LWE160

Repair manual 7588852-040
LWE140, 160, 180, 200, 250.
www.toyota-forklifts.eu stronger together

Translation of the original instructions.
Publication
Date Changes
number
2015-09-01 7588852-040 Completely new issue.
List of models:
Model T-Code Valid from serial number
LWE140, 160,180 838 6384351-
LWE200 839 6384351-
LWE250 840 6384351-
© TMHE T Code(s): 838, 839, 840

Repair manual: Contens Model(s): LWE140, 160, 180, 200, 250.
Publication number:7588852-040 Date: 2015-09-01 Applies from serial number: 6384351-
1. Contens
2. General introduction...................................................................................... 2–1
2.1 How to use this manual ............................................................................... 2–1
2.2 Warning levels and symbols ........................................................................ 2–2
2.3 Pictograms................................................................................................... 2–3
3. General safety rules....................................................................................... 3–1
3.1 Work safety.................................................................................................. 3–1
3.2 Electrical system.......................................................................................... 3–3
3.3 Safe lifting.................................................................................................... 3–4
3.4 Truck modifications...................................................................................... 3–5
4. Operation and connection sequences ......................................................... 4–1
Symbols on keypad and display 4–2
4.1 Battery is connected .................................................................................... 4–3
4.2 Login via keypad.......................................................................................... 4–3
4.3 Tiller arm lowered for driving ....................................................................... 4–4
4.4 Driving in fork direction ................................................................................ 4–4
4.5 Driving in the drive wheel direction .............................................................. 4–5
4.6 Neutral position braking............................................................................... 4–5
4.7 Reverse braking .......................................................................................... 4–6
4.8 Mechanical braking...................................................................................... 4–6
4.9 Emergency reversal..................................................................................... 4–7
4.10 Fork lifting .................................................................................................. 4–7
4.11 Fork lowering ............................................................................................. 4–8
4.12 Click-2-Creep............................................................................................. 4–8
4.13 Turtle function (option)............................................................................... 4–9
5. Parameters...................................................................................................... 5–1
5.1 General........................................................................................................ 5–1
5.1.1 Show/change parameters .............................................................. 5–2
5.1.2 Operator parameters ...................................................................... 5–3
5.1.3 Overview ........................................................................................ 5–3
5.1.4 Connection to logged-in operator ................................................... 5–4
Description of operator parameters 5–4
Parameters 3 and 4 – Acceleration/Deceleration 5–4
Parameters 6 and 7 – Maximum travel speed 5–5
5.2 General service parameters ........................................................................ 5–6
5.2.1 Overview ........................................................................................ 5–6
5.2.2 Description ..................................................................................... 5–7
Parameter 101/104 – Service/Log-out 5–7
Parameter 102 - Operator access 5–7
Parameter 103 - Start-up display 5–8
Parameter 105/106 - Collision sensor sensitivity for X/Y (Optional) 5–9
Parameter 107 – Battery size 5–10
Table applicable to LWE140, 160, 180, 200 5–11
Table concerning LWE250 5–12
Table concerning SWE 5–13
Verifying parameter settings for freely ventilated batteries
(lead-acid batteries) 5–14
Verifying the parameter setting for valve-regulated batteries
(Exide) 5–14
Parameters 109/110 - Built-in charger (option) 5–15
Parameter 111 - Reset procedure after collision (option) 5–16
Parameter 112 - Clear application data 5–16
© TMHE 1– 1 T Code(s): 838, 839, 840

5.3 Service parameters, travel functions ......................................................... 5–17

5.3.1 Overview ...................................................................................... 5–17
5.3.2 Description ................................................................................... 5–18
Parameter 201 – Deceleration when reversing 5–18
Parameter 202 – Maximum speed Turtle mode activated 5–18
Parameter 203 - Maximum speed, forks above 1.8 m 5–19
Parameter 204 - Maximum acceleration, forks above 1.8 m 5–19
Parameter 205 - Maximum reversing, forks above 1.8 m 5–19
Parameter 206 - Automatic speed reduction, forks above 1.8 m 5–20
5.4 Service parameters, hydraulic functions.................................................... 5–21
5.4.1 Description ................................................................................... 5–22
Parameter 301 – Ramping value for lowering stop 5–22
Parameter 302 - Fork, lowering speed 5–22
Parameter 303 - EVP start mode 5–22
Parameter 304 - EVP support arm lowering speed 5–23
Parameter 305 - EVP slow lowering speed 5–23
Parameter 306 - Activation of “Click-2-Creep” lifting/lowering 5–23
Parameter 307 - Automatic support arm lowering (On/Off) 5–24
Parameter 499 - (Not applicable) 5–24
5.5 Factory parameters ................................................................................... 5–25
5.5.1 Overview ...................................................................................... 5–25
5.5.2 Description ................................................................................... 5–26
Parameter 1001 - Truck type 5–26
Parameter 1002 - Non-configurable options 5–27
Parameters 1003-1042 – Optional functions 5–28
Parameter 1044 - Master maximum speed 5–41
Parameter 1045 - Type of battery in the truck 5–41
Parameter 1046 - Adapting to special trucks 5–42
Parameter 1101 - Built-in charger 5–42
Parameter 1102 - Controls for hydraulic function 5–43
Parameter 1110 – Reset voltage for BDI 5–44
Parameter 1118 - Hardware version 5–45
6. Installation and commissioning ................................................................... 6–1
6.1 Transporting the truck.................................................................................. 6–1
6.2 Transporting the fork carriage ..................................................................... 6–1
6.3 Safe lifting.................................................................................................... 6–2
6.4 Installing the battery .................................................................................... 6–3
6.5 Using PIN codes.......................................................................................... 6–4
6.5.1 General........................................................................................... 6–4
6.5.2 PIN code for resetting after a collision............................................ 6–4
6.5.3 Programming PIN codes ................................................................ 6–5
6.6 Programming PIN codes ............................................................................. 6–6
6.6.1 PIN code defaults ........................................................................... 6–7
6.7 Setting parameters ...................................................................................... 6–8
6.8 Function and safety checks ......................................................................... 6–9
7. Maintenance ................................................................................................... 7–1
7.1 Introduction.................................................................................................. 7–1
7.2 Maintenance instructions............................................................................. 7–1
7.2.1 Cleaning and washing .................................................................... 7–1
7.2.2 High-pressure washers .................................................................. 7–1
7.2.3 Degreasing agents ......................................................................... 7–2
7.2.4 Cleaning the exterior ...................................................................... 7–2
7.2.5 Cleaning the chain.......................................................................... 7–2
© TMHE 1– 2 T Code(s): 838, 839, 840

7.2.6 Cleaning the motor compartment ................................................... 7–2

7.2.7 Electric components ....................................................................... 7–3
7.3 Maintenance schedule................................................................................. 7–3
8. Troubleshooting............................................................................................. 8–1
8.1 General........................................................................................................ 8–1
Software compatibility 8–1
8.2 Towing a defective truck.............................................................................. 8–1
Tow using a tow truck and tow wagon: 8–2
8.3 Emergency driving mode............................................................................. 8–2
8.4 Troubleshooting methods ............................................................................ 8–3
8.4.1 General initial troubleshooting ........................................................ 8–3
8.4.2 Concluding troubleshooting............................................................ 8–4
8.5 Error code history ........................................................................................ 8–5
8.6 Error code system ....................................................................................... 8–6
8.7 Error codes .................................................................................................. 8–7
8.8 Troubleshooting chart................................................................................ 8–41
8.8.1 The truck cannot be driven........................................................... 8–42
8.8.2 Truck only travels at reduced speed ............................................ 8–43
8.8.3 The truck can be driven but behaves abnormally......................... 8–44
8.8.4 The truck can be driven, but some functions do not work ............ 8–45
Software compatibility 8–45
Hardware compatibility matrix 8–45
8.8.5 Defective hydraulic functions........................................................ 8–46
8.9 Built-in test function ................................................................................... 8–50
8.10 Digital input/output status ........................................................................ 8–52
8.10.1 Test mode “9” – .......................................................................... 8–52
8.10.2 Test function “10” – Logic card................................................... 8–53
8.10.3 Test mode “12” – Expansion unit SEU (option).......................... 8–54
8.11 Built-in test function for the tiller arm ....................................................... 8–55
8.11.1 Display test................................................................................. 8–55
8.11.2 Speed control ............................................................................. 8–55
8.11.3 Safety reversing ......................................................................... 8–55
8.11.4 Controls for lifting/lowering ......................................................... 8–55
8.11.5 Sensilift....................................................................................... 8–55
8.11.6 Keypad ....................................................................................... 8–56
8.12 Checking the built-in battery charger ....................................................... 8–57
9. Chassis 0000 .................................................................................................. 9–1
9.1 General........................................................................................................ 9–1
9.2 Fork chassis 0380 ....................................................................................... 9–2
9.2.1 Overview ........................................................................................ 9–2
9.3 Disassemble the drive unit from the fork frame ........................................... 9–3
9.4 Removing the platform ................................................................................ 9–4
9.5 Replacing the castor wheel bracket damper ............................................... 9–6
9.6 Replacing the castor wheel bracket springs and cylinder............................ 9–6
10. Electric drive motor 1700 .......................................................................... 10–1
10.1 Overview.................................................................................................. 10–1
10.2 Removing the motor from the truck ......................................................... 10–2
10.3 Removing the toothed wheel ................................................................... 10–3
10.4 Removing motor bearings ....................................................................... 10–5
10.5 Removing the RPM sensor...................................................................... 10–6
© TMHE 1– 3 T Code(s): 838, 839, 840

10.6 Installing the temperature sensor ............................................................ 10–7

10.7 Drive motor tightening torques ................................................................ 10–8
10.8 Cleaning .................................................................................................. 10–9
11. Drive gear 2550........................................................................................... 11–1
11.1 General .................................................................................................... 11–1
11.2 Overview.................................................................................................. 11–2
11.3 Removing the drive gear from the truck .................................................. 11–3
11.4 Fit grease nipples, steering bearings (option) ......................................... 11–4
11.5 Lubricate the steering bearing (Option) ................................................... 11–5
11.6 Checking and changing the oil ................................................................ 11–6
11.6.1 Draining oil ................................................................................. 11–6
11.6.2 Checking/refilling oil ................................................................... 11–7
11.7 Replacing the wheel hub seal.................................................................. 11–8
Removing the seal 11–8
Fitting the seal 11–9
11.7.1 Replacing studs ........................................................................ 11–10
12. Brake system/Wheels C3000..................................................................... 12–1
12.1 Brake system - C3100 ............................................................................ 12–1
12.1.1 Description ................................................................................. 12–1
Travel brake 12–1
Parking brake 12–1
Emergency brake 12–1
12.2 Parking brake 3180 ................................................................................. 12–2
12.2.1 Overview .................................................................................... 12–2
12.2.2 Emergency release of the parking brake.................................... 12–3
12.3 Removing the parking brake.................................................................... 12–4
12.4 Fitting the parking brake .......................................................................... 12–6
12.5 Checking the air gap................................................................................ 12–7
12.6 Drive wheel 3530 ..................................................................................... 12–8
12.6.1 Replacing the drive wheel .......................................................... 12–8
12.7 Castor wheels 3540 ................................................................................. 12–9
12.7.1 Overview .................................................................................... 12–9
12.7.2 Castor wheel mounting............................................................. 12–10
12.7.3 Replacing the castor wheel ...................................................... 12–11
12.7.4 Disassembling the castor wheel cradle .................................... 12–12
12.8 Spring replacement ............................................................................... 12–12
12.8.1 Removing springs..................................................................... 12–12
12.8.2 Fitting the spring....................................................................... 12–12
12.9 Support arm wheel 3550 ....................................................................... 12–13
12.9.1 Overview .................................................................................. 12–13
12.10 Climber wheels .................................................................................... 12–15
12.10.1 Overview ................................................................................ 12–15
13. Tiller arm 4000 ............................................................................................ 13–1
13.1 Overview.................................................................................................. 13–1
13.2 Removing the tiller arm............................................................................ 13–3
13.3 Replacing the gas spring ......................................................................... 13–3
13.4 Replacing the safety sensor .................................................................... 13–4
13.4.1 Disassembly ............................................................................... 13–4
13.4.2 Assembly.................................................................................... 13–4
13.5 Electrical steering system – 4000 ............................................................ 13–5
13.5.1 Tiller arm handle C4110 ............................................................. 13–5
13.5.2 Overview .................................................................................... 13–5
© TMHE 1– 4 T Code(s): 838, 839, 840

