Loosen the connection to the lower-
ing valve and try to restart.
• If the error persists, change the low-
ering valve or change the transistor
regulator.

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
lowering valve has short-circuited to B-.
Check connections and wiring harness
lowering valve is open.
Check:
• the lowering valve's coil.
Option
8.001 Safety speed, raising and lowering the The collision sensor has registered col-
forks not working. lision levels that are above the stated
limits.
• Drive carefully.
• Check the limits for registering colli-
sions (service parameters 105 and
106).
8.002 Safety speed, raising and lowering the The truck has deliberately been put in
forks not working. an unusable state by TLS.
Reset the truck to normal operation.
8.003 No event. The truck can be driven. Argument warning from the Spider
expansion unit.
Check the settings for selected param-
eters.
8.010 No event. The truck can be driven. CAN communication problem with the
battery charger when starting.
• Check connections and wiring har-
ness
• Make sure that the ICH [A5] and
BCU [A30] have compatible softwa-
re. See Section "7.1 General".
8.011 No event. The truck can be driven. The handle's logic card does not see
CAN data from the battery charger.
8.014 No event. The truck can be driven. The logic card in the control handle
cannot send CAN data to the battery
charger.
8.020 No event. The truck can be driven. The battery charger is not connected to
the battery.

Troubleshooting
Error codes
258944-040 2009-10-05 6053221- 838, 839, 840

Measure
8.021 No event. The truck can be driven. The battery charger has discovered
low battery voltage.
Check the battery's status
high battery voltage.
Check the battery's status
low charging temperature.
Charge the battery at normal tempera-
ture.
high charging temperature.
Check:
• dirt in the battery charger. Clean if
needed.
• that the fan works.
8.027 No event. The truck can be driven. Serious fault in the battery charger.
Change battery charger.
8.028 No event. The truck can be driven. The battery cahrger has exceeded the
time limit for charging.
Check the battery.
8.029 No event. The truck can be driven. The battery charger charges more than
maximum capacity.
Check:
• battery
• service parameter 110.
8.030 No event. The truck can be driven. There is a battery charger in the truck,
but has not been activated via factory
parameter 1101.
Check factory parameter 1101.
8.031 No event. The truck can be driven. Faulty parameter adjustment for the
battery charger.
Restart the truck. Check that the truck
and battery charger have the right soft-
ware.
8.032 No event. The truck can be driven. If the error code is displayed when
charging using a built-in charger,
parameter 109 is set incorrectly
Check service parameter 109

Troubleshooting
Error codes
838, 839, 840 6053221- 2009-10-05 258944-040

Measure
8.110 Safety speed, raising and lowering the CAN communication problem with Spi-
forks not working. der expansion unit 1 when starting.
forks not working. der expansion unit 1.
forks not working. der expansion unit 2 when starting.
forks not working. der expansion unit 2.
8.123 Safety speed, raising and lowering the Spider expansion unit 1 programme
forks not working. warning.
Check parameter selections.
8.124 Safety speed, raising and lowering the Spider expansion unit 2 programme
forks not working. warning.
Check parameter selections.

Troubleshooting
Troubleshooting diagram
258944-040 2009-10-05 6053221- 838, 839, 840
7.6 Troubleshooting diagram

The following section describes different types of error that may arise
and what these errors can be caused by.
The troubleshooting is grouped according to different symptoms that
can occur:
• The truck cannot be driven
• The truck can be driven but only at reduced speed
• The truck can be driven but behaves abnormally
• Faulty hydraulic functions.

Troubleshooting
838, 839, 840 6053221- 2009-10-05 258944-040
7.6.1 The truck cannot be driven
Symptom Influencing factors Possible cause

The mechanical brakes Sensor [B60] • The sensor is in the wrong po-
cannot be activated. sition and is affected by metal.
• The sensor is faulty.
The control handle in drive posi- The cable is damaged and gives
tion is always “Plus” faulty plus/minus measurement
Transistor regulator, input Broken transistor regulator
[T1:95].
The mechanical brakes Sensor [B60] • The sensor is in the wrong po-
cannot be released. sition and cannot be influ-
enced normally
• The sensor is faulty
• Break in the sensor's cable
Transistor regulator, input Broken transistor regulator
[T1:95]
Transistor regulator, output
[T1:90]
Corrosion The brakes are locked due to
corrosion
The truck cannot be Sensor [B60] • The sensor is in the wrong po-
driven after starting, sition and is affected by metal
despite the control handle
• The sensor is faulty
being folded up.
The control handle in drive posi- The cable is damaged and gives
tion is always “Plus” faulty plus/minus measurement
Transistor regulator, input Broken transistor regulator.
[T1:95].

Troubleshooting
258944-040 2009-10-05 6053221- 838, 839, 840
7.6.2 The truck can only be driven at reduced

speed

Always reduced speed Click-2-Creep function Click-2-Creep function activated
Turtle function Turtle function activated
Driver parameter 6 - speed Driver parameter 6 not set at the
maximum value
Pulse sensor [B11] The pulse sensor [B11] is bro-
ken, dirty or not connected
Connection of motor cables • One of the phases U, V, W is
unconnected
• Broken cable
Mechanical brakes • Partly working brakes
• Faulty play.

Troubleshooting
838, 839, 840 6053221- 2009-10-05 258944-040
7.6.3 The truck can be driven but behaves

abnormally

The truck goes in the wrong Connection of motor cables Connections U, V, W are
direction. wrongly connected
Always reduced accelera- Driver parameter 4 Set at a low value.
tion
Always reduced reverse Service parameter 201 Set at a low value.
braking.
Always reduced neutral Driver parameter 5 Set at a low value
braking
The truck cannot be Parameter 102 The Red off key Parameter 102 has been incor-
switched off. on the keypad does not work. rectly set for the log-in unit
installed in the truck.
Always reduced speed. Pulser [B11] The pulser [B11] is broken, dirty
or not connected
Connection of motor cables • Some of the phases U, V, W
are disconnected
• Cable breakage
7.6.4 The truck can be driven but lacks

certain functions.
Software compatibility
Make sure that the right software for the logic card [A5] and transistor
controller [T1], and battery charger [A30] are installed on the truck. See
Section "7.1 General".

Troubleshooting
258944-040 2009-10-05 6053221- 838, 839, 840
Matrix for hardware compatibility

Make sure the correct hardware for logic card [A5] and transistor regu-
lator [T1] has been installed in the truck by referring to the matrix below.
Not replaced transistor Replaced transistor

regulator ACT[T1] regulator ACT[T1]
Not replaced ICH OK Warning 2.004. Use TruckCom
logic card [A5] to download backup values. In
TruckCom, select “Copy config-
uration to secondary unit ACT”
Replaced ICH Error code 2.101. Use Truck- Replace a node at a time and
logic card [A5] Com to upload backup values. carry out the corresponding
Select “Copy configuration to step. See 17.2 and 16.5.2
primary unit: ICH”

Troubleshooting
838, 839, 840 6053221- 2009-10-05 258944-040
7.6.5 Faulty hydraulic functions
Symptom Influencing factors Possible cause/Action

The forks can be lowered but No or low hydraulic pressure • Low oil level
not raised.
• Blocked intake filter
• Faulty or wrongly adjusted
pressure limiting valve
• Faulty hydraulic pump,
change hydraulic unit
Pump contactor [Q25] does not • Measure the current and volt-
close age over the pump contactor
[Q25].
For more information read
more in the following table
Pump contactor [Q25] does
not close:
• The pump contactor [Q25]
current/voltage is normal”
• No current or voltage through/
across the contactor coil
[Q25]
• Voltage across the contactor
coil [Q25], but no current
through it.
Pump motor [M3] does not work • The hydraulic unit's fuse [F1],
125 A, has burned out:
change the fuse.
Pump motor [M3] does not
work:
• Measure the current and volt-
age respectively across the
pump motor [M3].
• The pump motor's [M3] cur-
rent/voltage is normal
across the motor [M3]
• Voltage across the motor
[M3], but no current through it
The height switch [B61] does not • Check the switch and its con-
work nections

Troubleshooting
258944-040 2009-10-05 6053221- 838, 839, 840

The forks can be raised but The magnetic valve [Q4] for low- • Measure the current and volt-
not lowered. eri ng the forks does not open age respectively across the
valve's coil.
The magnetic valve [Q4] for
the lowering of forks does not
open:
• The magnetic valve's voltage/
current is normal
across the magnetic valve's
coil
• Voltage across the magnetic
valve's coil, but no current
through it
The forks can neither be Fuse [F50] 7.5 A is faulty Change the fuse
raised or lowered
Logic card [A5] is faulty Replace logic card
Transistor regulator [T1] is faulty Change transistor regulator
Factory parameter 1023 Check the setting of the parame-
ter value
Continued. Pump contactor [Q25] does not close

The pump contactor [Q25] Fault in connector Change pump contactor
current/voltage is normal
No current or voltage Damage in the pump contactor Take control measurement of
through/across the contactor cables or connections the cable with regards to break-
coil [Q25] age or short circuit to another
cause
The control arm's Hall element Replace logic card [A5]
for fork lifting is faulty
Transistor regulator [T1], output Change transistor regulator [T1]
107 “OUT.PUMP CONTAC-
TOR” is faulty
Transistor regulator [T1], output See troubleshooting table The
82 “OUT. +24 V HIGH SIDE truck cannot be driven
DRIVER” is faulty

Troubleshooting
838, 839, 840 6053221- 2009-10-05 258944-040
Continued. Pump contactor [Q25] does not close

Voltage across the contactor Break in the pump contactor coil Change pump contactor
coil [Q25], but no current [Q25]
through it
Continued. Pump motor [M3] does not work:

The pump motor's [M3] current/ Mechanical fault in the pump Change hydraulic unit
voltage is normal
No current or voltage through/ Damage in the pump motor's Take control measurement of
across the motor [M3]” [M3] cables or connections the cable with regards to break-
age or short circuit to another
cause
Voltage across the motor [M3], Break in the pump motor [M3] Change hydraulic unit
but no current through it
Continued. The magnetic valve [Q4] for lowering the forks does not open:
The magnetic valve's [Q4] Mechanical fault in the valve Change hydraulic unit
current/voltage is normal [Q4]
No current or voltage Damage in the magnetic valve's Take control measurement of
through/across the magnetic [Q4] cables or connections the cable with regards to break-
valve's coil [Q4] age or short circuit to another
cause
The control arm's Hall element Replace logic card [A5]
for fork lowering is faulty
Transistor regulator [T1], output Change transistor regulator [T1]
108 “OUT.LOWER VALVE” is
faulty
Transistor regulator [T1], output See troubleshooting table The
82 “OUT. +24 V HIGH SIDE truck cannot be driven
DRIVER” is faulty
Voltage across the magnetic Break in the magnetic valve's Change hydraulic unit
valve's coil [Q4], but no cur- coil [Q4]
rent through it

Troubleshooting
Built-in test function
258944-040 2009-10-05 6053221- 838, 839, 840
7.7 Built-in test function

The control system of the truck has a number of built-in test functions
that are useful in the troubleshooting process. To activate the test func-
tions:
1. Connect the CAN service key to [X41] and log in.
2. The battery status symbol lights up.
3. Press the signal horn button [S18] repeatedly to select the mode of
the built-in test function.
NOTE!
All truck functions work as normal while the built-in test function is
active. Be careful if driving the truck and reading the display at the
same time.
Set- Flashing symbol Data shown in the display Normal

ting value
1 Battery voltage (V)
2 Current over battery (A) -
3 The set speed value that is sent to the Min: -142

transistor regulator Max: 142
4 Speed value from the speed sensor Min: approx. -

140
Max: approx.
140
5 Fork lowered to/from To: 1 From: 0
Fork lift to/from To: 2 From: 0
6 N/A -
7 N/A -
8 N/A -
9 Status of inputs/outputs, transistor regula- -

tor [T1]

Troubleshooting
Status of digital inputs/outputs
838, 839, 840 6053221- 2009-10-05 258944-040
Set- Flashing symbol Data shown in the display Normal

ting value
10 Input/output status, logic card [A5] -
11 Maximum value registered by the collision Min: 0

sensor (optional) Max: 100
12 Status of inputs/outputs, expansion unit 1 -

(optional)
13 Status of inputs/outputs, expansion unit 2 -

(optional)
7.8 Status of digital inputs/outputs
7.8.1 Test function “9” – Transistor regulator
In this mode, the digital inputs and outputs can be tested by checking
specific segments on the display as set out in the following tables.
A
F G B
E C
1 2 3 4 D H
Position:
1. Transistor regulator inputs
2. Transistor regulator outputs
3. Digital input to electronic card [A2]
4. Extra functions
A – H: Reference to segment
One or more segments can be lit in each position. Indications can also
be combined over several positions.
[xxx] in the table is a component name
{nn} in the table is a cable number in the wiring diagram.

Troubleshooting
258944-040 2009-10-05 6053221- 838, 839, 840
Function Pos 1 Pos 2 Pos 3 Pos 4

- A * * * Not assigned
Main contactor [Q10] B * * * On: Contactor closed
Off: Contactor open
Parking brake [Q1] C * * * On: Brake off
Off: Brake on
Tiller arm in drive position [B60] D * * * On: Tiller arm in drive
INP. TILLER ARM IN DRIVE position
POS. Off: Tiller arm in one of
the end positions
- E * * * Not assigned
- F * * * Not assigned
- G * * * Not assigned
- H * * * Not assigned
- * A * * Not assigned
- * B * * Not assigned
- * C * * Not assigned
- * D * * Not assigned
Pump motor contactor [Q25] * E * * On: Contactor open
Off: Contactor closed
- * F * * Not assigned
- ‘ G * * Not assigned
- * H * * Not assigned
A
F G B
E C
D H

Troubleshooting
838, 839, 840 6053221- 2009-10-05 258944-040

- * * A * Not assigned
Main contactor [Q10] * * B * On: Contactor closed
OUT. MAIN CONTACTOR Off: Contactor open
- * * C * Not assigned
Parking brake [Q1] * * D * On: Brake off
OUT. BRAKE RELEASE Off: Brake on
- * * E * Not assigned
- * * F * Not assigned
Lowering valve * * G * On: Lowering valve open
Off: Lowering valve
closed
- * * H * Not assigned
Pump motor contactor [Q25] * * * A On: Contactor closed
OUT. PUMP CONTACTOR Off: Contactor open
- * * * B Not assigned
- * * * C Not assigned
- * * * D Not assigned
- * * * E Not assigned
- * * * F Not assigned
- * * * G Not assigned
- * * * H Not assigned
A
F G B
E C
D H

Troubleshooting
258944-040 2009-10-05 6053221- 838, 839, 840
7.8.2 Test function “10” - Logic card

- A * * * Not assigned
- B * * * Not assigned
- C * * * Not assigned
Front fork lift button [A5:S19] D * * * On: Button pressed
Front fork lowering button E * * * On: Button pressed
[A5:S20]
Rear fork lift button [A5:S21] F * * * On: Button pressed
Rear fork lowering button G * * * On: Button pressed
[A5:S22]
Control for horn [S18] H * * * On: Button pressed
Outermost selection button, * A * * On: Button pressed
right side [S116]
Central selection button, right * B * * On: Button pressed
side [S115]
Innermost selection button, * C * * On: Button pressed
right side [S114]
Outermost selection button, left * D * * On: Button pressed
side [S113]
Central selection button, left * E * * On: Button pressed
side [S206]
Innermost selection button, left * F * * On: Button pressed
side [S111]
A
F G B
E C
D H

Troubleshooting
838, 839, 840 6053221- 2009-10-05 258944-040
7.8.3 Test function “12” – Expansion unit

SEU (optional).

Digital input 1, SEU1 A * * * -
Digital input 2, SEU1 B * * * -
Digital input 3, SEU1 C * * * -
Digital input 4, SEU1 D * * * -
Digital input 5, SEU1 E * * * -
Digital input 6, SEU1 F * * * -
Digital input 7, SEU1 G * * * -
Digital input 8, SEU1 H * * * -
Digital output 1, SEU2 * A * * -
Digital output 2, SEU2 * B * * -
Digital output 3, SEU2 * C * * -
Digital output 4, SEU2 * D * * -
- * E * * Not assigned
- * F * * Not assigned
A
F G B
E C
D H

Troubleshooting
Display test function
258944-040 2009-10-05 6053221- 838, 839, 840
7.9 Display test function

The digital display [A6] can be tested to verify that all segments light up
correctly.
Follow these steps to test the display:
1. Make sure the battery is connected.
2. Make sure the truck is switched off. Press the OFF button.
3. Enter the selected PIN code. NOTE: Do NOT press the ON button.
4. Keep [S18] pressed until “d” is displayed, then release [S18].
All segments and symbol icons must flash in sequence.

Troubleshooting
Display test function
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Chassis 0000
258944-040 2009-10-05 6053221- 838, 839, 840
8 – Chassis 0000
8.1 General
To gain access for certain inspection items, it may be necessary to dis-
assemble the drive unit from the fork frame.
Pos. Designation
A Cylinder locking
B Mounting hole
C Axle 2
D Stop screw 2
E Nut 2

Actions
Chassis 0000
838, 839, 840 6053221- 2009-10-05 258944-040
8.2 Disassemble the drive unit from the

fork frame
Proceed as follows to separate the fork frame from the drive unit:
1. Ensure that the truck is standing on a level surface.
2. Remove the inspection covers and the battery door
The top cover is secured with Velcro tape. Be careful when detach-
ing the cover. Use of a suitable tool is recommended.
3. Raise the forks.
4. Unscrew and remove the axle lockings on each side (D, E).
5. Lower the forks and disconnect the battery connector.
6. Unfasten the battery cables and clips as well as the emergency
stop cables from the fork frame.
7. Remove the cylinder locking (A).
8. Turn the drive unit until the drive wheel points to the side.
9. Insert a block under the rear edge of the drive unit (NB! Remember
to use the same size of all blocks when raising the truck, so that the
truck remains stationary).
10. Place the jack between the forks and lift the fork frame.
11. Lift up the truck approx 140 mm with blocks under the fork carriage
and forks.
Align the mounting hole (B) on the fork frame side with the axle.
12. Remove the axles (C).
13. Then pull apart the drive unit and fork frame.
NOTE!
Never lift the drive unit by the tiller arm when separating the drive unit
from the fork frame.
Assemble in reverse order.
NOTE!
Be careful when reassembling so that no cables are trapped.

Actions
Chassis 0000
258944-040 2009-10-05 6053221- 838, 839, 840
8.3 Removing the platform

1. Load the platform and loosen the upper damper stop and the
spring’s cover plate.
2. Remove the platform from the truck by undoing the four bolts
3. Place the platform on the floor behind the truck with the spring fa-
cing towards you and the other edge under the truck’s kick guard.
4. Undo all 8 screws holding the fastening against which the spring
bracket presses.

Actions
Chassis 0000
838, 839, 840 6053221- 2009-10-05 258944-040
NB! Take care when working with tensioned springs.