13.5.3 Replacing the keypad C9420 ..................................................... 13–7

13.5.4 Replacing the upper cover C4110.............................................. 13–8
Removing the upper cover 13–8
13.5.5 Replacing the tiller arm handle................................................. 13–10
Removing the tiller arm handle 13–10
Fitting the tiller arm handle 13–10
13.5.6 Replacing the logic card ........................................................... 13–11
Removing the logic card 13–11
Fitting the logic card 13–12
13.5.7 Checking the handle................................................................. 13–13
13.5.8 Update the software ................................................................. 13–13
13.5.9 Replacing the signal button/switch ........................................... 13–14
13.5.10 Replacing the lift/lower button ................................................ 13–15
13.5.11 Replacing the sensilift ............................................................ 13–16
13.5.12 Replacing the stomach button ................................................ 13–17
13.5.13 Changing the position of the controls -
support arm lift/fork lift ......................................................................... 13–18
14. Electric components-5000......................................................................... 14–1
14.1 Li-ion battery (Hoppecke) ........................................................................ 14–1
14.1.1 Resetting/restarting the battery .................................................. 14–1
14.2 Inspecting the battery .............................................................................. 14–1
14.3 Replacing the wiring harness .................................................................. 14–2
14.3.1 Replacing the transistor regulator wiring harness ...................... 14–3
14.4 Replacing the transistor regulator............................................................ 14–4
14.5 Lift height limitation sensor [B61]............................................................. 14–5
14.5.1 Replacing sensor [B61] .............................................................. 14–5
14.5.2 Adjusting the sensor [B61] ......................................................... 14–7
15. Hydraulic system 6000 .............................................................................. 15–1
15.1 General .................................................................................................... 15–1
15.2 Hydraulic hygiene .................................................................................... 15–2
15.2.1 Washing ..................................................................................... 15–2
15.2.2 Packaging................................................................................... 15–2
15.2.3 Handling ..................................................................................... 15–2
15.2.4 Storage....................................................................................... 15–3
15.2.5 Work procedures ........................................................................ 15–3
15.3 Hydraulic system components for LWE140, LWE160, LWE180 ............. 15–4
15.4 Hydraulic system components for LWE200 and LWE250 ....................... 15–5
15.5 Installing the hose coupling ..................................................................... 15–6
15.6 Hydraulic connections 6230 .................................................................... 15–7
15.6.1 Quick change connector............................................................. 15–7
Connecting the quick change connector 15–7
15.7 Adjusting the pressure limiting valve ....................................................... 15–8
15.8 Disassembling the hydraulic unit ............................................................. 15–9
15.9 Hydraulic unit tightening torques ........................................................... 15–11
16. Mast C7000 ................................................................................................. 16–1
17. Peripherals C8000 ...................................................................................... 17–1
18. Accessories ................................................................................................ 18–1
18.1 Spider expansion unit .............................................................................. 18–1
18.2 TLS - Truck log system............................................................................ 18–2
18.3 ID unit ...................................................................................................... 18–2
18.4 I_Site ....................................................................................................... 18–2
© TMHE 1– 5 T Code(s): 838, 839, 840

18.5 DC/DC converter ..................................................................................... 18–3

18.6 Collision sensor ....................................................................................... 18–3
18.7 Built-in battery charger ............................................................................ 18–4
18.7.1 Technical data ............................................................................ 18–4
18.7.2 Charging the battery ................................................................... 18–5
Main charging 18–5
Equalising charging 18–5
Charging completed 18–5
19. Instructions for disposal ........................................................................... 19–1
19.1 General .................................................................................................... 19–1
19.2 Marking of plastics ................................................................................... 19–1
19.2.1 General marking of products and packaging.............................. 19–1
19.2.2 Marking according to the manufacturer’s standards .................. 19–2
Abbreviations 19–2
Marking examples 19–2
19.3 Pressure vessels ..................................................................................... 19–3
19.3.1 Gas dampers.............................................................................. 19–3
19.4 Sorting categories.................................................................................... 19–4
20. Electrical components and wiring diagrams........................................... 20–1
20.1 Electric components ................................................................................ 20–1
20.2 Wiring diagram ........................................................................................ 20–5
20.2.1 List of symbols............................................................................ 20–5
20.2.2 General wiring diagram .............................................................. 20–6
20.2.3 Wiring diagram ........................................................................... 20–7
21. Hydraulics chart ......................................................................................... 21–1
22. Tools............................................................................................................ 22–1
22.1 MQS contacts .......................................................................................... 22–1
22.2 AMP connectors ...................................................................................... 22–3
22.2.1 AMP connectors, Multilock series 040 ....................................... 22–4
22.3 Molex connectors .................................................................................... 22–4
22.4 Grease guns ............................................................................................ 22–5
22.5 Other tools ............................................................................................... 22–6
23. Oil and grease specification ..................................................................... 23–1
23.1 General tightening torques ...................................................................... 23–1
23.2 Oil and grease specification .................................................................... 23–2
24. Technical data ............................................................................................ 24–1
24.1 LWE140, LWE160, LWE180, LWE200, LWE250.................................... 24–1
© TMHE 1– 6 T Code(s): 838, 839, 840

Repair manual: General introduction Model(s): LWE140, 160, 180, 200, 250.
2. General introduction
2.1 How to use this manual
The repair manual is divided into chapters containing the following informa-
tion:
• General safety rules.
• Operation and connection sequences – This chapter provides a basic
description of the main functions of the truck and their interdependencies.
• Parameters – This chapter provides a basic description of the truck pa-
rameters.
• Installation – This chapter describes the preparatory work that is to be
done before the truck is used for the first time.
• Maintenance – This chapter provides an overview of periodic mainte-
nance.
• Troubleshooting – This chapter describes the action you should take
when the truck is completely or partially malfunctioning. It also describes
the cause of the problem together with suggested remedies.
• C codes – This chapter describes the various truck systems, e.g. the hy-
draulic system and includes descriptions of system parts and the neces-
sary service procedures. These descriptions are divided according to BT's
C code system.
• Instructions for disposal – This chapter specifies the proper sorting cat-
egories for the materials used in the various truck components.
• Wiring diagram – This chapter provides information on electrical compo-
nents and wiring diagrams.
• Hydraulic diagram – This chapter provides information on hydraulic com-
ponents and hydraulic diagrams.
• Tools – This chapter provides a list of the special tools required.
• Service data and grease specifications – This chapter contains infor-
mation on general tightening torques and an oil and grease specification.
• Technical data.
© TMHE 2– 1 T Code(s): 838, 839, 840

2.2 Warning levels and symbols

The following warning levels and symbols are used in the repair manual:
DANGER
Indicates a dangerous situation that – if not avoided – will cause death or se-
rious bodily injury.
WARNING
Indicates a dangerous situation that – if not avoided – will cause a slight or
minor bodily injury.
NOTE
Indicates a dangerous situation that – if not avoided – will cause a slight or
minor bodily injury.
Note:
Used in connection with actions that can cause material damage but not bod-
ily injury.
Note:
Used to attract attention and to give information about various actions.
© TMHE 2– 2 T Code(s): 838, 839, 840

2.3 Pictograms
Symbol Measure Symbol Measure
Visual inspection of condi-

tion, wear and loose con- Component replacement.
nections.
Cleaning Measurement
Check of fluid level and Check that bolts, nuts, etc.

check for leaks. are tightened to torque.
Listening for noise. Lubrication, application.
Check of functions. Calibration
Adjustment Welding
Disassembly/removal Assembly/installation
© TMHE 2– 3 T Code(s): 838, 839, 840

Symbol Measure Symbol Measure
Open Close
Refilling Emptying
Update
An example of another type of pictogram is “Cut cable ties”:
Additional information under the pictogram can, for example, indicate the
number of cable ties to be cut.
— End of section —
© TMHE 2– 4 T Code(s): 838, 839, 840

Repair manual: General safety rules Model(s): LWE140, 160, 180, 200, 250.
3. General safety rules

Only personnel trained in servicing and repair of this type of truck are author-
ised to carry out service and repair activities.
3.1 Work safety

To make work safer and prevent accidents, always keep the following in
mind:
• Keep the maintenance work site clean. Oil and water on the floor will make
it slippery.
• Use the correct working posture. Service work often involves sitting on
your knees or bending over forwards. Try sitting on a toolbox, for example,
to relieve the strain on your knees and back.
• Loose items and jewellery can get caught in moving parts of the truck. So
never wear loose articles or jewellery while working on the truck.
• Exercise caution and always follow applicable local regulations when
working at high heights.
• Use the correct tools for the work you are carrying out.
• Keep all tools well maintained.
• Make sure that all safety equipment including guards and covers are prop-
erly secured and that they work as intended before starting the repair
work. If a guard or cover must be removed in order to perform the repair
work, extra care must be taken, and when the repair work is finished the
guard or cover must be refitted.
• Relieve the system pressure slowly before starting work on the truck’s hy-
draulic system.
• Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hands.
• Drive unit oil and the hydraulic system oil may be hot.
DANGER!
Risk of burn injury.
Hot drive unit and hydraulic oil.
Allow the truck to cool down before changing the oil.
• Only fill the hydraulic system with new and clean oil.
DANGER!
The hydraulic system can be damaged.
If the oil is contaminated, the hydraulic components will suffer damage.
Always use new and clean oil in the hydraulic system.
• Store and transport changed oil according to applicable local directions.
• Do not flush solvents, etc. down the drain unless they are intended to be
disposed of in this way.
Follow local disposal regulations.
© TMHE 3– 1 T Code(s): 838, 839, 840

• Disconnect the battery prior to performing any welding work on the truck.
Note:
The battery could be damaged.
When welding with an electric welding unit, the current may enter the battery.
The battery must be disconnected.
• Prior to welding or grinding on painted surfaces, be sure to remove the
paint at least 100 mm around the welding/grinding area by using sand-
blasting equipment or paint remover.
DANGER!
Harmful gasses.
Heated paint gives off harmful gases.
Remove all paint within 100 mm of the welding/grinding site.
© TMHE 3– 2 T Code(s): 838, 839, 840

3.2 Electrical system

When working on the electrical system of the truck, remember the following:
• Never wear loose items or jewellery when working with the truck.
DANGER!
Short-circuiting/Burn injury.
Short circuits and burn injuries can occur if metal objects come into contact
with live electrical connections when working on the truck's electrical sys-
tem.
Remove wristwatches, rings and other metal objects beforehand.
• Always use insulated tools when working on the electrical system.
• Always disconnect the battery before opening any covers to drive units or
the electrical system.
• Always disconnect the battery prior to welding work using an electric weld-
ing unit. The welding current may damage the battery.
• Always disconnect the battery when carrying out maintenance or repair
work on the truck unless otherwise stated in this repair manual.
• Clean electric motors using a rag or a vacuum cleaner.
• Clean electrical panels, electronic cards, contactors, contacts, magnetic
valves, etc. with a dampened cloth and a cleaning agent that will not dam-
age the part.
Note:
Risk of short-circuiting that may damage electrical components.
Do not break the warranty seal on the logic cards.
© TMHE 3– 3 T Code(s): 838, 839, 840

3.3 Safe lifting

All lifting must be carried out on a level, non-slip and stable surface. Asphalt
surfaces should be avoided if possible.
To prevent the truck moving while it is being lifted, it must not be lifted 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 wheels must be
chocked to stop the truck from moving.
Select the lifting point so that the lift is as light as possible, for example one
corner at a time. If the truck has marked lifting points on the lower part of the
chassis, these must be used to ensure balanced lifting.
Make sure the surface where the jack is placed is clean and free of oil and
grease.
Make sure your hands and the jack lever are free of grease and oil.
Only use the lever supplied with the jack. If the lever is too short, more exer-
tion than is necessary will be required. If the lever is too long, there is a risk
that the jack will be overloaded.
DANGER!
Risk of crushing since a poorly supported truck could fall down.
Never work under a truck that is not supported by trestles and secured by a
lifting device.
Support the truck:
• as close to the lifted part of the chassis as possible in order to reduce the
falling height if the truck should collapse
• so the truck cannot move.
Never support the jack on trestles to achieve a higher lift.
Never work under a raised truck without it being properly supported on tres-
tles.
© TMHE 3– 4 T Code(s): 838, 839, 840

3.4 Truck modifications

Any modification of the truck must be approved beforehand. No modification
of truck may be performed that may influence the capacity, stability and safety
of the truck without prior written approval from the manufacturer, its repre-
sentative or successor.
In the case of the manufacturer no longer being in business and there being
no successor, the user of the truck may arrange for modifications on the pre-
condition that the user:
• makes sure that an engineer with expert knowledge of industrial trucks
and their safety designs, tests and implements the modification,
• files all documentation of the designs, tests and implementation of the
modification,
• approves and makes the applicable changes to the capacity plate, adhe-
sive labels, markings and operator’s manual and
• affixes a permanent and well visible sign to the truck stating how the truck
has been modified, together with the date of the modification and the
name and address of the company that carried out the modification work.
© TMHE 3– 5 T Code(s): 838, 839, 840

© TMHE 3– 6 T Code(s): 838, 839, 840

Repair manual: Operation and connection sequences Model(s): LWE140, 160, 180, 200, 250.
4. Operation and connection sequences
This section provides a basic description of the main functions of the truck.
The terms below are used in the description of the truck’s main functions.
• Event – Use of one of the truck's main functions is referred to as an event.
• Prior event – Indicates an event which must have taken place immediately
before the current event in order for the latter to be performed correctly.
• Action(s) – An action that the driver must perform in order for an event to
happen.
• Influencing elements – Conditions that must be fulfilled in order for an
event to happen. Certain parameter settings may also affect the outcome
of the event.
• Resulting conditions – Describe the key events that can be checked in or-
der to confirm a function.
Note that resulting conditions indicate what is assumed to occur when there
is no error state.
Text within square brackets [ ] refer to the electrical component names in the
truck's electrical diagram.
{High} means ˜ 24 V and {low} means ˜ 0 V unless otherwise specified.
© TMHE 4– 1 T Code(s): 838, 839, 840

Symbols on keypad and display
Symbol Description
ON switch
This switch is used to start the truck
and confirm entered settings during
PIN code management
OFF switch
Error code
Battery charge as a percentage
Parameter
Hour meter
© TMHE 4– 2 T Code(s): 838, 839, 840

4.1 Battery is connected
Event Connection of battery

Preceding event -
Action(s) Connect the truck battery [G1]
Influencing Main power fuses OK [F1]

elements Operating circuit fuses OK [F50, F51]
Resulting The status LED for the transistor regulator lights

conditions continuously [T1].
4.2 Login via keypad
Event Logging in
Preceding event The battery is connected.
Enter a valid PIN code and press the ON button
Action(s)
on the keypad [S223].
The emergency stop [S21] has not been activated
Influencing elements [T1:INP. SUPPLY+24V DC] {high}.
Tiller arm sensor in drive position [B60].
The power indicator lamp is lit. Main display
shows the hour counter for 4 seconds and after
this the battery charge level as a percentage of
Resulting conditions
full charge.
The mechanical brake remains applied [Q1]
[T1:OUT.BRAKE RELEASE] {high}.
© TMHE 4– 3 T Code(s): 838, 839, 840

4.3 Tiller arm lowered for driving
Event Tiller arm lowered for driving

Preceding event Start the truck.
Action(s) Lower tiller arm
Influencing elements Tiller arm sensor in drive position [B60].

Tiller arm sensor in drive position activates [B60]
[T1:INP. TILLER ARM IN DRIVE POS] {low}.
Resulting conditions The main contactor output voltage goes {low}
[T1:OUT. MAIN CONTACTOR]
The main contactor closes [Q10].
4.4 Driving in fork direction
Event Driving in fork direction

Preceding event Tiller arm is lowered to the drive position.
Action(s) Turn the speed control in the fork direction.

Speed control with Hall sensor [A5:S310-318].
Influencing elements Settings of operator parameters 4, 5 and 6
determine truck travel performance.
[T1:OUT.BRAKE RELEASE] goes {low}.
Brake coil [Q1] is activated, and the mechanical
brake is released.
Resulting conditions Power is fed to the drive motor's field coils (S2 +ve
and S1 -ve).
Pulsed current feed to drive motor rotor is
proportional to speed control actuation.
© TMHE 4– 4 T Code(s): 838, 839, 840

4.5 Driving in the drive wheel direction
Event Driving in the drive wheel direction

Action(s) Turn the speed control in the drive wheel direction.

Speed control with Hall sensor [A5:S300-308].
Influencing
Settings of operator parameters 4, 5 and 6
elements
determine truck travel performance.
[T1:OUT. BRAKE RELEASE] goes {low}.
brake is released.
Resulting
The current feed to the drive motor field winding (S2
conditions
-ve and S1 +ve).
proportional to speed control actuation.
4.6 Neutral position braking
Event Neutral braking

Preceding event Truck travels in fork or drive wheel direction.
Allow the speed control to return to the neutral
Action(s)
position.
Influencing Setting of operator parameter 5.
elements
The drive motor [M1] works as a generator and via
the transistor regulator [T1] it converts the truck's
kinetic energy into electricity, thus reducing the
Resulting truck’s speed. The excess energy, in the form of
conditions electricity, is fed back to the battery [G1] helping to
recharge it. The mechanical brake [Q1] is applied
when the truck stops. [T1:OUT.BRAKE RELEASE]
goes {high}.
© TMHE 4– 5 T Code(s): 838, 839, 840

4.7 Reverse braking
Event Reverse braking

Action(s) Speed control turned to opposite travel direction.
Influencing elements Parameter 201.

The drive motor [M1] works as a generator and via
the transistor regulator [T1] it converts the truck's
kinetic energy into electricity, thus reducing the
truck’s speed. The excess energy, in the form of
Resulting conditions electricity, is fed back to the battery [G1] helping to
recharge it. The braking effect increases the more
the speed control is turned.
The mechanical brake [Q1] [T1:OUT. BRAKE
RELEASE] is applied when the truck stops.
4.8 Mechanical braking
Event Mechanical braking

Action(s) The tiller arm is folded completely up or down.
Influencing Tiller arm sensor in drive position [B60].

elements
Sensor for tiller arm in drive position [B60] is
deactivated [T1: INP. TILLER ARM IN DRIVE POS]
{low}.
Resulting When the tiller arm is completely raised or lowered,
conditions maximum permitted brake reduction is applied for
200 ms or until the travel speed is less than
0.8 m/s. After this, the mechanical brake [Q1] is
applied. [T1:OUT.BRAKE RELEASE] {high}.
© TMHE 4– 6 T Code(s): 838, 839, 840

4.9 Emergency reversal
Event Emergency reversal

Preceding event Driving in the drive wheel direction
When driving in the drive wheel direction, the emergency
Action(s)
reversal button is pressed
Influencing
Emergency reversal
elements
The Hall sensor [A5:S317] is immediately activated.
The card [A5] interprets this signal as a command to
the transistor regulator [T1] to run the drive motor at
Resulting
a reduced speed in the fork direction as long as the
conditions
button is depressed. The normal drive command
signal received from [L1] is blocked until [L1] is
released and returns to neutral position.
4.10 Fork lifting
Event Fork lifting

Action(s) Press the fork lift button [A5:S320].

Main contactor [Q10].
Fuse [F1].
Influencing elements Fork lift button [A5:S320].
Battery status OK (battery discharge indicator > 0
or battery charge > 20 %).
Resulting conditions Pump motor [M3] starts.
© TMHE 4– 7 T Code(s): 838, 839, 840

4.11 Fork lowering
Event Fork lowering

Preceding event Start the truck or commence fork lifting.
Action(s) Press the fork lowering button [A5:S321].

Influencing elements
Fork lowering button [A5:S321].
[T1:OUT. LOWER VALVE] goes {low}, the
hydraulic lowering valve [Q4] opens.
4.12 Click-2-Creep
Event Click-2-Creep
Quick double-actuation of the speed control to
activate the function.
Action(s) Put the tiller arm in the upright position and drive
the truck at low speed
(2.5 km/h).
Influencing elements
Setting of factory parameter 1002.
[T1:OUT.BRAKE RELEASE] goes {low}.
brake is released.
Power is fed to the drive motor's field coils (S2 +ve
and S1 -ve).
proportional to speed control actuation. “SLO” is
displayed (flashes).
© TMHE 4– 8 T Code(s): 838, 839, 840

4.13 Turtle function (option)
Event Turtle function (option)

Press [S206] to activate this function.
Action(s)
Turn the speed control in either direction.
Option button 1 [S206].
Influencing elements Setting of operator parameter 7 and service
parameter 202.
[T1: OUT. BRAKE RELEASE] goes {low}.
brake is released.
Power is fed to the drive motor's field coils (S2 +ve
Resulting conditions and S1 -ve).
proportional to speed control actuation. The
maximum travel speed is determined by operator
parameter 7. “SLO” is displayed (lit continuously).
© TMHE 4– 9 T Code(s): 838, 839, 840

© TMHE 4 – 10 T Code(s): 838, 839, 840

Repair manual: Parameters Model(s): LWE140, 160, 180, 200, 250.
5. Parameters
5.1 General
The truck's control system can store a number of different parameters. These
are used to configure the truck according to the task to be performed. The pa-
rameters are divided into groups:
– Operator parameters – The driver parameters (1-100) are used to
adapt the truck’s characteristics to a specific driver or task. Up to 10 op-
erator parameter profiles can be stored.
– Service parameters – The service parameters (range 101–1000) are
used to adapt the truck's performance/response and cover all other pa-
rameters not covered by the operator parameters.
– Factory parameters – (range 1001-1250). Truck-specific parameters.
Operator parameters are displayed and changed only for a selected operator,
but if a CAN service key is connected, the parameters for all operators can
be displayed and changed. Operator parameters can be changed by the op-
erator if the truck's program is set up for this.
The service parameters can be changed once a suitable CAN service key or
PDA/PC has been connected to the truck.
Factory parameters can only be changed using the TruckCom software ap-
plication.
© TMHE 5– 1 T Code(s): 838, 839, 840

5.1.1 Show/change parameters
1: Ensure that the truck is switched off. Connect the CAN key or enter the
PIN code. Note: Do not press the ON button.
2: Press and then release the horn button. “Info“ is shown on the display.
3: Move between menus by turning the speed control several times.
4: “Par” is shown on the display.
5: Press the horn button to select. The parameter symbol lights up.
6: By pressing the speed control repeatedly, you can move through the
parameter list.
See section "5. Parameters".For setting parameters.
To show a parameter, release the speed control when the required parameter
is shown on the display. Press the horn button to change the parameter.
© TMHE 5– 2 T Code(s): 838, 839, 840

5.1.2 Operator parameters

Note:
Changing specific truck parameters changes the truck's driving properties.
Do not change any parameter values without the necessary know-how.
5.1.3 Overview
Par. Description
3 Acceleration
4 Deceleration
6 Maximum speed
7 Maximum speed, forks above 1.8 m
© TMHE 5– 3 T Code(s): 838, 839, 840

5.1.4 Connection to logged-in operator

The operator parameters can be adjusted individually to the available log-in
profiles. The parameter’s connection to the operator is done by a combination
of operator and parameter numbers where the single digit always corre-
sponds to the parameter.
Operator Parameter
profile range
1 1–7
2 11 – 17
3 21 – 27
4 31 – 37
5 41 – 47
6 51 – 57
7 61 – 67
8 71 – 77
9 81 – 87
10 91 – 97
Description of operator parameters
Parameters 3 and 4 – Acceleration/Deceleration

These two parameters can be used to get a smoother acceleration/retarda-
tion where the application or operator profile so requires.
Defa Incre
Par. Description Min. Max. Unit
ult ment
3 Acceleration 10 80 100 5 %
4 Deceleration 10 90 100 5 %
# 3 - Acceleration
The lower the parameter value, the more time is needed to accelerate to the
maximum speed.
#4 - Deceleration
Defines plug braking force when speed control [L1] returns to the neutral po-
sition. The lower the value of parameter, the longer it takes to reduce speed.
© TMHE 5– 4 T Code(s): 838, 839, 840

Parameters 6 and 7 – Maximum travel speed

These two parameters are used to limit the maximum travel speed for the
logged-in operator profile.
Defa Incre
ult ment
6 Maximum speed 30 100 100 5 %
Maximum speed, forks above
7 30 100 100 5 %
1.8 m
The maximum travel speed can also be limited by factory parameter #1044
and it is always the lowest speed for a parameter that is the limiting one.
# 6 - Maximum speed
Determines the maximum travel speed.
# 7 - Maximum speed, forks above 1.8m

Adjusts the truck maximum speed when the forks are above 1.8 m, Is set as
a % of parameter 203.
© TMHE 5– 5 T Code(s): 838, 839, 840

5.2 General service parameters

Before any service parameter can be changed, the CAN service key must be
connected to the contact [X41].
5.2.1 Overview
Note:
Changing specific truck parameters changes the truck's driving properties.
Do not change any parameter values without the necessary know-how.
Par. Description
101 Service intervals
102 Operator access
103 Start-up - alternative
104 Automatic logout/min
105 Collision sensor X-level
106 Collision sensor Y-level
107 Battery adjustment, Ah
109 Battery type, built-in charger
110 Battery size, built-in charger
111 Reset following a collision
112 Clear application data
© TMHE 5– 6 T Code(s): 838, 839, 840

5.2.2 Description
Parameter 101/104 – Service/Log-out

Defa Incre
ult ment
101 Service intervals 0 0 2000 50 h
104 Time to automatic log-out 0 20 20 1 min.
#101 - Service interval

This parameter determines the time value (in hours) to the next service from
0 to 2000 hours in increments of 50 hours. Whenever this value is changed,
the timer is reset and will start to count the truck activity time. On reaching the
set value, code “S - 0h” is shown on the display and the red LED flashes.
If the value is set as '0', no service interval is given
#104 - Time to automatic log-out
Gives the time, in minutes, before automatic log-out if the truck is inactive.
If the value is set as ‘0’, logout takes place after 4 hours.
Parameter 102 - Operator access

Defa Incre
ult ment
102 Operator access 1 3 10 1
#102 - Operator access

Specifies which login method should be used and if the operator will have the
possibility of changing the operator parameter settings.
Values 1 and 2 = Key
Values 3 and 4 = Keypad with 100 PIN codes. See section "6.6 Programming
PIN codes".
Values 5 and 6 = Keypad with DHU
Values 7 and 8 = ID unit
Values 9 and 10 = SA2
Odd values = Operator parameters are open and can be changed by the op-
erator.
Even values = Operator parameters can only be changed with a CAN key
connected.
© TMHE 5– 7 T Code(s): 838, 839, 840

Parameter 103 - Start-up display

Defa Incre
ult ment
103 Start-up display 1 2 5 1
#103 - Start-up display

Sets which value is shown on the display when the truck is started.
When the truck is started, one of the truck's 5 values is shown on the hour
meter display "H" (hour meter display) for 5 seconds. After the menu has dis-
appeared, the battery capacity is continuously shown in the numeric field at
the same time as the battery indicator is lit.
The truck control system stores five different time values. "Value 2 - Operat-
ing time" is the default value on the start-up display.
Hour meter values Display
Value 1 = (A) Key time

The total time the truck has been in use
Value 2 = (B) Operating time

Combined time during which the pump or drive motor has
been in operation.
Default display.
Value 3 = (C) Drive motor time

The total time the drive motor has been in operation.
Value 4 = (D) Pump motor time

Total time the pump motor has been in operation.
Value 5 = (S) Remaining time until next service.