5. Relieve the pressure on the spring using a crow-bar or a large
screwdriver and carefully remove the fitting.
6. Pull out the axle and replace the part(s) that need to be changed.
7. Assemble in reverse order.

Actions
Chassis 0000
258944-040 2009-10-05 6053221- 838, 839, 840
8.4 Change of damper for castor cradle

1. Undo the nuts at the ends of the damper
2. Slip the damper off the threaded metal pins

3. Slip on the new damper and fasten both nuts again
8.5 Changing the springs and cylinder

for the castor cradle
1. Raise the back part of the truck using a jack to release the pressure
from the cylinder
2. Undo the hydraulic connection to the cylinder using a number 14
spanner

Actions
Chassis 0000
838, 839, 840 6053221- 2009-10-05 258944-040
3. Undo the cylinder fastening using hex key 5 and 10
4. Undo the cylinder fastening from the cylinder
5. Change cylinder and/or spring
Assemble in reverse order

Actions
Fork frame 0380
258944-040 2009-10-05 6053221- 838, 839, 840
9 – Fork frame 0380
9.1 Components
D
K
G
F
L
H
I
J
Pos. Component Pos. Component

A Cotter J Bush
B Bush K Torsion tube
C Axle L Bush
D Screw M Bush
E Greasing nipple N Locking pin
F Bush O Axle
G Locking pin P Axle
H Axle Q Stop screw
I Push rod R Nut

Actions
Fork frame 0380
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Electrical drive motor 1700
258944-040 2009-10-05 6053221- 838, 839, 840
10 – Electrical drive motor 1700
10.1 Components
B
A
C
E D
Pos Name
A Speed sensor
B Cover
C Motor: LWE140/160/180 1,0 kW
LWE200/250 1.5 kW
D Tension pin
E Lift cylinder
F Temperature sensor

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
10.2 Remove motor from truck

1. Remove the inspection covers.
The upper inspection cover is fastened using velcro. Take care
when you loosen the inspection cover. By all means use a tool to
help you.
2. Lift the drive unit using a jack and lift up the truck using blocks un-
der the drive unit so that the drive wheel hangs freely.
3. Cut the cable duct tie on the transistor regulator's side and loosen
the cable connections X5 and X60.
4. Loosen the operating console's mounting screws and remove the
operating console and tiller arm.
5. Loosen the brake's mounting screws and the cable connection Q1.
6. Remove the brake.
7. Loosen the speed sensor and cable connection B1.
8. Loosen the motor cables and the motor's mounting screws.
9. Lift the motor out of the truck.
NOTE!
Cover the drive gear so that no loose objects can fall into the drive
gear when the drive motor is removed.
Install the motor in the reverse order.

See section “10.4 Tightening torque Drive motor”.
NOTE:
When fitting it is very important that the motor is adjusted so that the
slots in the motor and motor bracket are exactly opposite each other
before tightening the mounting screws. See the picture below.
Screw the drive motor into place using the 4 screws (a). Always
tighten the screws alternately in two stages. In other words, do not
tighten the screw to its full torque in the first stage. See section
“10.4 Tightening torque Drive motor”.

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
10.3 Fitting the tempreature sensor

1. Unclip the cable from the broken temperature sensorand fit the new
temperature sensor.
2. Place the new temperature sensor in the motor.
3. Clean thoroughly and ensure that the surface is dry.
4. Apply the plastic padding by squeezing out a strand of the hardener
half the length of the filler and mix well (be careful not to mix more
than can be used within 5 minutes).
5. Apply a layer of the plastic padding at least 4 mm thick, and overlap
the repaired surface by at least 2 cm.
6. Fix the plastic padding with masking tape and allow to harden.
7. Remove the masking tape.
The temperature sensor should now be covered by plastic pad-
ding.
8. After hardening, it is a good idea to add a further layer of the plastic
padding

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
10.4 Tightening torque Drive motor

The tightening torques for the drive motor are indicated in the picture:
3.5Nm
T30
3 + 0,5 Nm
10 mm
8 Nm
T30

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
10.5 Cleaning
It is crucial to the correct function that the motor is kept as clean as pos-
sible. The motor and motor housing must be regularly inspected for
dust, oil and other contaminants.
Dirty and/or oily components must be cleaned using a clean cloth,
moistened with solvent. Use a lint-free cloth. Do not apply so much sol-
vent that it finds its way into the motor parts.
After cleaning, the components must be dried well, which is most effec-
tively done by heating.
NOTE!
Windings and insulation should not be heated above 125°C and for no
more than 6 hours.

Actions
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Drive unit/gear 2550
258944-040 2009-10-05 6053221- 838, 839, 840
11 – Drive unit/gear 2550
11.1 General
The gear together with the motor and the brake are combinded as a
complete drive unit.
A complete reconditioning of the driving gear must be performed in the
workshop by trained technicians.
11.2 Components
Pos Component
A Main lift cylinder
B Screw
C Gear

Actions
Drive unit/gear 2550
838, 839, 840 6053221- 2009-10-05 258944-040
11.3 Remove the gear from the truck

1. Raise the forks and lift the drive unit up approx. 190 mm.
2. Loosen the drive wheel.
3. Remove the inspection covers.
The upper inspection cover is fastened using velcro. Take care
when you loosen the inspection cover. By all means use a tool to
help you.
5. Loosen the operating console's mounting screws and remove the
operating console and tiller arm.
6. Loosen the speed sensor and cable connections Q1 and B1.
7. Loosen the motor cables and the motor's mounting screws.
8. Lift the motor out of the truck.
9. Put a plug in the hole in the gear to prevent any oil spills when tak-
ing the gear out of the truck.
10. Loosen the gear's mounting screws.
11. Lay down the gear and move it out under the forks.
Put a block under the gear in order to simplify assembly.

Actions
Brake 3180
258944-040 2009-10-05 6053221- 838, 839, 840
12 – Brake 3180
In normal environments, the brake in principle is maintenance free.
12.1 Components
A
B
G
E
Pos no. Description

A Circlip
B Complete brake
C Screw
D Key
E Hub
F Brake disc
G Flange

Actions
Brake 3180
838, 839, 840 6053221- 2009-10-05 258944-040
12.2 Release of brakes

NOTE!
The brakes must only be released when the truck has to be moved for
service and repair work.
A
The truck's brakes can be released manually when needed by screwing
in two (M5) screws into holes (A). The screws must be 30-35 mm long.
NOTE!
Remember to remove the screws before the truck is put back into use
again.

Actions
Drive wheel 3530
258944-040 2009-10-05 6053221- 838, 839, 840
13 – Drive wheel 3530

A
13.1 Changing drive wheel

1. Raise the forks and elevate the truck (approx 100 mm).
2. Loosen the drive wheel (A).
It is simplest to loosen the drive wheel between the forks. Angle the
wheel to the side in order to work more easily under the truck.
3. Put the new wheel in position (A) and tighten the nuts (B)
81 ±19 Nm.

Actions
Drive wheel 3530
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Castor wheel 3540
258944-040 2009-10-05 6053221- 838, 839, 840
14 – Castor wheel 3540
14.1 Components
A
B
C
L M
K J
Pos. Name Pos. Name

A Circlip H Screw
B Washer I Distance
C Screw J Distance
D Fitting K Storage
E Nuts L Protection
F Storage M Nuts
G Circlip

Actions
Castor wheel 3540
838, 839, 840 6053221- 2009-10-05 258944-040
14.2 Castor wheel mounting

A
B
C
F
H
G
I
Pos. Name Pos. Name

A Nuts G Screw
B Nuts H Cradle
C Steering I Bushing
D Spring J Fitting
E Steering K Screw
F Washer

Actions
Castor wheel 3540
258944-040 2009-10-05 6053221- 838, 839, 840
14.3 Changing castor wheel

1. Elevate the truck securely.
2. Unscrew the castor wheel.
14.4 Changing castor wheel cradle

1. Raise the forks.
2. Remove the inspection cover.
3. Loosen the spring fasteners.
4. Loosen the bracket for the castor wheel mounting.
5. Lift the drive unit so that the cradle is free.
14.5 Changing springs
14.5.1 Removing springs

1. Loosen the upper lock nuts.
2. Lift the drive unit so that the springs are released from the upper
bracket.
3. Loosen the lower lock nut on the spring that is to be changed.
NOTE!
The spring is pre-tensioned, take care when loosening the lower lock
nut.
14.5.2 Fitting the spring

1. Place a block under the spring bolt so that the spring screw is held
in place.
2. Fit the spring with the lower lock nut and washer.
Use a short sleeve in order to screw the lower lock nut tight whilst
pressing the spring together.
3. Screw down the lower lock nut so that the distance between the
edge of the washer and the top of the screw is 15 mm.
4. Ensure that the springs are sitting correctly in the upper fasteners
when the drive part is lowered.
5. Screw the upper lock nuts tightly.