Parameter 101 controls the initial value.
© TMHE 5– 8 T Code(s): 838, 839, 840

Parameter 105/106 - Collision sensor sensitivity for X/Y (Optional)

Defa Incre
ult ment
Collision sensor X sensitivity
105 0 0 100 1
level
Collision sensor Y sensitivity
106 0 0 100 1
level
# 105 - Collision sensor Y sensitivity level

Indicates the level of sensitivity for what should be interpreted as a frontal/
rear-end impact. 0 = Collision sensor not activated
The collision sensor can also be used in combination with DHU. In such cas-
es, the parameters should not be set in the truck. Collision monitoring is in-
stead administrated via I_Site.
This parameter must be set during truck installation.
#106 - Collision sensor Y sensitivity degree
Indicates the degree of sensitivity for what should be interpreted as a side im-
pact. 0 = Collision sensor not activated
The collision sensor can also be used in combination with DHU. In such cas-
es, the parameters should not be set in the truck. Collision monitoring is in-
stead administrated via I_Site.
This parameter must be set during truck installation.
© TMHE 5– 9 T Code(s): 838, 839, 840

Parameter 107 – Battery size

Defa Incre
ult ment
107 Battery size 1 9 20 1
# 107 - Battery size

Specifies what type of battery the truck is equipped with.
The parameter can be used to compensate for different ways of driving by:
• increasing the value to discharge the battery even more.
• reducing the value if the battery is discharged too much.
In order to set the meter for battery charge level, consideration must be given
to the following:
• Acid density when the battery is fully charged; to check the quality of the
battery. This value should be between 1.27 and 1.29.
Please note that the acid density may vary between different kinds of bat-
tery.
• When the lifting capacity is disabled (battery 80% discharged), the value
must be close to (but not below) 1.14.
© TMHE 5 – 10 T Code(s): 838, 839, 840

Table applicable to LWE140, 160, 180, 200

Refer to the table below for recommended parameter settings.
Parameter 107 Battery size Battery size Battery size
Lead/acid Hawker Evolution gel battery
battery
1
Slight 2
discharge 3
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
discharge 18 125-140 Ah
19
20
© TMHE 5 – 11 T Code(s): 838, 839, 840

Table concerning LWE250

battery
1
Slight 2
discharge
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
discharge 17 171-185 Ah 110-130 Ah
18 156-170 Ah
19 141-155 Ah
20 125-140 Ah
DANGER!
Battery service life will be reduced if the value of parameter 107 is set too
high. The standard setting of parameter 107 is set for normal truck handling.
Other applications may require a different setting of parameter 107. Check
that the parameter setting is the correct one using the instructions below.
© TMHE 5 – 12 T Code(s): 838, 839, 840

Table concerning SWE

battery
1
Slight 2
discharge 3
4
5
6 271-280 Ah 271-290 Ah
7 251-270 Ah 251-270 Ah
8 231-250 Ah 231-250 Ah
9 286-320 Ah 211-230 Ah 211-230 Ah
10 251-285 Ah 191-210 Ah 191-210 Ah
11 221-250 Ah 171-190 Ah 171-190 Ah
12 206-220 Ah 151-170 Ah 151-170 Ah
13 191-205 Ah 131-150 Ah 131-150 Ah
14 176-190 Ah 120-130 Ah 110-130 Ah
15 161-175 Ah
16 146-160 Ah
17 131-145 Ah
Deeper
discharge 18 115-130 Ah
19
20
WARNING!
Battery service life will be reduced if the value of parameter 107 is set too
high. The standard setting of parameter 107 is set for normal truck handling.
Other applications may require a different setting of parameter 107. Check
that the parameter setting is the correct one using the instructions below.
© TMHE 5 – 13 T Code(s): 838, 839, 840

Verifying parameter settings for freely ventilated batteries (lead-acid

batteries)
1. Charge the battery.
2. Use the truck in its normal application until the battery indicator shows a
discharged battery (0% on the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
minutes.
Note:
Do not charge or discharge during this time.
4. Measure the specific gravity of the electrolyte at ambient temperature.
If the specific gravity is below 1.15 g/cm3, the parameter value must be re-
duced.
If the value is considerably higher than 1.15 g/cm3 the risk of damage to the
battery is reduced. At the same time, the operating time of the truck is
reduced. If extended operating time is desired, then increase the parameter
value by no more than one unit.
Note:
Each change should be followed up by a new verification of the parameter
setting.
Verifying the parameter setting for valve-regulated batteries (Exide)

1. Charge the battery.
2. Operate the truck in its normal application until the battery indicator
indicates a discharged battery (0% in the display).
3. Disconnect the battery from the truck and allow it to rest for at least two
hours.
Note:
Do not allow any charging or discharging during this time.
4. Measure the battery voltage at room temperature.
If the voltage is less than Uend (see the table below) the parameter value
must be reduced. If the value is considerably higher than Uend the risk of
damage to the battery is reduced. At the same time, however, the operating
time of the truck decreases. If extended operating time is desired, then
increase the parameter value, but maximum by one unit.
Note:
Each change should be followed up by a new verification of the parameter
setting.
Battery type Battery voltage while resting,

Uend
Exide 24.24 V
© TMHE 5 – 14 T Code(s): 838, 839, 840

Parameters 109/110 - Built-in charger (option)
Defa Incre
ult ment
109 Battery type, built-in charger 0 0 3 1
110 Battery size, built-in charger 100 100 300 1 Ah
#109 - Battery type, built-in charger

Sets the type of battery in case of built-in charger. This parameter has no use
unless there is a built-in charger.
#0 = No charging
#1 = Lead/acid battery
#2 = Hawker Evolution battery
#3 = Exide gel battery
#110 - Battery type, built-in charger (Optional)

Sets the battery size used with the built-in charger so the correct charging
current is chosen. For Hawker Evolution only the sizes 134 Ah, 174 Ah and
201 Ah are approved. This parameter has no use unless there is a built-in
charger.
© TMHE 5 – 15 T Code(s): 838, 839, 840

Parameter 111 - Reset procedure after collision (option)
Defa Incre
ult ment
Resetting procedure after col-
111 0 0 3 1
lision
#111 - Reset procedure after collision

Specifies the condition for how the truck is to be taken into operation again
after the collision sensors have been triggered.
Value Function
0 Function not activated
1 The operator can reset the truck.
2 Horn sounds once every five seconds.
3 Options 1 and 2 combined.
The PIN code to be activated for resetting can be found in operator profile 1
and special block 10. Page 6–4
Parameter 112 - Clear application data
Defa Incre
ult ment
112 Erase application data 0 0 2 1
#112 - Clear application data

Specifies whether information from the histogram/collision sensor is to be de-
leted at login.
Value Function
0 Do not clear
1 Clear histogram at start-up
2 Clear collision log at start-up
The histogram data consists of the logged motor temperature, motor control and
steering motor in the form of a histogram. You clear this data by setting parameter
112 =1. This is useful when transferring the truck from one client to another.
The collision log is a log with the 10 latest collisions are stored together with the
operator PIN code. You clear this data by setting parameter 112 =2.
© TMHE 5 – 16 T Code(s): 838, 839, 840

5.3 Service parameters, travel functions
5.3.1 Overview
Par. Description
201 Braking force when reversing the travel direction
202 Maximum speed Turtle mode activated
203 Maximum speed, forks above 1.8 m
204 Acceleration, forks above 1.8 m
Braking force when reversing the travel direction, forks
205
above 1.8 m
206 Automatic deceleration, forks above 1.8 m
© TMHE 5 – 17 T Code(s): 838, 839, 840

5.3.2 Description
Parameter 201 – Deceleration when reversing
Defa Incre
ult ment
201 Deceleration when reversing 70 100 100 5 %
#201 – Deceleration when reversing
Sets how hard the truck will brake when the speed control is turned in the opposite
direction, and used to get a smoother deceleration where the application requires
this for all operator profiles.
Parameter 202 – Maximum speed Turtle mode activated
Defa Incre
ult ment
Maximum speed Turtle mode
202 0.5 3.0 6.0 0.5 km/h
activated
#202 - Maximum speed Turtle mode activated
Sets the maximum speed when Turtle mode is activated

.
© TMHE 5 – 18 T Code(s): 838, 839, 840

Parameter 203 - Maximum speed, forks above 1.8 m

Applies to SWE
Defa Incre
ult ment
Maximum speed, forks above
203 0.5 2.5 5.0 0.5 km/h
1.8 m
# 203 - Maximum speed, forks above 1.8m

Sets the maximum speed when the forks are above 1.8 m.
Parameter 204 - Maximum acceleration, forks above 1.8 m

Applies to SWE
Defa Incre
ult ment
Maximum acceleration,
204 10 45 60 5 %
forks above 1.8 m
#204 - Maximum acceleration, forks above 1.8 m

Sets the maximum acceleration when the forks are above 1.8 m. As a per-
centage of maximum acceleration for this application.
Parameter 205 - Maximum reversing, forks above 1.8 m

Applies to SWE
Defa Incre
ult ment
Maximum reversing, forks
205 45 80 80 5 %
above 1.8 m
#205 - Maximum reversing, forks above 1.8 m

Sets the maximum reversing when the forks are above 1.8 m. As a percent-
age of maximum acceleration for this application.
© TMHE 5 – 19 T Code(s): 838, 839, 840

Parameter 206 - Automatic speed reduction, forks above 1.8 m

Applies to SWE
Defa Incre
ult ment
Automatic speed reduc-
206 45 60 80 5 %
tion, forks above 1.8 m
#206 - Automatic speed reduction, forks above 1.8 m

Sets the maximum speed reduction when the forks are above 1.8 m. As a
percentage of maximum acceleration for this application.
© TMHE 5 – 20 T Code(s): 838, 839, 840

5.4 Service parameters, hydraulic functions
Par. Description
301 Lowering stop ramp
302 Fork lowering speed
303 EVP start position
304 Support arm, lowering speed
305 EVP slow lowering speed
306 Activates two lifting/lowering speeds
307 Automatic support arm lowering
499 (Not applicable - for field test software only)
© TMHE 5 – 21 T Code(s): 838, 839, 840

5.4.1 Description
Parameter 301 – Ramping value for lowering stop

Applies to SWE
Defa Incre
ult ment
301 Lowering stop ramp 3 7 20 1
# Parameter 301 – Ramping value for lowering stop

Determines the closing ramp of the proportional valve.
Parameter 302 - Fork, lowering speed

Applies to SWE
Defa Incre
ult ment
302 Fork lowering speed 70 190 255 5
# Parameter 302 - Fork, lowering speed

Determines the maximum lowering speed of the forks. This parameter can be
adjusted manually or can be set by using the calibration function
Parameter 303 - EVP start mode

Applies to SWE
Defa Incre
ult ment
303 EVP start position 30 90 150 5
# Parameter 303 - EVP start mode

Determines the start position of the proportional valve. This parameter can be
adjusted manually or can be set by using the calibration function
© TMHE 5 – 22 T Code(s): 838, 839, 840

Parameter 304 - EVP support arm lowering speed

Applies to SWE
Defa Incre
ult ment
EVP support arms
304 50 130 220 5
lowering speed
Parameter 304 - EVP support arm lowering speed

Specifies the lowering speed of the support arms. This parameter can be ad-
justed manually or can be set by using the calibration function
Parameter 305 - EVP slow lowering speed

Applies to SWE
Defa Incre
ult ment
305 EVP slow lowering speed 40 105 220 5
Parameter 305 - EVP slow lowering speed

Determines the slow lowering speed when using "Click-2-Creep”. This pa-
rameter can be adjusted manually or can be set by using the calibration func-
tion
Parameter 306 - Activation of “Click-2-Creep” lifting/lowering

Applies to SWE
Defa Incre
ult ment
Activate “Click-2-Creep” lift-
306 0 1 1 1
ing/lowering
Parameter 306 - Activation of “Click-2-Creep” lifting/lowering
Activate “Click-2-Creep” lifting/lowering
Value Function
0 Off
1 On:
© TMHE 5 – 23 T Code(s): 838, 839, 840

Parameter 307 - Automatic support arm lowering (On/Off)

Applies to SWE
Defa Incre
ult ment
Automatic support arm lower-
307 0 1 1 1
ing
#307 - Automatic support arm lowering (On/Off)
Controls whether the support arms should be lowered automatically when the forks
reach the 1.8 m sensor.
Value Function
0 Off
1 On:
Parameter 499 - (Not applicable)

This parameter is only used for field test software
© TMHE 5 – 24 T Code(s): 838, 839, 840

5.5 Factory parameters

The truck's factory parameters are preset in the truck during production at the
factory. Factory parameters can only be changed using the TruckCom soft-
ware application.
Note:
Remember that a change of specific truck parameters changes the truck's
properties. Do not change any parameter values without the necessary know-
how. Only authorised service technicians with personal TruckCom user iden-
tities have the rights to change factory settings. The parameters should only
be changed when a specific need for this arises.
The user ID and time of changing parameters will be logged in the logic card
housed in the tiller arm handle.
5.5.1 Overview
Par. Description
1001 Truck type
1002 Non-configurable options
1003-
Optional functions FUNC1 - FUNC8
1042
1044 Master maximum speed
1045 Battery type
1046 Special truck
1101 Built-in charger
1102 Controls for hydraulic function
1110 BDI
1118 Hardware version
© TMHE 5 – 25 T Code(s): 838, 839, 840

5.5.2 Description
Parameter 1001 - Truck type
Defa Incre
ult ment
1001 Truck type 0 0 108 1
# Parameter 1001 - Truck type

This parameter is used to set which truck type the program is to adapt oper-
ational data for.
Value Function
0 Unknown truck type
1 LWE140
2 LWE160
3 LWE180
4 LWE200
5 LWE250
101 SWE100
102 SWE120
103 SWE140
104 SWE120L
105 SWE140L
106 SWE200D
107 SWE080L
108 SWE120S
© TMHE 5 – 26 T Code(s): 838, 839, 840

Parameter 1002 - Non-configurable options
Defa Incre
ult ment
1002 Non-configurable option 0 1 7 1
#1002 - Non-configurable options

3 different functions are accessible via parameter 1002. These functions are
either active or inactive. The functions do not require any further adjustment
and are thus referred to as non-configurable options.
Value Function
0 No optional function
1 CLICK-2-CREEP
2 TURTLE
3 CLICK-2-CREEP and TURTLE
4 SAFETY REVERSING HORN
5 SAFETY REVERSING HORN and CLICK-2-CREEP
6 SAFETY REVERSING HORN and TURTLE
SAFETY REVERSING HORN, CLICK-2-CREEP and TUR-
7
TLE
© TMHE 5 – 27 T Code(s): 838, 839, 840

Parameters 1003-1042 – Optional functions
Defa Incre
ult ment
1003 Optional function 1 0 0 21 1
1004 Optional function 1Arg1 0 0 255 1
© TMHE 5 – 28 T Code(s): 838, 839, 840

Parameters #1003-1042
Factory parameters # 1003 to 1042 - configurable optional functions
Parameters #1003 to #1042 are reserved in the truck’s control system for ex-
tra truck options and/or special product modifications. The parameters con-
figure and control the Spider expansion unit (SEU) that must be fitted to the
truck, in some cases it is enough to have an empty I/0 in the motor control.
This method of implementation enables use of the standard program. This
eliminates the need for any special program.
Normally, these parameters are configured by the manufacturer when the
truck is modified or customised. It is advisable to upload the parameter set-
tings from the truck when carrying out any modification. If the main control
unit [A2] has been replaced, the original parameter settings can be trans-
ferred to the new unit, thus ensuring that special options function correctly.
Factory parameter nos. #1003, #1008, #1013, #1018, #1023, #1028, #1033
and #1038 can be adjusted to allow up to a maximum of 8 pre-programmed
"Basic options" to be activated and configured to suit a specific special option
or customisation.
Activation of optional functions

The system can use up to eight configurable optional functions simultaneous-
ly. Each configurable function is controlled by five factory parameters. During
activation, an index parameter (#1003, #1008, #1013, #1018, #1023, #1028,
#1033, #1038) must first be set to a value equivalent to an optional function.
Linked to each index parameter are four parameters that can be modified to
configure the optional function.
• The index parameter is allocated one optional function (optional function is
determined).
• Each optional function can have up to 4 arguments associated with it.
Each argument holds a value which can be changed to configure the func-
tion (optional function is configured).
• If the value of an argument is outside of the highest or lowest permitted
value, an error code is generated and the option cannot be used.
The error code cannot be eliminated until the argument is given a permis-
sible value.
© TMHE 5 – 29 T Code(s): 838, 839, 840

Base option 1 - Option button controls SEU output

Argument #1 Selection of SEU unit 1 or 2
Values Meaning
0 option is handled by SEU unit 1 (A36)
1 option is handled by SEU unit 2 (the second SEU unit)
Argument #2 Selection of SEU digital output
Values Meaning Pin no.
0 activates digital output 1 (1.6 A) on SEU 16
Argument #3 Selection of option button
Values Meaning
0 activated by option button 2 or 5
1 activated by option button 1
Argument #4 Type of switching

Values Meaning
0 activated when the button is pressed
1 option is toggled when button is pressed
© TMHE 5 – 30 T Code(s): 838, 839, 840

Basic option 2 - Reduced driving speed via SEU inputs

Values Meaning
Argument #2 Selection of SEU digital input
0 activates digital input 1 (1 mA) on SEU 5
Argument #3 Speed limitation as a percentage of max. speed
Values Meaning
Max. speed adjustable from 0-100%
0-100
(driving is not possible when value = 0)
Argument #4 Speed range
Values Meaning
0 Affects only high speed range
1 Affects only low speed range
2 Affects both speed ranges
© TMHE 5 – 31 T Code(s): 838, 839, 840

Basic option 3 - Truck movement activates SEU output

Values Meaning
Argument #2 Selection of SEU digital output
Pin
Values Meaning
no.
© TMHE 5 – 32 T Code(s): 838, 839, 840

Basic option 3 - Truck movement activates SEU output

Argument #3 Selection of activation movement
Driving
Driving Fork Fork
Values drive wheel
fork direction lifting lowering
direction
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16
17 X
18 X
19 X X
20 X
21 X X
22 X X
23 X X X
24 X
25 X X
26 X X
27 X X X
28 X X
29 X X X
30 X X X
31 X X X X
Argument #4 Output switching mode
Values Meaning
0 Output continuously on
1 Output switches at 1 Hz
© TMHE 5 – 33 T Code(s): 838, 839, 840

Basic option 4 - Activate main contactor by SEU input

Values Meaning
0 activated by digital input 1 (1 mA) on SEU 5
2 activated by digital input 3 (1 mA) on SEU 3 33
Argument #3 Hold time in minutes
Values Meaning
Contactor is held from 0 to 30 minutes after the digital input is
0-30
activated
Argument #4 Not used
© TMHE 5 – 34 T Code(s): 838, 839, 840

Basic option 5 - Activate lifting/lowering by SEU input

Values Meaning
Argument #2 Selection of SEU digital inputs
Lift - SEU digital input 1 on SEU 5
0 Lower - SEU digital input 2 on SEU 19
Lowering block - SEU digital input 3 on SEU 33
Argument #3 Enable/disable lowering block
Values Meaning
0 Lowering block disabled
1 Lowering block enabled
Argument #4 Selection of fork/support arm
Values Meaning
0 Selects fork lifting/lowering
1 Selects support arm lifting/lowering
© TMHE 5 – 35 T Code(s): 838, 839, 840

Basic option 6 - Lift height limitation by SEU input and override

Values Meaning
Argument #2 Selection of SEU digital input for limitation switch
Argument #3 Selection of option button for override function
Values Meaning
8 no override possible
Argument #4 Selection of time interval for override function
Values Meaning
0 open button must be held depressed for override
1-15 value corresponds to time in seconds, e.g. value 1 = 1 second
© TMHE 5 – 36 T Code(s): 838, 839, 840

Basic option 11 - Automatic height preselector

Values Meaning
Argument #2 Selection of option button for automatic lift and lowering movement
Values Meaning
0 option not activated by option button
6 activated by option button 1.6 or 2.5
7 activated by option button 2.5 or 3.4
Argument #3 Selection of SEU digital inputs/outputs
photocell - digital input 1 on SEU 5
lowest position - digital input 2 on SEU 19
highest position - digital input 3 on SEU 33
0
external lift button - digital input 4 on SEU 6
external lower button - digital input 5 on SEU 20
lamp - digital output 1 on SEU 16
1
2
3
© TMHE 5 – 37 T Code(s): 838, 839, 840

Basic option 11 - Automatic height preselector

Argument #4 Engagement/disengagement of external lift/lower button

Values Meaning
0 external lift/lower button disengaged
1 external lift/lower button engaged
Basic option 13 – Activate SEU outputs on login

Values Meaning
Argument #2 Selection of SEU digital output Pin no.
Argument #4 SEU output connection mode

Values Meaning
0 Output continuously on
© TMHE 5 – 38 T Code(s): 838, 839, 840

Basic option 14 – Activate restrictions on hydraulics via operator profiles

Argument #1 Not used. SEU unit not required
Argument #2 Selection of operator profile

Values Meaning
1 Operator profile 1
2 Operator profile 1-2
Connecting restrictions. The values in argument #3 can be combined
Argument #3
through addition, e.g. value 1 + value 8 = value 9
Values Meaning
1 Block the lift/pressurising of hydraulic function 1
2 Block the lowering/depressurising of hydraulic function 1
© TMHE 5 – 39 T Code(s): 838, 839, 840

Basic option 15 – Activate restrictions on hydraulics via SEU inputs

Values Meaning
Connecting restrictions. The values in argument #3 can be combined
Argument #3
through addition, e.g. value 1 + value 8 = value 9
Values Meaning
Argument #4 Override button
Values Meaning
0 Option button 2 or 5 has override function
1 Option button 1 has override function
7 Option button 3 or 4 has override function
8 No override possible
© TMHE 5 – 40 T Code(s): 838, 839, 840

Parameter 1044 - Master maximum speed
Defa Incre
ult ment
1044 Master maximum speed 0.5 6.0 6.0 0.5 km/h
#1044 - Master maximum speed

Sets the maximum speed for the application. The speed can never exceed
the value of this parameter, regardless of the settings of the other parame-
ters.
Parameter 1045 - Type of battery in the truck
Defa Incre
ult ment
1045 Type of battery in the truck 0 0 1 1
# 1045 - Type of battery in the truck

Specifies the type of battery found in the application.
Value Function
0 Lead/acid battery
1 Li-ion battery from Hoppecke
© TMHE 5 – 41 T Code(s): 838, 839, 840

Parameter 1046 - Adapting to special trucks
Defa Incre
ult ment
1046 Adapting to special trucks 0 0 1 1
# Parameter 1046 - Adapting to special trucks
Value Function
0 Function not activated
1 The function is activated
Parameter 1101 - Built-in charger
Defa Incre
ult ment
1101 Built-in battery charger 0 0 1 1
#1101 - Built-in charger

Indicates if there is a battery charger on the application. If there is a battery
charger, parameters 109 and 110 must also be set.
Value Function
0 No battery charger
1 Battery charger present
© TMHE 5 – 42 T Code(s): 838, 839, 840

Parameter 1102 - Controls for hydraulic function
Defa Incre
ult ment
1102 Controls for hydraulic function 1 1 4 1
#1102 - Controls for hydraulic function
Value Function
The rear lifting and lowering control is connected
1 to the second hydraulic function, while the front
control is connected to the first hydraulic function
The rear lifting and lowering control is connected
2 to the first hydraulic function, while the front con-
trol is connected to the second hydraulic function
Both lifting and lowering controls are connected
3 to the first hydraulic function. There is no second
hydraulic function.
The analogue lifting and lowering control is con-
nected to the first hydraulic function, while the
4
front control is connected to the second hydraulic
function.
Note: The rear one means the control towards the operator
© TMHE 5 – 43 T Code(s): 838, 839, 840

Parameter 1110 – Reset voltage for BDI
Defa Incre
ult ment
1110 BDI 24.8 25.2 27.0 0.1 V
#1110 – Reset voltage for BDI

After the battery is charged to full capacity, BDI is reset to 100% provided that
battery voltage comes up to the pre-programmed reset value. If the reset
voltage value is not reached, it could be due to a voltage drop between the
battery and the logic card.
In case of reset problems:
• Charge the battery to full capacity following the instructions in the opera-
tor's manual.
• Then drive the truck for at least 25 seconds before logging out.
• BDI is only set to 100% if the battery has been disconnected/reconnected.
• Check the voltage across the battery compared to the voltage between
wires 20 and 40 on the tiller arm logic card (A5)
• A voltage drop between the battery and the logic card (A5) could be
caused by poor contacts/connections or a loose connection in the battery
connector.
© TMHE 5 – 44 T Code(s): 838, 839, 840

Parameter 1118 - Hardware version
Defa Incre
ult ment
1118 Hardware version 0 1 1 1
#1118 - Hardware version

Determines the [T1] ACT version on the truck
Value Function
0 Before 2010-03-22
1 After 2010-03-22
* Matrix for hardware/software compatibility

See the matrix below for the correct setting of factory parameter 1118. The
setting depends on which version of motor control is installed on the truck.
• Value 0 = 1.5 kHz (default value)
• Value 1 = 8 kHz
Motor controller: Factory parameter 1118

Value = 0 Value = 1
243428-001/-002 OK Not permitted

246889-001/-002
246890-001/-002
7513528-001/-newer Not OK
7513526-001/-newer recommended
7513527-001/-newer
© TMHE 5 – 45 T Code(s): 838, 839, 840

© TMHE 5 – 46 T Code(s): 838, 839, 840

Repair manual: Installation and commissioning Model(s): LWE140, 160, 180, 200, 250.
6. Installation and commissioning

This chapter describes the work that is necessary before the truck can be put
into use.
6.1 Transporting the truck

When transporting the truck on a lorry or the like, the truck must be properly
anchored with stropping (A). Use inserts and sheets of shock-absorbing ma-
terial to prevent damage to the truck during lashing and transport.
6.2 Transporting the fork carriage

When transporting the fork carriage alone, you must properly anchor all loose
parts. Cables and any hoses must be secured so they cannot come loose or
be damaged. The entire fork carriage must then be anchored on a load pallet
or another suitable support for transport.
© TMHE 6– 1 T Code(s): 838, 839, 840

6.3 Safe lifting
• Lift the truck at its centre of gravity using another fork lift truck.
• Secure the truck to the forks of the lifting truck.
• Lift it very carefully.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted incorrectly.
Always lift the truck when it has been fastened to the forks of the lifting truck
and its centre of gravity between the forks.
• Only lift the truck at the indicated lifting points using suitable lifting equip-
ment.
WARNING!
Risk of tipping.
The truck may tip over if it is lifted in the wrong places.
Always lift the truck in the indicated lifting points.
© TMHE 6– 2 T Code(s): 838, 839, 840

6.4 Installing the battery

The battery to be installed in the truck must be of the right size. If the battery
is too small in terms of size and weight, it can seriously affect the truck's brak-
ing ability and truck stability when lifting goods. See the truck's identification
plate for the correct battery data.
1. Lift the battery into place using an approved lifting device and a suitable
battery lifting yoke or lifting loops.
DANGER!
To prevent the battery from falling down when it is released from the lifting
device, prepare trestles or other suitable supports of the right height to sup-
port it. Check the height of the supporting material before releasing the lifting
hook.
2. Check the electrolyte level in the battery. Normally, the level should be
around 10-15 mm above the cell plates.
3. Connect the battery cables/battery connector.
DANGER!
Check that the polarity is correct when connecting the battery cables. Com-
pare the markings on the cables with those on the battery terminals. An incor-
rectly connected battery may cause short-circuiting.
4. Close the battery compartment cover.
5. Refit the battery disconnecter.
6. Check and if required reset the parameters for the battery and battery
charger. See the "Setting the parameters for the battery and battery
charger" section in this chapter.
7. Test the functions of the truck, and check that the sensor for the lift height
limiter is correctly set before using the truck. See section
"14.5.2 Adjusting the sensor [B61]".
© TMHE 6– 3 T Code(s): 838, 839, 840

6.5 Using PIN codes
6.5.1 General
PIN codes can be used e.g. to link different operator experience levels to spe-
cific truck characteristics – Operator profiles.
Operator parameters can be adjusted individually for up to ten different oper-
ator profiles.
The PIN codes are organised in blocks and profiles. Each block can hold ten
operator profiles, each with its own PIN code.
In order to use the PIN codes in a block, the block must first be activated.
By default, block 0 (zero) is always active, which means that the truck has 3
ready-to-use operator profiles from the beginning. Page 6–7
PIN codes can be activated or changed according to the preferences of the
operator. An operator profile is activated upon normal log-in by all PIN codes
whose block number is activated.
6.5.2 PIN code for resetting after a collision

If the truck has stopped as a result of a collision, it needs to be reset by enter-
ing a special PIN code. This PIN code must be programmed by a service
technician during installation. Page 6–6
The PIN code to be activated can be found in operator profile 1 and special
block 10. The default value of the PIN code is 0000. This must be changed to
the PIN code selected by the service technician.
Note:
The PIN code cannot contain the same combination of digits as any of the
other programmed PIN codes.
With parameter #111, it is possible to change how reset after collision is car-
ried out. Page 5–16
© TMHE 6– 4 T Code(s): 838, 839, 840