Actions
Castor wheel 3540
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Fork Wheel 3550
258944-040 2009-10-05 6053221- 838, 839, 840
15 – Fork Wheel 3550
15.1 Changing climber wheel

B
C
D
G
H
K
I
J
Pos. Component Pos Component

A Screw, K6S 8x12 G Wheel, complete
B Screw, MF6S 8x35 H Wheel bracket
C Sleeve I Axle
D Climber wheel J Wheel
E Friction block K Locking pin
F Nut, M8

Actions
Fork Wheel 3550
838, 839, 840 6053221- 2009-10-05 258944-040
15.2 Support arm wheel 3550

c
Pos Name
a Screw
b Bracket
c Bogie wheel
d Single wheel
e Axle
f Locking ring

Actions
Tiller arm 4000
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16 – Tiller arm 4000
16.1 Components in tiller arm

A
T
B
E
S
D I
F J
R G
H K
Q
L
P M
N
O
V
Pos. Name Pos. Name

A Steering arm M Indicator socket
B Rubber fender N Plate
C Cylindrical bolt O Ok
D Gas spring P Cable clamp
E Locking ring Q Screw
F Rubber fender R Ok
G Bushing S Screw
H Wire thread inserts T Cover
I Tension pin U Cover
J Holder V Cable clamp
K Safety sensor B60 W Mounting screw for
L Axle cable clamp

Actions
Tiller arm 4000
838, 839, 840 6053221- 2009-10-05 258944-040
16.2 Removing tiller arm

2. Remove the housing (T).
3. Loosen the yoke's (R) mounting screws.
4. Detach cable clamp (P) by pressing the clamp with your thumbs
and lifting it upwards. Remove the cable clamp through the hole in
the tiller arm.
NOTE:
Do not try to prise off the cable clamp using a screwdriver.
16.3 Changing gas suspension

1. Remove the casing (T).
2. Loosen the cable clamp mounting screws (W).
3. Loosen the adjustment screw (Q).
4. Remove the catch (E) from the gas suspension's lock axle (C).
5. Loosen the gas suspension's lock axle (C).
6. Remove the gas suspension.
NOTE!
Be careful when assembling so that no cables are crushed.
See image for correct positioning of the cable.

Actions
Tiller arm 4000
258944-040 2009-10-05 6053221- 838, 839, 840
16.4 Changing the safety sensor
16.4.1 Dismantling
1. Remove the gas spring. See section “16.3 Changing gas
suspension”.
2. Knock the axle’s (L) spiral pin (I) into place. Use a drift to knock the
spiral pin to a depth at which the spiral pin goes into the axle
completely.
3. Knock out axle (L) approximately 5 mm to expose the hole for the
spiral pin. Take care not to trap indicator sleeve (M).
4. Turn the axle (L) so that the reverse of the indicator sleeve (M) be-
comes accessible.
Prize the indicator sleeve away from both sides simultaneously to
avoid damaging the sleeve.
5. Remove the axle (L).
6. Loosen the cable clamp's (P) mounting screws.
NOTE:
Ensure that the handle does not fall down and pull apart the cables.
7. Remove the cable clamp mounting screw (W).
8. Remove the sensor mounting screw (S).
9. Loosen the contact [B60] from the sensor (K).
10. Remove the sensor.
16.4.2 Assembly
1. Fit the sensor (K)
2. Fit contact [B60] to the sensor.
3. Apply Loctite to the sensor mounting screw (S), or replace it. Screw
in the screw.
4. Screw in the cable clamp mounting screw (W).
NOTE:
Route the cable to the right of the sensor (K), against the spiral pin.
5. Knock the spiral pin (I) out of the axle (L) before fitting the axle.
6. Fit the indicator sleeve and then turn the axle so that the sleeve is
turned in towards the sensor. Turn it exactly so far that the spiral
pin can go into the axle.
7. Use a drift to knock the spiral pin into the yoke (O) and axle (L).
Knock in the spiral pin so that the drift goes approximately 19 mm
into the yoke. See picture.
19
8. Fit the gas spring. See section “16.3 Changing gas suspension”.
m
m
9. Check the function of the safety sensor.

Actions
Tiller arm 4000
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16.5 Components in tiller arm handle

H
G
A
F I
C
A B
D
K
J
L
S
T
M
X
K
L
Q P
O
Pos Description Pos Description

A Symbol board M Speed regulator/
direction selector
B Push button N Display
C Push button O Cable holder
D Push button for safety P Cable holder
reversing
E Spring Q Cover
F Logic card R Plug
G Seal S Lid, transparent plas-
tic
H Spring T Seal
I Cover U Handle
J Seal V Lid
K Signal button X Wiring harness
L Signal switch

Actions
Tiller arm 4000
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16.5.1 Removing the tiller arm handle

1. Unscrew the keyboard.
2. Loosen the screws and hold opposite the upper cover (Q).
3. Disconnect the cable connected to the logic card (F).
4. Loosen the screws and carefully lift away the undercover (I),
Place a finger between the undercover (I) and the switch for safety
reversing (D) to hold the switch in place.
WARNING!
Static electricity!
Risk of static discharge that can damage the electronics.
Ensure that necessary measures are taken before working with elec-
tronics.
16.5.2 Replacing the logic card

Note!
Access to TruckCom is required to be able to perform this action!
1. Loosen the housing's (I) mounting screws.
2. Disconnect the logic card connections.
3. Remove the logic card.
Use TruckCom in order to load the software and reset the parameters
from backup that are stored in the main unit.
1. Load new software into the logic card.
2. When downloading is complete, press the red button and wait for
error code 2.002 to be shown clearly.
3. Press “Connect” again in TruckCom and choose the current
software if TruckCom does not locate it.
4. Select “Copy truck configuration” in TruckCom.
5. Select “Copy configuration to primary unit: ICH”
Start the truck.

Actions
Tiller arm 4000
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16.5.3 Changing signal button/switch

1. Remove the button according to the image.
2. Disconnect the switch connector on the logic card.

3. Push the switch out from its fastening.

Actions
Tiller arm 4000
258944-040 2009-10-05 6053221- 838, 839, 840
16.5.4 Changing raising/lowering button.

1. Remove the button by placing a screwdriver in holes (A) according
to the picture below.
A A
2. Unscrew the holder so that the arm is loose.

16.5.5 Changing push button

1. Push the button sideways manually.
2. Place a screwdriver according to the image and carefully prise the
button loose.
3. Unscrew the button's holder and arm.


Actions
Tiller arm 4000
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16.5.6 Changing the lifting control lever –

from front to back
1. Undo the buttons for the lifting control using a narrow chisel and
swap with the rear unmarked buttons.
2. Ensure that the projections hook into position when fitting the new
buttons.
3. Connect a PDA or PC and use TruckCom to change parameter
1023 to 2.
4. Start the truck to verify the change.

Actions
Tiller arm 4000
258944-040 2009-10-05 6053221- 838, 839, 840
16.5.7 Changing a switch for safety reversing

1. Remove the display by undoing the screws.
×1
2,5 mm
2. Undo the screws to the upper part of the control lever.
×4
4 mm
3. Disconnect the CAN contact.

Actions
Tiller arm 4000
838, 839, 840 6053221- 2009-10-05 258944-040
4. Undo the screws so that the holder for the switch comes loose.
×3
3 mm
5. Remove the button by unhooking the locks on both sides
6. Assemble in reverse order.

Actions
Electrical components
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17 – Electrical components- 5000
17.1 Changing wiring harness
A
B
X5
C
X21
X60
Pos. Name
A Contact locking
B Contact, flange
C Fitting
D Contact, handle
When changing the wiring harness, work according to the following

instructions:
1. When spacing the X contacts, press the contact locking (A) into the
flange (B) and pull upwards.
2. Loosen the contact's flange (B) from the handle (D).
3. Then release the handle (D) by pulling it downwards.
The remainder is fastened (C) to the contact panel.
Actions
838, 839, 840 6053221- 2009-10-05 258944-040
17.1.1 Changing the wiring harness to the

transistor regulator
When you are loosening the contact (A) to the transistor regulator, think
about the following:
• Press in the ring-lock first (B).
• Then lift up the contact ring (C).

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
17.2 Replacing the transistor regulator

Note!
Access to TruckCom is required to be able to perform this action!

2. Cut the cable duct tie on the transistor regulator's side.
3. Remove the contacts (a) from the contact holder.
4. Loosen all cables and contacts in the transistor regulator.
5. Loosen the fastening nuts on the fixing plate (b).
6. Remove the transistor regulator.
Angle the fixing plate on the upper edge and turn it in the drive
wheel direction in order to remove it from the truck.
Assemble in reverse order
After fitting a new transistor regulator, the truck will display error code
2.004.
1. Connect TruckCom.
2. Select “Copy truck configuration”.
Select “Copy configuration to secondary unit: ACT”

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
17.3 Lift height limit sensor [B61]
17.3.1 Replacing sensor [B61]
Location of lift height limit sensor [B61] in the truck

1. Disconnect the truck battery.
2. Disconnect the sensor electrical connection (a).
3. Mark (using tape for example) the position of the sensor bracket
(b).
d
b
c
4. Loosen the screws (c) of the sensor bracket (torx T30)(spanner
9mm).

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
5. Remove the bracket together with the sensor, so that the two
sensor screws (d) can be accessed.
6. Unscrew the sensor (torx T20) (spanner 7mm) and discard the lock
nuts.
7. Screw the new sensor into place using new lock nuts. The screws
(d) are only to be tightened enough so that the sensor is in place
with no play.
8. Line up the bracket with the marking
9. Screw the sensor bracket into place (b) and remove any marking.
10. Connect the sensor electrical connection (a).
11. Connect the truck battery.
12. Test the function of the sensor.
13. If necessary adjust the sensor. See section “17.3.2 Adjusting
sensor [B61]”.
17.3.2 Adjusting sensor [B61]
1. Loosen the screws holding the sensor bracket (torx T30)(spanner

9mm) so that the position of the bracket can be adjusted.
2. Adjust the sensor as high as possible without the forks coming into
contact with the mechanical stop. Push the sensor bracket
upwards or downwards to find the correct position.
3. Tighten the bracket (torx T30)(spanner 9mm).

Actions
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Hydraulic system 6000
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18 – Hydraulic system 6000
18.1 General
Remember to take the following safety measures before you beging
working with the truck's hydraulic system:
• Release the system's pressure gradually.
• Use paper or a stiff piece of cardboard when checking for possible
leakage. Do not use hands.
• Be careful as the oil in the transmission and hydraulic systems may
be hot.
DANGER!
If you come into contact with hot transmission and hydraulic oil
there is a risk of burns. Allow the truck to cool down before changing
the oil.