6.5.3 Programming PIN codes

Note:
There are two possible methods for programming PIN codes.
The first and the simplest is to use TruckCom, which provides clear instruc-
tions.
The other alternative is to use the truck keypad.
If the truck is configured to handle PIN codes, 100 different PIN codes can be
programmed.
The first time a block is activated, all PIN codes in the block are set to “0000”.
If a block with PIN codes not set to “0000”, is deactivated and later reactivat-
ed, the PIN codes with other values than “0000” will again be valid.
Use of PIN code “0000” is permitted, but it means that the position is deacti-
vated. It is never possible to log in with PIN code “0”.
The truck program stores a standard set of PIN codes as indicated in the
table in the section “PIN code defaults”.
Note:
The truck program will not accept attempts to program PIN codes that have
already been set. The previous code will be restored.
When a PIN code is programmed, there is a check to ensure that it is not used
elsewhere in the table, regardless of whether the block is active or inactive.
The PIN code setting menu is used for managing PIN codes; the menu can
only be accessed when a service key is connected.
© TMHE 6– 5 T Code(s): 838, 839, 840

6.6 Programming PIN codes
1. Ensure that the truck is switched off. Connect the CAN service key to
connector [X41]. Enter the PIN code.
2. Press and then release the horn button. “Info“ is shown on the display.
3. Turn the speed control several times until “Pin” is shown on the display.
4. Press and then release the horn button to select.
5. Select programming commands from the table below:
Function Programming Comments
Blocks 1-9 are deacti-
vated. The original PIN
Restore factory settings. Press 1 + ON switch codes are reset according
to the Default assignment
of PIN codes table.
b = Block 0-9
Upon activation of a PIN
Activate a new PIN
Press 2 + b + ON button code's block, the codes
code's block.
already stored become
available again.
b = Block 0-9
No codes will be deleted.
Deactivate a PIN code's
Press 3 + b + ON button They will be available
block
again when the PIN code's
block is reactivated.
Press 4 + b + P + NNNN + ON button
b = Block 0-9
Note:
P = Operator profile 1-10
The block that should apply must first be activated (see func-
NNNN = PIN code
tion 2 in the table above).
Note:
Programming a new If the PIN code is correct, the code is shown for 3 seconds,
It is only possible to assign
PIN code followed by the text "donE" for 2 seconds. It is possible to
one digit to an operator
enter a new PIN code within these 5 seconds by pressing a
profile. As a result, opera-
key on the keyboard.
tor profile 10 should be
If the PIN code is wrong, the display shows “Err”. If you press
assigned as 0 (zero).
the red button, the new PIN code is not saved.
PIN code programming
for truck reset after colli- Press 6 + NNNN + ON switch NNNN = PIN code
sion
6. Switch off the truck by pressing the OFF button.

PIN code programming is now complete. Verify that programming has been
done correctly by logging in using one of the new PIN codes.
For PIN code management via TruckCom, refer to the TruckCom manual.
Note:
It is important to ensure the correct operator profile is activated when a spe-
cific PIN code is entered. This is especially important when an operator pro-
file has been set to apply for a specific truck application.
© TMHE 6– 6 T Code(s): 838, 839, 840

6.6.1 PIN code defaults

The PIN codes are factory set so that only block 0/operator profiles 1 – 9 are
activated.
Note:
Service personnel are urged to keep notes on activated blocks, changed
PIN codes and special operator profile settings.
Default assignment of PIN codes
Operator 10
Note:
profile 1 2 3 4 5 6 7 8 9
Entered
no. as 0
Block 0 0001 0002 0003 0004 0005 0006 0007 0008 0009 0000
Block 1 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 3 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 4 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 5 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 6 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 7 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 8 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 9 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
Block 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
The factory-set operator profiles are classified as follows:

Profile Characteristic Remarks
1 Standard profile –
2 Beginner profile –
Operator parameters set to
3 Advanced profile
max. values
© TMHE 6– 7 T Code(s): 838, 839, 840

6.7 Setting parameters

This chapter covers only those parameters that need to be set upon commis-
sioning of the truck and which require detailed description. Fore more infor-
mation on the parameters, please refer to the Parameters chapter.
Check to make sure all parameters are set to the desired values in terms of
• maximum speed, operator parameter - Page 5–3
• acceleration, operator parameters - Page 5–3
• deceleration, operator parameters - Page 5–3
• collision sensor (option) - Page 5–9
• battery - Page 5–10
• battery charger (option) - Page 5–15, Page 5–42
Note:
When checking or setting parameters, be sure to keep written records, e.g. in
a truck report, of the truck's specific parameter values. This separate infor-
mation on truck-specific parameters can come in handy, e.g. in case of down-
time, since the information is not available elsewhere.
© TMHE 6– 8 T Code(s): 838, 839, 840

6.8 Function and safety checks

2
3
1, 5 4
12 6
11
10
9 8
13
Prior to putting the truck into use, check the following items:
Pos. Inspection point Measure

1 Operating control Check the function
2 Switch for safety reversing Check the function
3 Horn Check the function
4 Steering Check the function
5 Brakes Check the function
6 Emergency switch off Check the function
7 Hydraulic system Check all components
8 Drive unit Check for any noise or oil leakage
9 Wheels Inspect for any damage, remove dirt etc.
10 Chassis Inspect for any damage, remove dirt etc.
11 Battery cover and lock Check the function
12 Battery Inspect the battery acid level and charge level
13 Fork carriage Inspect for any damage, remove dirt etc.
© TMHE 6– 9 T Code(s): 838, 839, 840

© TMHE 6 – 10 T Code(s): 838, 839, 840

Repair manual: Maintenance Model(s): LWE140, 160, 180, 200, 250.
7. Maintenance
7.1 Introduction
To maintain a high level of truck safety and to minimise downtime, all the
points specified in the service programme must be carried out.
The intervals specified are those that fulfil the truck manufacturer's require-
ments for a truck used in standard applications. The local operating environ-
ment may require service intervals that differ from those specified.
Once a truck's service intervals have been determined, the hour recorder is
primarily used for determining when servicing is to be carried out.
To maintain truck safety, only spare parts approved by the truck manufacturer
may be used for servicing and repairs.
During the truck's warranty period: If repairs/servicing have been carried

out by non-authorised personnel, or if non-approved spare parts are used,
the truck warranty ceases to be valid.
7.2 Maintenance instructions
7.2.1 Cleaning and washing

Cleaning and washing the truck is an important factor in maintaining truck re-
liability.
• Carry out general cleaning and washing each week.
Note:
Risk of short circuiting.
Risk of damage to the electrical system.
Disconnect the battery before washing by pulling out the battery connector.
7.2.2 High-pressure washers

High-pressure washers may only be used on metal surfaces.
Under no circumstances may high-pressure washers be used in the truck's
motor compartment.
When using a high-pressure washer, the jet must be directed in such a way
that it does not damage electric cables, electric sensors, hydraulic hoses or
decals.
Lifting chains, piston rods and end pieces of hydraulic cylinders, ball and roll-
er bearings – including those that are fully enclosed – must not be exposed
to the jet, as there is a risk that water may penetrate and cause corrosion.
After washing with a high-pressure washer, all the truck bearings and chains
must be lubricated/greased as specified in the maintenance instructions.
© TMHE 7– 1 T Code(s): 838, 839, 840

7.2.3 Degreasing agents

When using degreasing agents, only environmentally-friendly cold degreas-
ing agents may be used, such as those that are designed for general vehicle
cleaning and do not damage paintwork, plastic components, cables, hydrau-
lic hoses or decals.
7.2.4 Cleaning the exterior

• Remove rubbish, etc. from the wheels daily
• Degreasing agents can be used as needed, in line with the previous sec-
tion.
• Rinse off loose grime using tepid water.
Note:
Seizing, corrosion.
Risk of damage to mechanical parts.
Once washed, the truck should be lubricated as set out in the maintenance
instructions.
7.2.5 Cleaning the chain

We recommend you to replace a chain that is very dirty.
Dirty chains should be cleaned before they are lubricated, e.g. by washing
with solvent such as diesel or petrol.
The chain should be blown dry using compressed air and lubricated directly
after cleaning.
Note:
Exercise care with degreasing agents as these can contain abrasives.
7.2.6 Cleaning the motor compartment

• Cover electric motors, connectors and valves prior to washing.
Note:
Risk of damage to the electrical system.
Electrical components must not be washed with high-pressure washers.
• Clean the motor compartment using a well-known degreasing agent, dilut-
ed to a suitable concentration
• Rinse off loose grime using tepid water.
© TMHE 7– 2 T Code(s): 838, 839, 840

7.2.7 Electric components

• Clean electric motors using vacuum cleaner or a rag.
• Clean electric panels, logic cards, contactors, connectors, magnetic
valves, etc. with a rag moistened with water and a suitable detergent.
Note:
Risk of damage to electrical components.
Do not break the warranty seals on the logic cards.
7.3 Maintenance schedule

Service maintenance should be performed in intervals of 750 operating hours
or every 12 months, whichever occurs first.
The order in the maintenance schedule is not optimal for the working order;
it is simply sorted according to the C codes.
See chapter 23.2 for details on oil and grease specifications.
© TMHE 7– 3 T Code(s): 838, 839, 840

Truck area Pos. Measure 750h/12m Time

used
0000 Chassis 1 Inspect cover mountings. X 5:20
minutes
2 Check signs and adhesive X
including
labels.
removal
3 Check for any crack or X of covers.
damage.
4 Inspect cylinder mounting X
in the fork carriage.
5 Inspect the locking screws X
in the castor wheel
suspension assembly
6 Inspect the motor plate for X
cracks and other damage.
7 Secure the paper holder X
strap if necessary
2
4
1
7 1
2
2
2
2
2 2
5
*The M-label is only affixed on specially produced trucks.
© TMHE 7– 4 T Code(s): 838, 839, 840

Truck area Pos. Measure 500h/12m 750h/12m Time

used
0380 1 Check for cracks and X 1:30
Fork frame damage. minutes.
2 Inspect bushings and links X
for possible play.
3 Inspect the push rods and X
welds for cracks and other
damage.
4a Check the functionality X
4b and mounting of the
battery locking
mechanism and check the
clamp on the battery tray
(Option)
5 Grease the nipples of the X
push rods and fork
wheels. Applies to
LWE140/160.
4b replaces 4a.
4b
1
2
4a
© TMHE 7– 5 T Code(s): 838, 839, 840


used
0560 Platform 1 Check for cracks or damage X 1:30
and brackets 2 Check the spring and that the X minutes.
(Option) platform returns to the upright
position from the lowered position
2
1
© TMHE 7– 6 T Code(s): 838, 839, 840

Truck area Pos. Measure 750h/ Time

12m used
1700 Drive 1 Check the drive motor's attachment. X 4:30
motor 2 Clean the drive motor. X minutes
(excluding
3 Check for abnormal noise from the bearings in X changing
the drive motor the oil in
the drive
2550 Drive gear 4 Check for abnormal noise X
gear)
5 Lubricate the steering bearing, lubricant type G (X1)
See section "11.5 Lubricate the steering
bearing (Option)".
5 Inspect the steering bearing for correct X
mounting and play, 23±3 Nm.
6 Change the drive gear oil X2
3180 Brakes 7 Clean the brake. X
8 Check the air gap in the released position. X
Nominal brake air gap: 0.3 mm
Minimum permitted gap: 0.2 mm
Max. permissible spacing: 0.5 mm.
Measuring must be done around the entire
pressure disc, both on the inside and the
outside.
8 Inspect the brake disc for wear. X
Minimum brake disc thickness: 7.9 mm
1. Option! Does not need any lubrication when used normally. For trucks that are used intensively or in cold storages,
we recommend lubrication every 1500 hrs.
2. Note: The oil in the drive gear only needs to be replaced after 750 hrs. For trucks that are used intensively or in cold
storages, we recommend replacing the oil more often.
7, 8
5 1, 2, 3
4, 6
© TMHE 7– 7 T Code(s): 838, 839, 840


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

mm (H) dimensions, mm
Drive wheel 30 15
Castor wheel 10 5
Fork wheels 11 5.5
© TMHE 7– 8 T Code(s): 838, 839, 840


used
4110 Tiller arm 1 Check for proper X 1:45
attachment. minutes
2 Inspect the steering yoke X
for correct mounting (4
pcs.)
23 ± 3 Nm.
3 Check the mounting of X
the handle.
4 Check the force and X
locking of the gas spring.
The tiller arm should
return to the top position
both from the bottom
position and from the
lower position where the
brake is applied.
3
1
© TMHE 7– 9 T Code(s): 838, 839, 840


used
5000 Electrical 1 Inspect the contacts, wiring harness X 4:30
system (including the battery cables), cable minutes
insulation and that all cables can move
freely.
2 Inspect the contactors for correct X
operation.
3 Check error code log, operating times X
and all the segments on the display.
4 Clean and check that there is no play X
between the transistor regulator and
the heat dissipation plate.
5 Check and tighten the cable X
connections.
6 Check all switches and sensors. X
5
5
2
4
© TMHE 7 – 10 T Code(s): 838, 839, 840


used
6000 Hydraulic 1 Check wear on hoses and pipes. X 16
system 2 Check the oil level. X minutes
(Permitted oil level window with lowered
forks as illustrated)
3 Check the mounting of the hydraulic unit. X
4 Inspect the hydraulic system for possible X
leakage.
5 Change the oil and clean the oil tank. X
Note: Initially after 750 h/12 m, then every
4500 h/36 m.
6 Clean the oil strainer. X
Note: Initially after 750 h/12 m, then every
4500 h/36 m.
6600 Lift cylinder 7 Check for leaks from the lift cylinder and X
the "Powerlink cylinder" (option).
20 mm 2
30 mm 1, 3, 4, 5, 6
2
10 mm
© TMHE 7 – 11 T Code(s): 838, 839, 840

This page has been intentionally left blank
© TMHE 7 – 12 T Code(s): 838, 839, 840