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
18.2 Hygiene when working on

hydraulics
NOTE:
Risk of malfunction.
If contaminants get into the hydraulic system there is a risk of
malfunctions in parts of or in the entire hydraulic system. There is also
a risk of serious damage to incorporated components.
Observe the following instructions at all times when working on
hydraulic systems.
NOTE!
Only new and clean oil should be put into the hydraulic system.
If the oil is polluted, the hydraulic components will be damaged.
18.2.1 Washing
Wash hydraulic components, including hydraulic hoses and pipes,
using filtered cleaning fluid, in a manner suitable for that component.
The cleaning fluid is to have a cleanliness code of 19/16/13 according
to ISO4406:1999, or alternatively 16/13 according to ISO4406:1987.
Components can be blown clean using dry filtered air when this is the
only practically feasible cleaning method.
18.2.2 Packaging
After cleaning all openings must be sealed using protective plugs.
Connection faces must be protected against damage caused by
handling and against the ingress of dirt.
Completely dry components can be packaged in plastic bags or boxes
with lids.
Packaging (protective plugs, masking, plastic bags etc.) must not be
removed until immediately before components are to be fitted, and then
in a workplace that is adapted for the handling of hydraulic
components.
Tape must never be used without subsequent cleaning.
Protective plugs are to be stored in plastic bags or boxes with lids until
they are used.
Plugs and plastic bags are to be discarded after use.
18.2.3 Handling
Hydraulic components are to be handled and transported with great
care.
Transport packaging is to be used throughout the chain of operations.
This packaging is to be clean and free of swarf etc.

Actions
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18.2.4 Storage
Hydraulic components are to be handled and stored so:
• that corrosion does not occur
• that they are shielded from dust and dirt particles
• that mechanical deformation does not occur
18.2.5 Carrying out work

When work is being carried out on hydraulic systems, observe a level
of cleanliness such that contaminants do not get into the system.
Machining by chip removal must never take place at the same, or close
to a workplace at which work is carried out on hydraulic systems.
The service technician is to ensure that components being used are
thoroughly deburred and cleaned.
Closures for pipe ends or other openings must not be removed until the
component is being connected to its mated component.
NOTE:
All hydraulic components that have not been washed such as pipe
unions and nipples must be blown clean prior to fitting.

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
18.3 Hydraulic system components

LWE140, LWE160, LWE180
B
A
Pos. Name
A Pump motor
B Screw
C Pressure limit valve
D Magnetic valve, fork lowering
E Tank (suitable oil volume 0.8 l)
F Filling tube

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
18.4 Hydraulic system components for

LWE200 and LWE250
A
B
Pos. Name
A Pump motor
B Screw
C Pressure limit valve
D Tank (suitable oil volume 0.5 l)
E Filling tube
F Magnetic valve, fork lowering

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
18.5 Fitting the tube connection

1. Removing the dust shield.
Use the dismantling tool to remove the dust shield from the flange.
NOTE!
Foreign objects in the flange may cause damage.
2. Installing the assembly stop.
The assembly stop is moved into place on the handle.
3. Connect the handle and the flange by pushing them together.
Turning the handle during connection reduces the connection pow-
er.
NOTE!
The handle should not be without the assembly stop as there is a risk
of accidental disconnection.
4. Complete the connection until the assembly is against the flange.
NOTE!
Chect that there is no play between the assembly stop and the flange.
5. Try pulling the connection apart to check that the handle is locked.

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
18.6 Hydraulkopplingar 6230
18.6.1 Quick change connector

Assembling the quick change connector
1. Place the assembly stop (1) on the male fitting and make
sure that the dismantling ring (2) runs freely in the groove.
2. Push the male fitting into the female fitting until the assembly
stop makes contact with the female fitting.
3. The coupling is now made and locked.

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
18.7 Adjusting the pressure-limiting

valve
1
2
The truck must be capable of lifting the rated load on the forks.
Place the rated load on the forks and check that the truck is able to lift it.
If the truck is unable to lift the rated load:
1. Prize off the white sealing stopper (1) around the pressure-limiting
valve using a screwdriver..
2. Loosen the lock nut (2) by unscrewing it anticlockwise.
3. Screw in the adjusting screw (3) clockwise until the truck is able to
lift the load easily.
4. Screw in the locking washer (2) clockwise.
If the truck is able to lift the rated load, place a further 100 kg on the
forks. Check that the truck is not able to lift the load.
If the truck is able to lift 100 kg more than the rated load:
1. Prize off the white sealing stopper (1) around the pressure-limiting
valve using a screwdriver.
2. Loosen the lock nut (2) by unscrewing it anticlockwise.
3. Unscrew the adjusting screw (3) clockwise until the truck is no long-
er able to lift the load.
4. Screw down the locking washer (2) clockwise.
5. Press a new sealing stopper (1) around the pressure-limiting valve

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
18.8 Removing the hydraulic unit

Ensure that the forks are lowered before you start working on the
hydraulic unit.
2
1
3
1. Disconnect the hydraulic hose (1); see the quick-release coupling,

section 18.5.1 for further information.
2. Disconnect the motor cables (2) with a number 13 spanner.
3. Undo the connection (3) to the lowering valve.
4. Undo the bracket for the hydraulic unit (4) and lift out the unit from
the truck.
5. Undo screw (5) to remove the tank from the motor and lift off the
motor from the tank.

Actions
838, 839, 840 6053221- 2009-10-05 258944-040
6. Loosen the locking ring (6) on the oil filter (7).

7. Remove and clean the filter, and then fit it back into position.
8. Change the oil and clean the tank.
9. Fit everything back in reverse order.

Actions
258944-040 2009-10-05 6053221- 838, 839, 840
18.9 Tightening the torque for the

hydraulic unit
The tightening torque for the hydraulic unit should be as shown in the
figure:
8 +- 11 Nm
10 mm
33 +- 55 Nm
33 +- 55 Nm 25 mm
24 mm
8 +- 11 Nm
22 mm
5 +- 0,8
0,8
Nm
30 +- 55 Nm
19 mm
4 +- 0,5
0,5
Nm
7 mm

Actions
838, 839, 840 6053221- 2009-10-05 258944-040

Actions
Accessories
258944-040 2009-10-05 6053221- 838, 839, 840
19 – Accessories
19.1 Spider expansion unit

The spider expansion unit, called SEU, allows the main logic card to
manage a large number of inputs and outputs. There is no truck control
logic in SEU, which means that a faulty SEU can be changed without it
affecting the truck's function.
SEU is used for modifying the truck in accordance with special require-
ments from the customer.
Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector
Motor
Controller
The image above shows how SEU is used to allow a large number of
functions to be controlled via the CAN bus. SEU has a 42 pin, multipin
contact that manages all inputs, outputs, CAN and power supply sig-
nals.

Actions
Accessories
838, 839, 840 6053221- 2009-10-05 258944-040
19.2 TLS - Truck log system

See the separate manual that follows about the truck log system.
19.3 ID unit
See the separate manual that follows about the software.
19.4 Toyota Wireless Information

System T.W.I.S.
See the separate manual that follows about the software.

Actions
Accessories
258944-040 2009-10-05 6053221- 838, 839, 840
19.5 Intergrated battery charger

The integrated battery charger (B) is adjusted from the factory for the
type of battery and size of battery that applies to the truck.
19.5.1 Technical data

Name SMCO 24/30
Measurement, mm 240x111x77
Weight, kg 1,7
Ambient temperature, ºC -25 - +40
Mains voltage, V AC 195-264
Rated voltage, V DC 24
Rated current, A 30
Maximum output, W 800

Actions
Accessories
838, 839, 840 6053221- 2009-10-05 258944-040
19.5.2 Battery charging

Open the battery door and connect the charger's contact to wall socket
to begin charging.
NOTE!
Always switch off the truck before charging and disconnect other
electrical connections to the truck.
When the truck is being charged, the following is shown on the display:
Main charge
On the left of the sign window, lines are shown in sequence as the bat-
tery is charged. The battery symbol and OFF button blink.
Uneven charging
Four lines on the left of the sign window shine constantly while four
lines on the right are shown in sequence. The battery symbol and OFF
button blink.
Charging complete
The sign window shows the capacity value and the unit (Ah) alternately.
The battery symbol shines at a fixed brightness and the OFF button
blinks.
Remove the contact from the wall socket when the battery charge is
complete. The OFF button now shines permanently. The truck is ready
for use.

Appendix
General
258944-040 2009-10-05 6053221- 838, 839, 840
20 – Appendix
20.1 General
In the Appendix chapter you can quickly find the following information:
• Technical data
• General tightening torques
• Tools
• Oil and grease specification
• Electrical components and wiring diagrams
• Hydraulics diagram
• Destruction.