Repair manual: Troubleshooting Model(s): LWE140, 160, 180, 200, 250.
8. Troubleshooting
8.1 General
The troubleshooting section describes the error codes that are displayed
when the truck is partially or completely disabled. It also describes the cause
of the problem together with corrective remedies.
The electronic control system of the truck has built-in error code display and
logging. When an error occurs, the error code is shown on the display and
the error code LED flashes.
The first time an error code is displayed, try to restart the truck to check
whether the error condition remains.
If the error cannot be remedied through troubleshooting, contact the supplier
for more information.
Note:
The request "Restart the truck" means that the battery connector must be
disconnected before attempting to start the truck again.
Software compatibility
Ensure that the logic card ICH [A5], motor control ACT [T1] and battery
charger BCU [A30] have software from the same software package.
To ensure full functionality, the latest software package must be downloaded.
8.2 Towing a defective truck

The towed truck shall always have an operator who can steer and apply the
brake when towing using a tow-truck and tow-rope.
Always remove the load before towing or transporting the truck to the speci-
fied repair site.
Tow or transport a defective truck as follows:
• Start the truck, move the tiller arm to the drive position and push the truck
by hand.
DANGER!
The truck can start to roll when the parking brake function is disabled.
Never leave the truck with the parking brake disconnected, chock the wheels
in a satisfactory manner.
© TMHE 8– 1 T Code(s): 838, 839, 840

Tow using a tow truck and tow wagon:
1. Lift the truck onto the tow wagon. See the instructions under Lifting a
truck.
2. Connect the truck to the wagon.
3. Drive with care.
4. Lift off the truck according to the instructions under Lifting a truck.
8.3 Emergency driving mode

If the truck for some reason stops operating and remains immobile in an un-
suitable place, it is possible to active the emergency travel mode to move the
truck out of the way (max. 1.3 km/h). In this mode, it is possible to lower and
lift the forks.
1. Ensure that the truck is switched off. Enter your PIN code.
3. Turn the speed control several times until “Ed” is shown on the display.
5. All lamps flash and “SLO” is shown on the display.
It is now possible to drive the truck, but exercise extreme caution. It is not
possible to brake suddenly by raising the steering unit.
If the truck is on an incline, be even more careful when using the emergency
travel mode. If you apply too much throttle, there is a risk the truck will roll
away. To stop the truck, turn the sped control in the opposite drive direction.
Note:
Some errors block emergency travel mode. You then cannot obtain informa-
tion on the error.
© TMHE 8– 2 T Code(s): 838, 839, 840

8.4 Troubleshooting methods
8.4.1 General initial troubleshooting
Inled felsökningen
Har en felkod visats? Följ instruktionerna i

Eliminera osannolika fel
kapitlet Felsökning
Ja
Nej
Följ instruktionerna Välj ut och prioritera de

i felsökningsschemat mest sannolika
Ja orsakerna
Nej
Samla så mycket När du lokaliserat felet,

information som Var på arbetsplatsen
uppstod problemet? se instruktioner i
möjligt om problemet sektionen för åtgärder
När uppstod
problemet?
Vilka funktioner
är påverkade?
Vilka förhållanden
utlöste problemet?
Identifiera alla delar som

kan orsaka problemet.
Använd vid behov
kopplingsschema.
© TMHE 8– 3 T Code(s): 838, 839, 840

8.4.2 Concluding troubleshooting
Kör trucken på samma sätt

Avsluta felsökningen som den kördes när problemet
först uppstod.
Verifiera att problemet
inte uppstår igen.
Se till att alla

kablar och slangar Låt föraren köra trucken.
har satts tillbaka på ett Verifiera att problemet
korrekt sätt inte uppstår igen.
Genom återkoppling
Om du har kontaktat kan du bidra till en gemensam
Se till att de delar som har avdelning för teknisk support kunskapsdatabas.
tömts på vätska har blivit för att diskutera problemet, Detta är viktigt för fortsatt förbättrad
återfyllda till korrekt nivå hör av dig igen och berätta support till servicetekniker i fält.
hur du löste problemet.
Återskapa samma
förutsättningar som
gällde när problemet
först uppstod
© TMHE 8– 4 T Code(s): 838, 839, 840

8.5 Error code history

Up to 50 of the most recent error code events can be stored in a log along
with the hour meter reading when the error occurred. The error code log dis-
plays error codes in chronological order starting with the most recent error
code.
Do as follows to display the error code log:
1. Ensure that the truck is switched off. Connect the CAN key or enter the
PIN code. Note: Do not press the ON button.
3. Press and then release the horn button to select the "Info" menu.
4. Turn the speed control several times until “E” is shown on the display.
The error code symbol lights up.
6. The most recent error is then displayed. The display alternates between
the error code and the hour counter reading when the error occurred. If
the error code log contains more than one error code, the codes can be
displayed by repeatedly pressing the speed control.
7. Switch off the truck by pressing the OFF button or return to the previous
menu by selecting "ESC".
The display of error code history is now complete.
© TMHE 8– 5 T Code(s): 838, 839, 840

8.6 Error code system

See the tables below for an explanation of the error code system.
Structure Description
X.YZZ Example: 3.510
X (3) Group. Indicates which truck system is affected by the
error.
YZZ (510) Sequential number
Group. Description
1 Not used.
2 Main control unit A5 (ICH)
3 Drive system
4 Hydraulic system
5 Steering system:
6 Not used.
7 Not used.
8 Option/auxiliary system
9 Not used.
© TMHE 8– 6 T Code(s): 838, 839, 840

8.7 Error codes

Please note that some error codes are saved in the log and disappear from
the display, while other error codes remain on the display and require that the
truck be switched off and then on again for the error code to disappear.
Truck
Code Description Error cause(s) Measure
behaviour
Parameters set to 1: New software 1: Check parameters
default values. has been load-
• Check that factory parameters
At start-up, it was ed in the truck,
detected that one
are set according to the truck
adding a new
or more parame- configuration.
parameter, or
2:002 ters were not within Not influenced it has changed • Check that other parameters
acceptable inter- the parameter are set correctly.
vals; they have
limit values 2: Replace A5:
therefore been
reset to default val- 2: Corrupt mem-
ues ory A5
1: Hardware (T1 1: Copy the truck configuration
or A5) has using TruckCom
been
• See the separate manual for
replaced.
Backup copies do TruckCom.
not match. 2: Software has
Backup copy in 2: Copy the truck configuration
been updated
2:004 secondary unit (T1) Not influenced using TruckCom
to an older
does not match version • See the separate manual for
data in primary unit TruckCom.
(A5) 3: Corrupt mem-
ory T1 3: Replace T1
4: Corrupt mem- 4: Replace A5
ory A5
Everything is • Create a truck report. Send a re-
stopped at once, port to the manufacturer.
Internal program the parking brake Internal program
2:005 • Update the truck software to the
error is activated, and error A5
the main contac- latest version.
tor opens
© TMHE 8– 7 T Code(s): 838, 839, 840

Truck
behaviour
1: Battery con- 1: Connect the battery connector.
nector discon-
2: Check battery voltage
nected from
truck that is • Check the voltage using the
started built-in test procedure and com-
paring with value from external
2: Voltage loss
Saving to memory volt meter
on supply to
failed. • Check connectors, joints and
A5
Saving to memory
splices for damage or corrosion.
2:006
failed because low
Not influenced
3: The battery is
battery voltage. defective • Check fuses F1 and F50
Battery voltage
below 15 V at the 4: Battery 3: Inspect the battery.
time of saving parameter 4: Check parameters
#107 has an
erroneous val- • Check that factory parameters
ue are set according to the truck
configuration.
• Check that other parameters
are set correctly.
• Create a truck report. Send a re-
Internal program Internal program port to the manufacturer.
2:007 Not influenced
error A5 error • Update the truck software to the
latest version.
latest version.
latest version.
© TMHE 8– 8 T Code(s): 838, 839, 840

Truck
behaviour
1: Error on CAN 1: Check the CAN bus
bus wiring or
• Check that CAN is intact in
connections
terms of wiring harness, resist-
2: Loose connec- ance and connectors. Discon-
tions nect the battery. Check that the
resistance between (X41:3) and
3: CAN node
(X41:4) is 54 - 66 ohms.
defective
• Check that the CAN wiring har-
4: Software fail-
ness is not pinched. Measure
ure
resistance between the chassis
and CAN contact. Limit value
>24 kOhm
2: Check for loose connections
CAN communica-
tion warning. • Switch on the truck, and pull
2:010 A5 has received Not influenced carefully in the branches of the
too may erroneous wiring harness to find any loose
signals connections, and note when/if
the error code appears.
3: Check the CAN node
• Deactivate and disconnect the
option unit connected to the
CAN wiring. Activate and then
connect them one by one to
identify which unit produces the
communication error.
4: Update the truck software
• Update the truck software pack-
age to the latest available ver-
sion.
New software.
New software
installed. In order
New software Logged in the error log to see when
2:011 to look in the error Not influenced
installed the software was updated
code log to see
when new soft-
ware was installed.
1: Internal pro- 1: Create a truck report. Send a
Creep speed, gram error report to the manufacturer.
Internal program blocked lifting/
2:080 2: Manufactur- • Update the truck software to the
error lowering move-
ment ing defect in latest version.
A5
2: Replace A5:
© TMHE 8– 9 T Code(s): 838, 839, 840

Truck
behaviour
1: Check parameters
Configuration error. Creep speed, • Check that factory parameters
Truck configura- blocked lifting/ Incorrect value for are set according to the truck
2:102
tion does not match lowering move- parameter 1102 configuration.
parameter 1102 ment
are set correctly.
Creep speed, • Create a truck report. Send a re-
Internal program blocked lifting/ Internal program port to the manufacturer.
2:180
error lowering move- error • Update the truck software to the
ment latest version.
1: High signal 1: Check the sensor signal
from both B62
• Check that the distance be-
and B65
tween the sensor and the oppo-
2: Constantly site part is correct.
high signal at
• Check that there is no dirt or for-
inputs (T1:94)
eign objects on the sensor
and (T1:87)
• Inspect cabling.
• Measure the signals from the
sensor with a volt meter and ver-
Incorrect signal Creep speed,
ify using TruckCom or the built-
combination from blocked lifting/
2:285 in test that the signal is correct
the support arm lowering move-
position sensor ment 2: Check the signal to the unit
• Compare the signals from the
sensor with the input signal (use
a volt meter and verify using
TruckCom or the built-in test
that the signals are the same)
• Check the pins on the unit and in
the connector
• Replace the unit if you cannot
get it to work properly
© TMHE 8 – 10 T Code(s): 838, 839, 840

Truck
behaviour
1: The battery is 1: Charge the battery.
discharged
2: Voltage loss
• Check the voltage using the
on supply to
built-in test procedure and com-
A5
paring with value from external
3: The battery is volt meter
Everything is defective
• Check connectors, joints and
Low battery voltage stopped at once,
4: Battery splices for damage or corrosion.
below 16.8 Volts for the parking brake
2:501 parameter
more than 2 sec- is activated, and • Check fuses F1 and F50
onds the main contac- #107 has an
tor opens erroneous val- 3: Inspect the battery.
ue 4: Check parameters
configuration.
are set correctly.
1: A5 is replaced 1: Copy the truck configuration
and/or errone- using TruckCom
ous value for
Everything is factory param-
TruckCom.
stopped at once, eters
Truck type not set
the parking brake 2: Check parameters.
2:502 Parameter 1001 is
is activated, and
2: Incorrect value
incorrectly set
the main contac- for parameter • Check that factory parameters
tor opens 1001 are set according to the truck
configuration.
are set correctly.
1: A5 is replaced 1: Copy the truck configuration
and/or errone- using TruckCom
ous value for
Everything is factory param-
Wrong truck model TruckCom.
stopped at once, eters
set.
the parking brake 2: Check parameters.
2:503 Parameter 1108 is
is activated, and
2: Wrong value
wrongly set in com-
the main contac- for parameter • Check that factory parameters
bination with 1001 1108 and/or are set according to the truck
tor opens
1001 configuration.
are set correctly.
© TMHE 8 – 11 T Code(s): 838, 839, 840

Truck
behaviour
bus wiring or
connection
2: Loose connec- ance and connectors. Discon-
tions nect the battery. Check that the
resistance between (X41:3) and
3: CAN node
(X41:4) is 54 - 66 ohms.
defective
4: Software fail-
ure
>24 kOhm
Everything is 2: Check for loose connections
stopped at once,
A5 has received
the parking brake • Switch on the truck, and pull
2:511 too may erroneous
signals
is activated, and carefully in the branches of the
the main contac- wiring harness to find any loose
tor opens connections, and note when/if
3: Check the CAN node
• Deactivate and disconnect the
option unit connected to the
CAN wiring. Activate and then
connect them one by one to
identify which unit produces the
communication error.
• Update the truck software to the
latest version.
© TMHE 8 – 12 T Code(s): 838, 839, 840

Truck
behaviour
bus wiring or
connection
2: Wrong setting ance and connectors. Discon-
for parameter nect the battery. Check that the
102 resistance between (X41:3) and
(X41:4) is 54 - 66 ohms.
3: No connec-
tion with K110 • Check that the CAN wiring har-
4: Loose connec-
tions
5: Software fail- >24 kOhm
ure
2: Check parameters.
configuration.
are set correctly.
Everything is 3: Check K110 (DHU/TWIS)
No return signal
stopped at once,
from K110 (DHU/
the parking brake • Check that the DHU's green
2:515 TWIS) within 0.6
is activated, and LED is lit. If the LED is not lit:
seconds after log-
the main contac- Check the DHU's feed voltage =
ging on
tor opens battery voltage
• Check that it is possible to con-
nect TruckCom to the DHU. If it
is possible to connect them,
check the DHU's configuration.
If there is a power supply but no
communication, check the CAN
bus. If it still not possible to com-
municate with the DHU, replace
the unit.
4: Check for loose connections
• Switch on the truck, and pull
carefully in the branches of the
wiring harness to find any loose
connections, and note when/if
• Update the truck software to the
latest version.
© TMHE 8 – 13 T Code(s): 838, 839, 840