Appendix
General
838, 839, 840 6053221- 2009-10-05 258944-040

Appendix
Technical data
258944-040 2009-10-05 6053221- 838, 839, 840
21 – Technical data
21.1 LWE140, LWE160, LWE180,

LWE200, LWE250
Model LWE140, LWE200,

LWE160, LWE250
LWE180
Drive motor
Type Iskra AML7108 Iskra AML7109
Output, kW 1,0 1,5
Duty cycle S2-60 min S2-60 min
Weight, kg 9,0 10,5
Brake
Type Warner PK10 Warner PK10
Braking force, Nm 15 15
Output, W 51/13 51/13
Resistance coil, Ω 10,5-12,0 10,5-12,0
Nominal play in actuated position, mm 0,3-0,6 0,3-0,6
Minimum thickness brake disc, mm 7,9 7,9
Thickness of a new brake disc, mm 8,2 8,2
Transmission/drive gear
Oil volume, litre 0,8 0,8
Oil type Synthetic Synthetic
at normal temperature API GL-5 API GL-5
at temperature < -15oC SAE 75W-90 SAE 75W-90

Appendix
Technical data
838, 839, 840 6053221- 2009-10-05 258944-040

LWE160, LWE250
LWE180
Wheels
Drive wheel, mm 230 230
Axle pressure without load, kg 200, 255, 260 260
Axle pressure at rated load, kg 590, 695, 760 815, 950
Tightening torque for wheel bolts, Nm 81±19 81±19
Fork wheel, mm 125 125
Axle pressure without load, kg 105, 115, 135 135
Axle pressure at rated load, kg 1115, 1275, 1435 1580, 1945
Support castors, mm 85 85
Axle pressure without load 150 150
Axle pressure at rated load, kg 150 150
Hydraulic system
Output, kW 1 1,4
Minimum carbon brush length, mm - 12,5
Pressure at rated load, bar 85-125, 100-140, 130-170, 170-210
115-155
Overflow pressure, bar 120-145, 135- 165-190, 205-230
160, 150-175
Pump flow, litre/minute 4,5-6,0 6,0-10,0
Suitable oil volume, litre 0,5 0,5
Oil type: Hydraulic oil Hydraulic oil
at normal temperature ISO-HM32 ISO-HM32
at temperature < -15oC ISO-HV32 ISO-HV32
Fuses
Drive motor circuits, A 125 125
Pump motor circuits, A 125 125
Control circuits, A 7,5 7,5

Appendix
Technical data
258944-040 2009-10-05 6053221- 838, 839, 840

LWE160, LWE250
LWE180
Battery compartment, Batteries
Weight, kg 120-165, 120- 180-270
220, 180-270
Driving speed
Without load, km/t 6,0 6,0
Without load, m/s 1.7 1.7
With rated load, km/t 6,0 6,0
With rated load, m/s 1,7 1,7
Lift/lowering speed
Lift without load, m/s 0,05 0,09
Lift with rated load, m/s 0,04 0,06, 0,05
Lowering without load, m/s 0,08 0,08
Lowering with rated load, m/s 0,09 0,09
Incline climbing ability
With rated load 8, 8, 9 9, 8
Measurement, L2
Short 1628 -
Medium 1685 1685
Long 1735 1735
Lift height 205 205
Weight
Truck without battery, Medium 290, 300, 325 325

Appendix
Technical data
838, 839, 840 6053221- 2009-10-05 258944-040

Appendix
General tightening torques
258944-040 2009-10-05 6053221- 838, 839, 840
22 – General tightening torques

Millimetre thread M3 to M24. The following applies under ideal condi-
tions, e.g. steel against steel.
22.1 Galvanised, non-oiled bolts

Tightening torques (Nm)
Strength class:
8,8 10,9 12,9
M3 1,1 1,6 2,0
M4 2,8 3,8 4,7
M5 5,5 7,7 9,3
M6 9,5 13 16
M8 23 32 38
M10 45 62 76
M12 78 109 130
M14 123 174 208
M16 189 266 320
M20 370 519 623
M24 638 898 1075
22.2 Untreated, oiled bolts

Tightening torques (Nm)
Strength class:
8,8 10,9 12,9
M3 1,2 1,7 2,1
M4 2,9 4,0 4,9
M5 5,7 8,1 9,7
M6 9,8 14 17
M8 24 33 40
M10 47 65 79
M12 81 114 136
M14 128 181 217
M16 197 277 333
M20 385 541 649
M24 665 935 1120
NOTE:
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will achieve the correct torque value for
galvanised bolts. Do not tighten more than the values set out in the ta-
ble, as the bolts may otherwise be destroyed.

Appendix
General tightening torques
838, 839, 840 6053221- 2009-10-05 258944-040

Appendix
Tools
258944-040 2009-10-05 6053221- 838, 839, 840
23- Tools
23.1 MQS connectors
Tools Number Use

257841 MQS Basic toolbox.
The box contains:

1 set pliers with tools
25 x splice 0.5-1.5 mm2
2 x 2, 3, 4, 6, 8 and 12 pin complete
contacts (male and female) with cables
and splice attached.
Used for replacing damaged contacts
in the truck.
© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 23- 1

Appendix
Tools
838, 839, 840 6053221- 2009-10-05 258944-040
Tools Number Use

257842 MQS assortment box.
Used for the complete MQS 257843
toolbox.
The assortment box contains:

200 x sleeves 0.2-0.5 mm2
200 x SWS sleeves 0.2-0.5 mm2
400 x SWS sleeves 0.5-0.75 mm2
100 x Clean body sleeves 0.5-0.75
mm2
200 x SWS pins 0.2-0.5 mm2
400 x SWS pins 0.5-0.75 mm2
1200 x seals
200 x blindplugs
257843 Complete MQS toolbox.
Contains 4 pliers with tools:

MQS SWS 0.25-0.5 mm2
MQS SWS 0.5-0.75 mm2
MQS Std&Clean body 0.25–0.5 mm2,
MQS Std&Clean body 0.5-0.75 mm2
Extraction tool for 2, 3, 4, 6, 8 and 12

pin male and female contacts.
23- 2 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

Appendix
Tools
258944-040 2009-10-05 6053221- 838, 839, 840
23.2 AMP connectors

PT = Power Timer (4,8. 5,8. 6,3 mm)
JPT = Junior Power Timer (2,8 mm)
MPT = Micro Power Timer (1,5 mm)
Figure Number Application

151080 (PT) Tools for removing pins/sleeves
213296 (JPT) Tools for removing pins/sleeves
213298 (MPT) Tools for removing pins/sleeves
1=163787 Tools for fitting sleeves

2=163788
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Tools for fitting pins
2=213549 (JPT) For 0,5-2,5 mm2
1
2

Appendix
Tools
838, 839, 840 6053221- 2009-10-05 258944-040
23.2.1 AMP Connectors, 040 series

213130 Pin removal tool
213129 Tools for fitting pins
23.3 Molex connectors

16
9
8
1
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins

Appendix
Tools
258944-040 2009-10-05 6053221- 838, 839, 840
23.4 Grease guns
Figur Nummer Användning

24981 A tool with a pointed nozzle used to apply
grease. Length 170 mm.
755132 Single-hand grease gun with straight discharge

pipe and nozzle.
755142 Two-hand grease gun with angled discharge pipe

fif
and nozzle.
755152 Two-hand grease gun with hose and nozzle.
755146 Grease hose 450 mm.

Grease hose 750 mm.
Grease hose 1500 mm.
202154PM Pointed nozzle for grease guns used to apply

grease in recessed nipples.
Fits grease guns with hose and discharge pipe.
Length 125 mm.
755140 Nozzle for neck nipples. Fits grease guns with
hose and discharge pipe.

Appendix
Tools
838, 839, 840 6053221- 2009-10-05 258944-040
23.5 Other tools

156263 Service instrument (CAN)
1=163793 Service instrument for pro-

2=163792 gramme changes
08-13022 Driving gear puller

Appendix
Oil and grease specification
258944-040 2009-10-05 6053221- 838, 839, 840
24 – Oil and grease specification
Table 1: Oil and grease specification

Lubricant type Specification Use
> - 15°C < - 15°C
A Grease S213366 S213366 Storage and bushings
Q8 Rubens WB Q8 Rubens WB
B Hydraulic oil ISO-HM32 ISO-VG32 Hydraulic system
C Transmission oil Synthetic Synthetic Gear
API GL-5 API GL-5
SAE 75W-90 SAE 75W-90
D Grease See table below See table below Chains
E Grease Grafloscon Grafloscon Toothed rim
A-G1 (Klüber) A-G1 (Klüber)
F Grease 755711-040 755701-040 Castor
G Grease S213366 S213366 Mast
Q8 Rubens WB Q8 Rubens WB
Pos Ambient tem- Viscosity class Recommended products*

perature
D > - 40°C VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< - 30°C
D > - 30°C VG 68 Klüberoil 4UH 1-68N, Klüber Lubrication
Anticorit LBO 160 TT, Fuchs DEA
< + 5°C
D > + 5°C VG 150 Klüberoil 4UH 1-150N, Klüber Lubrication
Anticorit LBO 160, Fuchs DEA
< +45°C
Rexoil, Rexnord Kette
D >+ 45°C VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
<+ 80°C
* Similar products from another manufacturer may be used.

Appendix
Oil and grease specification
838, 839, 840 6053221- 2009-10-05 258944-040
24.1 Lubrication schedule
Pos. Service point Service Lubricant type

interval (see table
12 m above)
0380 Grease nipples Greasing1 E
6000 Hydraulic system Oil change2 B
1 = Lubrication of nipples must happen at continuous intervals of 500 h

or 12 months, depending on which comes first.
2 = The oil is changed and the filter cleaned for the first time after 750 h/
12 months, and then after 4,500 h/36 months.
6000
0380

Appendix
Electrical components and electrical diagram
258944-040 2009-10-05 6053221- 838, 839, 840
25 – Electrical components and

electrical diagram
25.1 Electrical components

The table below shows a compilation of the most important electrical
components on the truck.
Symbol Description Function Remarks

A5 Logic card Logic card actuating lever
A5:S1-18 Hall sensor Speed control forwards/back-
wards
A5:S17 Hall sensor Safety reversing
A5:S19 Hall sensor Fork lifting control
A5:S20 Hall sensor Fork lowering control
A5:S21 Hall sensor Control of support arm lift
A5:S22 Hall sensor Control of support arm lowering
A30 Battery charger Onboard battery charger Option
B1 Temperature sen- Temperature sensor for drive

sor motor
B11 Pulse converter Speed sensor
B60 Inductive switch Mechanical brake activation
B61 Inductive switch Lifting height limiting
B90 Collision sensor Option
F1 Fuse Main fuse 125 A

F50 Fuse Working circuit A5 7.5 A
F51 Fuse Working circuit T1 7.5 A
F52 Fuse Optional equipment Option
G1 Battery 24 V
K110 Data handling unit Unit for handling data Option

(DHU)
M1 Motor Drive motor

M3 Motor Pump motor

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040
Symbol Description Function Remarks

P4 Horn
P6 Display Truck function display
Q1 Electromechanical Mechanical brakes

brakes
Q4 Magnetic valve Fork lower
Q10 Contactor Main contactor
Q25 Contactor Pump contactor
S18 Switch Horn button

S21 Switch Emergency switch
S206 Switch Turtle button (Turtle) Option
S111 Switch Option button Option
S223 Keypad/Smart card Login with PIN code
T1 Transistor regula-
tor
T7/T8 DC/DC transformer T7=24V/12V Option
T8=24V/24V
X1 Connection Battery
X21 Connection point DC/DC transformer Option
X40 Connection point CAN communication (Extra I/O)
X41 Connection point CAN communication (External)

Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
A5:S22 A5:S21 A5:S1-9 A5:S10-18 A5
1
10
18
A5:S17 A5:S20 A5:S19

P6
S113 S116
S206 S115
S111 S114
S18:1 S18:2
A5:S20
A5:S22
A5:S19 A5:S21
A5:S17
S223
B60
X41

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040
S21
X1
G1
T7/T8
F50, F51, F52

F1 Q25
Q10
X21
X40
B90
T1
A30

Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
25.2 Electrical diagram
25.2.1 Index of symbols
Table 2: Index of symbols

Symbol Description Symbol Description
Truck battery Emergency switch NC
Fuse Switch, pressure (weight) oper-

ated
Horn Sensor, inductive NO
Motor, a.c.a Sensor, inductive NC

M
Contactor Variable resistance (potentiome-

ter)
Brake (normally joined) Push switch NO
Coil for hydraulic magnetic valve Contact, multipolar
Pressure sensor, analogue NO = Normally open

P NC = Normally closed
a. AC = Alternating Current

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040
25.2.2 Overview diagram

F51
6 (+) B+ F1
24 (83) +24V S21
40 (-) B- U
V M1
W
Q10
MAIN CONTACTOR (106) 31
+
B60 G1
72 (95) TILLER ARM
-
M3
IN DRIVE POS. A1
M
A2
T1 40
Q25
PUMP CONTACTOR (107) 34
B61 Q1
73 (87) LIFT LIMIT BRAKE RELEASE (90) 32
Q4
LOWER VALVE (108) 33
F
+24V (82) 30
20 (84) ENABLE/PRE-CHARGE
EXT.
B11 P4
EQUIP.
61 (104) CH A, SPEED SENSOR
62 (103) CH B, SPEED SENSOR
SIGNAL HORN (112) 50 F52
+5V SPEED SENSOR (85) 60
64
NEGATIVE SPEED/ (105)
B1 63 (92) THERMAL
THERMAL SENSOR
SENSOR 25
+24VDC
40
CAN HIGH/LOW 0VDC T7/T8 X23
(99/100) 12VDC/24VDC 26
119/120 0VDC 41
OPTION
20 F50 20
24 24
119/120
(3/4) 119/120 119/120
CAN HIGH/LOW (X3/X3) (3/4)
A2:S17
B90
20 (1) +24V DC
CAN HIGH/LOW Hall SAFETY CAN HIGH/LOW
RED (+) POS. VOLT.
REVERSE
40 (2) 0V DC 20 (X3) +24V DC A2:S19 BLACK (-) NEG. VOLT.
40 (X3) 0V DC Hall FORK
OPTION LIFT A30
A2:S20 MAINS, VAC
(X1 1) HORN 2 Hall FORK MAINS, VAC
(X4 1) HORN 1 LOWER MAINS, EARTH
A2:S1-S9 A2:S10-S18
S18:2 OPTION
Hall Hall SPEED
S18:1 REF.
(X4 2) VALUE 119/120
(X1 2) (2/3)
A5 CAN HIGH/LOW
(X2:1/2) TURTLE 20 (1) +24V DC
X41
+24V DC (X3) 20 40 (8) 0V DC
0V DC (X3) 40 T20
K110
S206
(X2:1/3) TURTLE CAN HIGH (X3) 119 ANTENNA
CAN LOW (X3) 120 OPTION
KEYBOARD /
SMART CARD (X11) (X12)
DISPLAY
S223 P6

© BT
40
Sh. 2
1 MOTOR CONTROLLER
258944-040
Sh. 2 T1
7,5A
Order number
X21 S21 X21 F51 G1

24 24/BN 1 2 21/WH 21 1 2 1 + - 40
Sh. 2 INP. B-
7,5A
F50
20
F1 84 INP. ENABLE / PRE-CHARGE
125A
PUMP MOTOR
Date
A1/1D1 A2/2D2 10 1 2 6 6
M3 INP. B+
2009-10-05
20
Sh. 3
Q10
30 1 2 31
Sh. 2 106 OUT. MAIN CONTACTOR
Q25
1 2 34
107 OUT. PUMP CONTACTOR
Repair Manual
2
OUT. U
DRIVE MOTOR
3
OUT. V
6053221-
M1
4
OUT. W
B11
1 60
85 OUT. +5V SPEED SENSOR
B11
B11
25.2.3 Electrical diagram
RD BU 2 61
Valid from serial number
104 INP. CH A, SPEED SENSOR
B11
BK WH 3 62
103 INP. CH B, SPEED SENSOR
|R
B1 B1
GN 1 63
92 INP. THERMAL SENSOR
TEMP. DRIVE MOTOR RD
2
B11 B1
4 64
105 OUT. NEGATIVE SPEED / THERMAL SENSOR
T-code

1/9 PROD E
838, 839, 840
236994
02318.wmf
Appendix
25 – 7
25 – 8
T-code
MOTOR CONTROLLER
T1
838, 839, 840
24 24
Appendix
Sh. 1 83 INP. +24V, "HIGH SIDE DRIVER"
B60
X65 X65
1 2 72
95 INP. TILLER ARM IN DRIVE POS.
3
X65
40
Sh. 1 3
EXTERNAL EQUIPMENT
B61
1 2 73
87 INP. LIFT LIMIT
6053221-
3
NOTE!
Repair Manual
EXTERNAL EQUIPMENT SHALL NOT BE ELECTRICAL
CONNECTED TO THE TRUCK FRAME.
P4
IN
50
112 OUT. SIGNAL HORN
30 30
Sh. 1 82 OUT. +24V, "HIGH SIDE DRIVER"
Q1
1 2 32
90 OUT. BRAKE RELEASE
Date
Q4
1 2 33
108 OUT. LOWER VALVE
2009-10-05
119/RD 119/RD
Sh. 3 99 INP. CAN HIGH
120/WH 120/WH
Sh. 3 100 INP. CAN LOW

258944-040
2/9 PROD E
Order number
236994
02319.wmf
© BT
© BT
258944-040
Order number
Date
2009-10-05
ELECTRONIC CARD TILLER ARM

A5
X5 A5
120/WH 120 3 120
Sh. 2 6 X3 CAN LOW
Repair Manual
X5 A5
119/RD 119 7 119
Sh. 2 6 X3 CAN HIGH
X5 A5
40 2 40
Sh. 2 6 X3 INP. 0V DC
6053221-
X5 A5
20 6 20
Sh. 1 8 X3 INP. +24V DC
X41 A5
1 20 5 20
X3 OUT.+24V DC
A5
2 40 1 40
X3 OUT. 0V DC
A5
3 119 8 119
X3 CAN HIGH
A5
4 120 4 120
X3 CAN LOW
CAN, SERVICE CONNECTOR

T-code
3/9 PROD E

236994
02320.wmf
838, 839, 840
Appendix
25 – 9
DISPLAY ELECTRONIC CARD TILLER ARM
25 – 10
T-code
P6 A5 838, 839, 840
X1 1 X12 1 +5V DC
Appendix
X1 2 X12 2 SI
DISPLAY
P6
X1 3 X12 3 SCK
8 8 8 8
X1 4 X12 4 ENABLE
6053221-
X1 5 X12 5 LCLK
Repair Manual
X1 6 X12 6 0V DC
S18:1
1 2
X4 1 INP. HORN 1
X4 2 OUT. OV DC HORN 1
S18:2
1 2
X1 1 INP. HORN 2
Date
2009-10-05
X1 2 OUT. 0V DC HORN 2
S206
1 2
X2:1/2 TURTLE
OPTION
X2:1/3 TURTLE

258944-040
Order number
4/9 PROD E
236994
02321.wmf
© BT
Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
5/9 PROD E
236994
02322.wmf
ELECTRONIC CARD TILLER ARM
LED_GREEN
LED_RED
2580
369#
0V DC
147-
123
456
789
-0#
X11 10
X11 1
X11 2
X11 3
X11 4
X11 5
X11 6
X11 7
X11 8
X11 9
A5
SMART CARD
KEY BOARD / SMART CARD
3
6
9
I
2
5
8
0
1
4
7
S223

25 – 12
T-code
838, 839, 840
OPTION
Appendix
ONBOARD CHARGER
BCU
A30
1 (RED) RED
Sh. 2 7 + OUT. POSITIVE CHARGER VOLTAGE
40 (BLACK) BLACK
Sh. 3 7 - OUT. NEGATIVE CHARGER VOLTAGE
6053221-
Repair Manual
X40
120/WH 120/WH
Sh. 3 8 4 INP. CAN LOW
X40
119/RD 119/RD
Sh. 3 8 3 INP. CAN HIGH
MAINS CONNECTOR
Date
MAINS, VAC
2009-10-05
MAINS, VAC
MAINS, EARTH

258944-040
6/9 PROD E
Order number
236994
02323.wmf
© BT
Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
7/9 PROD E
236994
02324.wmf
OUT. 12VDC / 24VDC
DC/DC CONVERTER
INP. +24VDC
OUT. 0VDC
INP. 0VDC
T7 / T8
25
40
26
41
(T7=24V/12V, T8=24V/24V)
DC/DC CONVERTER
OPTION
26
41
X23
X21
X21

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040
8/9 PROD E
236994
f
02325
INP. +24V DC
INP. 0V DC
CAN HIGH
CAN LOW
SHOCK SENSOR
B90
4
20
40
120/WH
119/RD
SHOCK SENSOR
OPTION
X40
X40
X40
X40

Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
9/9 PROD E
236994
02326.wmf
INP. ANTENNA
INP. +24V DC
INP. 0V DC
CAN HIGH
CAN LOW
K110
DHU
8
20
40
120/WH
119/RD
DATA HANDLING UNIT (DHU)
T20
OPTION
X40
X40
X40
X40

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040

Appendix
Hydraulic diagram
258944-040 2009-10-05 6053221- 838, 839, 840
26 – Hydraulic diagram
Only for trucks with Power Link
B
H
Max 230 Bar
C
G
D
M3
E
F
T
Pos. Description
A Lift cylinder
B Magnetic valve, lowering forks
C Flow control valve
D Air filter
E Filter
F Pump
M3 Pump motor
G Pressure reducing valve, max 230 Bar
H Non return valve
T Tank

Appendix
Hydraulic diagram
838, 839, 840 6053221- 2009-10-05 258944-040

Appendix
Destruction instructions
258944-040 2009-10-05 6053221- 838, 839, 840
27 – Destruction instructions
27.1 General
These destruction instructions have been introduced to support our
company's objective of protecting the environment. By recycling mate-
rials, resources can be utilised more efficiently, while emission of unde-
sirable substances is reduced.
The instructions below indicate the proper sorting category for the
materials used in the various truck components. To achieve optimum
sorting, all components should be disassembled to a level correspond-
ing to the sorting categories.
27.2 Marking of plastics
27.2.1 General marking of products and

packaging material
Markings on plastics consist of three arrows, a number and usually also
a designation for the plastic material used. The picture shows an exam-
ple with the marking for polypropylene.
• 01: PET – Polyethylene terephthalate
• 02: PE-HD – Polyethylene with High Density
• 03: PVC – Polyvinyl chloride
• 04: PE-LD – Polyethylene with Low Density
• 05: PP - Polypropylene
• 06: PS – Polystyrene
• 07: O – Others

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040
27.2.2 Marking according to BT Standard

Standards: BT 58-02-001, BT58-02-003 and BT58-02-004.
Only a few examples of markings are presented here. Fore more infor-
mation, please refer to the standards mentioned above.
The product material and trade name are indicated between arrows.
Example: >PP<.
Abbreviations
- ABS: acrylonitrile/butadiene/styrene
- HDPE: High Density Polyethylene
- LDPE: Low Density Polyethylene
- PA: Polyamide
- PA6: Amide resin 6
- PA66: Amide resin 66
- PBT: Polybutylene terephtalate
- PC: Polycarbonate
- PET: Polyethylene terephtalate
- PMMA: Plexiglas
- POM: Polyoxymethylene, Polyformaldehyde
- PP: Polypropylene
- PUR: Polyurethane
Marking examples
Products made from a single substance
ABS (acrylonitrile/butadiene/polystyrene):
>ABS<
Polyurethane:
>PUR<
Plastic compounds
A compound based on acrylonitrile/butadiene/polystyrene and carbon-
ate plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<

Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
27.3 Pressure vessels

Pressure vessels sent for recycling/destruction must have been
depressurised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas dampers and accumula-
tors used in hydraulic systems.
27.3.1 Gas dampers

DANGER
Gas dampers have extremely high internal pressure. To prevent inju-
ry, always heed the instructions of the manufacturer.
Use safety goggles when disassembling springs.
To allow the gas to escape, only open and disassemble gas dampers
as prescribed by the manufacturer. An example of how to perform this
is given for “Stabilus Lift-O-Mat/Inter-stop”:
2 1
ca 20 mm
1: Drill or cut a hole in the cylinders, approximately 20 mm from the bot-

tom.
2: Drill or cut a hole in the cavity at the piston rod end.

Appendix
838, 839, 840 6053221- 2009-10-05 258944-040
27.4 Sorting categories

• Plastic and rubber material
• Iron/steel (including bolts, washers and nuts)
• Oils
• Oil filters
• Oil-polluted material
• Electronic parts (including switches and sensors)
• Cables
• Hazardous waste
• Complex materials - large amounts of several categories but non-
combustible and not hazardous
• Combustible material (including small plastic and rubber parts)
• Please return batteries to the manufacturer.
COMPONENT Category Comment

Chassis • Iron/steel
Covers and doors, • Iron/steel
sheet metal
• Handles: >ABS<
Covers and doors, • Plastic Sort according to the
plastic material marking
Forks and bodies • Iron/steel
Operator platforms • Iron/steel, also possible gas damp- Be sure to depressurise
ers dampers
• Mats, cushions: combustible
Roofs and overhead • Iron/steel
guards
Gates and operator • Iron/steel
protective devices
• Plastic handles: >PA<
• Crush protectors: >PMMA<
Hydraulic units • Oil Ensure the system has
been depressurised.
• Hydraulic hoses: Oil polluted mate-
Carefully drain all oil.
rial
Any accumulators should
• Oil tank: >PP< be emptied of gas and if
• Motor, valves: Electronic parts possible opened.
• Pump: Iron/steel
• Accumulator: Iron/steel

Appendix
258944-040 2009-10-05 6053221- 838, 839, 840
COMPONENT Category Comment

Travel drive motors • Motor: Electronic parts
• Cables
• Parking brake: Hazardous waste
Drive gears • Iron/steel Carefully drain all oil.
Hazardous waste
• Oil
Wheels • Tread: Plastic according to mark- If the tread and hub can-
ing not be separated, then
sort the wheel as com-
• Hub: Iron/steel
plex material
Tiller arms • Electronic parts Be sure to depressurise
dampers
• Cables
• Iron/steel, also gas dampers
Electric systems • PCBs, transistor regulators, Exan- Hazardous waste
sion unit SEU, contactor: Electron-
ic parts
• Cables
• Small batteries Hazardous waste
• Fluorescent tubes Hazardous waste
Because of the chemical
content in fluorescent
tubes, do not destroy
them.
Obsolete fluorescent tube
must be packaged and
transported according to
local regulations.
Masts • Mast members, rollers, cylinders, Oil-polluted components
hydraulic pipes: Iron/steel should be handled as
hazardous waste
• Hydraulic hoses: Oil-polluted ()
• Cables
• Sensors/switches: Electronic parts
• Plastic components: According to
marking or as combustible waste
Chargers and connec- • Electronic parts
tors
• Cables

© BT
SE-595 81 Mjölby
Sweden
www.toyota-forklifts.eu

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Repair Manual en

LWE140, LWE160, LWE180, LWE200, LWE250

Order number: 258944-040

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250

3 – General safety rules .......................................................................... 3-1

4 – Installation ......................................................................................... 4-1

5 – Maintenance ....................................................................................... 5-1

6 – Functions and parameters ................................................................ 6-1

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 1– 1

6.5 Parameters .................................................................................... 6-9

7 – Troubleshooting ................................................................................ 7-1

8 – Chassis 0000 ...................................................................................... 8-1

9 – Fork frame 0380 ................................................................................. 9-1

10 – Electrical drive motor 1700 ........................................................... 10-1

1– 2 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

11 – Drive unit/gear 2550 ...................................................................... 11-1

12 – Brake 3180 ...................................................................................... 12-1

13 – Drive wheel 3530 ............................................................................ 13-1

14 – Castor wheel 3540 ......................................................................... 14-1

15 – Fork Wheel 3550 ............................................................................ 15-1

16 – Tiller arm 4000 ............................................................................... 16-1

17 – Electrical components .................................................................. 17-1

18 – Hydraulic system 6000 .................................................................. 18-1

18.2.2 Packaging ...................................................................... 18-2

19 – Accessories ................................................................................... 19-1

20 – Appendix ........................................................................................ 20-1

21 – Technical data ............................................................................... 21-1

22 – General tightening torques ........................................................... 22-1

23- Tools ................................................................................................ 23-1

24 – Oil and grease specification ......................................................... 24-1

25 – Electrical components and electrical diagram ........................... 25-1

1– 4 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

25.2 Electrical diagram ........................................................................ 25-5

26 – Hydraulic diagram ......................................................................... 26-1

27 – Destruction instructions ............................................................... 27-1

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 1– 5

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1– 6 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

2.1 How to use the manual

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 2– 1

2.2 Warning symbols

2– 2 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

3 – General safety rules

3.1 Safety while working

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 3– 1

3.2 Electrical system

3– 2 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

3.3 Safe lifting

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 3– 3

3– 4 Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 © BT

4.2 Battery installation

© BT Repair Manual LWE140, LWE160, LWE180, LWE200, LWE250 4– 1

4.2.2 Install battery