Truck
behaviour
A5 has an incorrect 1: Check whether contact X203
box address. Everything is is short circuited. If a jumper is
There is a jumper/ stopped at once, fitted, remove it.
short circuit in con- the parking brake Box address error on
2:516 2: Replace A5
tact X203 between is activated, and A5
pin 1 and 0 V inter- the main contac-
nally on the A5 tor opens
card.
1: New software 1: Check parameters
has been load-
ed in the truck,
adding a new
configuration.
parameter, or
it has changed • Check that other parameters
the parameter are set correctly.
limit values 2: Replace A5
2: Corrupt mem- 3: Set new checksum
ory circuit
• If the problem with the check
3: Checksum sum occurs directly in connec-
Everything is error tion with the software update,
The checksum of
stopped at once,
the parameter val- proceed as follows:
the parking brake
2:520 ues does not match
is activated, and • Change the value of one param-
the parameter val-
the main contac- eter in each category, operator
ues.
tor opens parameters, service parameters
and calibration parameters.
• Save the changes and restart
the truck.
• Reset the values you changed
in the previous step back to their
original values.
• Restart the truck.
• The program will have per-
formed a new checksum calcu-
lation.
1: Check the Hall sensors
Incorrect power
Plug braking to
• Check with TruckCom or the
supply to the Hall built-in test that the Hall sensors
stop, then the
sensors. Incorrect power sup- work the way they should.
parking brake is
2:522 High (or low) sig- ply to the Hall sen-
activated and the • A Hall sensor that is being influ-
nal from all Hall sors.
main contactor enced should give a low signal.
sensors A5:S300-
opens
S318
• Replace A5 if the Hall sensors
have an error function.
© TMHE 8 – 14 T Code(s): 838, 839, 840

Truck
behaviour
Internal memory
Everything is • Corrupt memo- 1: Replace A5
stopped at once, ry circuit
(FRAM or RAM) is
the parking brake
2:523 faulty Reading from
is activated, and
or writing to mem-
the main contac-
ory failed
tor opens
1: Check the Hall sensors
• Check with TruckCom or the
Plug braking to built-in test for the Hall sensors
The Hall element
stop, then the
for the speed con- that they work the way they
main contactor
2:580 trol gives a signal A5 defective should. A Hall sensor that is be-
opens and the
(active low) when it ing influenced should give a low
parking brake is
should not signal.
activated
1: Control manip- 1: Let go of the control, and wait
ulated. for four seconds
2: The speed 2: Check the speed control
control does
• Check the spring function
not spring
back to neutral • Check that the speed control is
The speed control position. not seized
was not in the neu-
tral position at start- 3: A5 defective • Check that the plastic cover
up The truck cannot where the spring is attached is
3:001 One or more Hall be driven, other intact.
elements for the functions OK 3: Check the Hall sensors
speed control give
an active signal at • Check with TruckCom or the
start built-in test for the Hall sensors
that they work the way they
should. A Hall sensor that is be-
ing influenced should give a low
signal.
© TMHE 8 – 15 T Code(s): 838, 839, 840

Truck
behaviour
1: Cooling is 1: Check the cooling
reduced or the
• Check the cooling flanges of the
temperature
transistor regulator, motor and
sensor is
steering motor as well as the
defective.
battery charger and fans and fil-
ters for accumulations of dirt
and dust. Too much dust and dirt
cause the cooling not to work
properly.
• Check that the fans work when
the speed control is activated
The motor control The motor control (fans behind T1 and motor fan)
3:002 unit temperature is limiting the
• Check that the fan on charger
exceeds +85°C. voltage
T14 works when the charging
begins, i.e. when the mains ca-
ble is connected
• Check the signal from the tem-
perature sensors for T1 and T13
and from B1 using the built-in
test or TruckCom. Determine if
the temperature signals are
plausible relative to the real
temperatures of the compo-
nents. If not, replace T1,T13 or
replace B1 with a repair kit.
Incorrect power 1: Internal error 1: Restart the truck.
saving function in in T1
3:040 Not influenced 2: If the error persists, replace
the standby
the motor control T1.
mode.
© TMHE 8 – 16 T Code(s): 838, 839, 840

Truck
behaviour
reduced or the
temperature
sensor is
defective.
properly.
The temperature the speed control is activated
sensor in the motor
The motor control (fans behind T1 and motor fan)
control power stage
3:080 is limiting the
is outside the limit • Check that the fan on charger
voltage.
values. Above T14 works when the charging
130°C begins, i.e. when the mains ca-
ble is connected
© TMHE 8 – 17 T Code(s): 838, 839, 840

Truck
behaviour
reduced or the
temperature
sensor is
defective.
properly.
the speed control is activated
The motor temper-
Creep speed and (fans behind T1 and motor fan)
ature sensor is out-
3:081 motor control lim-
side of limit values. • Check that the fan on charger
its the voltage.
Above 210°C. T14 works when the charging
ble is connected
Creep speed, 1: Internal pro- 1: Create a truck report. Send a
Motor control warn- gram error report to the manufacturer.
blocked lifting/
3:100 ing. Unknown
lowering move- 2: Software fail- 2: Update the truck software to
warning
ment ure the latest version.
1: The motor 1: Restart the truck.
Creep speed, control is
2: If the error persists, replace
blocked lifting/ using pre-set
3:101 Internal error in T1 the motor control T1.
lowering move- power amplifi-
ment cation. Internal
error
Incorrect checksum
Creep speed, 1: Update the truck software to
blocked lifting/ the latest version.
3:120 for the motor con- Motor control corrupt
lowering move-
trol parameters 2: Replace T1
ment
© TMHE 8 – 18 T Code(s): 838, 839, 840

Truck
behaviour
1: Restart the truck.
Creep speed, 2: Update the truck software

The motor control
blocked lifting/ • Update the truck entire software
3:121 T1 cannot use Internal error in T1
lowering move- package to the latest available
internal memory.
ment version.
3: If the error persists, replace T1
1: Check for overcurrent or short
circuit:
• Check the ohms and the am-
Hardware protec- peres of the component, com-
tion in T1 detects a pare them to the setpoint values
short circuit in the if they outside the accepted
output for the horn.
range.
The current High power con-
3:140 through the horn is Not influenced sumption or short • Check the connections and wir-
above the valid circuit ing harness for short-circuit.
limit value. Maxi-
mum value = • Check that the component does
500mA, continu- not seize or is jammed.
ous value = 300mA • If points 1-3 are OK, it indicates
that the output stage is short cir-
cuited - Replace the power-sup-
plying component
© TMHE 8 – 19 T Code(s): 838, 839, 840

Truck
behaviour
bus wiring or
connection
2: Incorrect value ance and connectors. Discon-
for parameter nect the battery. Check that the
1001 resistance between (X41:3) and
(X41:4) is 54 - 66 ohms.
3: No power sup-
ply • Check that the CAN wiring har-
4: Wrong kind of
motor control
>24 kOhm
2: Check parameters.
Motor control start- The truck cannot
3:303
up failed be started • Check that factory parameters
configuration.
are set correctly.
3: Check wiring after the break.
• Disconnect the battery
• Using instruments, check that
there is no break in any wire.
• Measure and check the voltage
for the activated functions
4: Replace T1
Everything is 1: Replace T1
stopped at once,
the parking brake Defective motor con-
3:500 Internal error in T1
is activated, and trol
the main contac-
tor opens
1: Check:
Everything is
stopped at once, • T1
Defective motor the parking brake Defective motor con- • Factory parameter 1001 (Truck
3:501
controller is activated, and trol type).
the main contac-
tor opens 2: If the error persists, replace
T1.
© TMHE 8 – 20 T Code(s): 838, 839, 840

Truck
behaviour
stopped at once,
Error in T1 when the parking brake Defective motor con-
3:502
saving parameters is activated, and trol
the main contac-
tor opens
Everything is 1: Update the truck software
stopped at once,
Unknown error in the parking brake No software compat- • Update the truck entire software
3:505 package to the latest available
T1 is activated, and ibility
the main contac- version.
tor opens
stopped at once,
the parking brake Defective motor con-
is activated, and trol
the main contac-
tor opens
bus wiring or
connection
2: CAN module ance and connectors. Discon-
Everything is in A5 defective nect the battery. Check that the
CAN communica-
stopped at once, resistance between (X41:3) and
tion problem
the parking brake (X41:4) is 54 - 66 ohms.
3:511 between T1 and
is activated, and
A5, A5 gets no sig- • Check that the CAN wiring har-
the main contac-
nals from T1
tor opens ness is not pinched. Measure
>24 kOhm
2: Replace A5
bus wiring or
connection
Everything is ance and connectors. Discon-
CAN communica- nect the battery. Check that the
stopped at once,
tion problem
the parking brake resistance between (X41:3) and
3:512 between A5 and
T1, T1 gets no sig-
is activated, and (X41:4) is 54 - 66 ohms.
the main contac-
nals from A5 • Check that the CAN wiring har-
tor opens
>24 kOhm
© TMHE 8 – 21 T Code(s): 838, 839, 840

Truck
behaviour
bus wiring or
connection
2: CAN module ance and connectors. Discon-
Everything is in A5 defective nect the battery. Check that the
stopped at once, resistance between (X41:3) and
CAN communica-
the parking brake (X41:4) is 54 - 66 ohms.
3:514 tion problem, A5
is activated, and
cannot send to T1 • Check that the CAN wiring har-
the main contac-
tor opens ness is not pinched. Measure
>24 kOhm
2: Replace A5
1: Short circuit in 1: Check the motor
motor
• Disconnect motor wiring includ-
2: Short circuit in ing sensor wires.
motor wiring
• Insulation test. Check that the
harness
coils are not electrically con-
3: Short circuit in nected to the chassis. Replace
power stage M1 if the motor is not isolated
2: Check the motor wiring har-
ness
Everything is
stopped at once, • Visual check of the motor wiring
The motor control
the parking brake harness. Check that there is no
3:515 has detected low
is activated, and contact between the pole con-
motor voltage.
the main contac- nections on the motor/motor
tor opens control. Search for contact and
damaged insulation on the wir-
ing harness.
• Disconnect the motor wiring
harness at the motor control and
the motor and measure the
ohms of the wiring harness be-
tween the phases and verify that
there is no contact.
3: Replace T1
© TMHE 8 – 22 T Code(s): 838, 839, 840

Truck
behaviour
motor
motor wiring
harness
ness
Everything is
stopped at once, • Visual check of the motor wiring
The motor control
3:521 has detected high
motor voltage.
ing harness.
3: Replace T1
Everything is 1: Software fail- 1: Update the truck software to
stopped at once, ure the latest version.
the parking brake
3:526 Internal error in T1 2: Defective 2: Replace T1
is activated, and
the main contac- motor control
tor opens
the parking brake
is activated, and
tor opens
the parking brake
is activated, and
tor opens
© TMHE 8 – 23 T Code(s): 838, 839, 840

Truck
behaviour
the parking brake
is activated, and
tor opens
Everything is • The motor con- • Replace T1
stopped at once, trol has detect-
the parking brake ed an internal
is activated, and problem in the
the main contac- AD converter.
tor opens
• The charging 1: Check:
voltage for the
• connections and wiring harness
motor control
Everything is • Wire 20
The charging volt- capacitor indi-
stopped at once,
age for the motor
the parking brake
cates abnormal • The connection point (T1:84)
3:533 control capacitor values.
indicates abnormal
is activated, and must be 24 V
the main contac-
values. • Motor controller:
tor opens
• Pump contactor
2: If the error persists, replace T1
Everything is • Incorrect check- 1: Update the truck software
stopped at once, sum for the mo-
Incorrect checksum • Update the truck entire software
the parking brake tor control pa-
3:535 for the motor con- package to the latest available
is activated, and rameters.
trol parameters. version.
the main contac-
tor opens
Everything is • Multi-direction • What to do?
stopped at once, command is-
the parking brake sued by handle.
3:537 Internal error in A5
is activated, and
the main contac-
tor opens
© TMHE 8 – 24 T Code(s): 838, 839, 840

Truck
behaviour
1: The battery is 1: Charge the battery.
discharged
2: Check the voltages in T1
2: Voltage loss
• Check fuses F50 and F1
on power sup-
ply to T1 • Check the voltage using a volt
meter (Measuring point F50 - B-
3: The battery is
) and compare with the Truck-
defective
Com value “Battery Voltage”
4: Battery (Node:ACT, Analogue I/O) (Lim-
parameter # it values?) (TBD)
107 has an
• Check the voltage using a volt
erroneous val-
meter (Measuring point F1 - B-)
ue
and compare with the Truck-
Com value “Battery Voltage”
Everything is (Node:ACT, Analogue I/O) (Lim-
The motor control
stopped at once, it values?) If the contactor is
detects that the
the parking brake open, there is several volts of
3:539 battery voltage is
is activated, and difference -- normal. If the con-
between 18 V and
the main contac- tactor is closed, voltage should
28.8 V.
tor opens match the point over +XX
• Check the connectors, joints
and splices
• Check that any extra equipment
is connected in accordance with
our recommendation.
3: Inspect the battery.
4: Check parameters
configuration.
are set correctly.
© TMHE 8 – 25 T Code(s): 838, 839, 840

Truck
behaviour
motor
motor wiring
harness
Hardware in T1 ness
Everything is
detects a short cir- • Visual check of the motor wiring
stopped at once,
cuit in the power
3:540 stage and a phase-
to-phase short cir-
cuit, phase B- and
phase B+
ing harness.
3: Replace T1
circuit:
short circuit in the if they outside the accepted
Everything is
output to the brake
stopped at once, range.
(Q1) The current High power con-
the parking brake
3:545 through the brake sumption or short • Check the connections and wir-
is activated, and
exceeds the limit circuit ing harness for short-circuit.
the main contac-
values. Maximum
tor opens • Check that the component does
value = 5.95A, con-
tinuous value = 3A not seize or is jammed.
• If points 1-3 are OK, it indicates
plying component
© TMHE 8 – 26 T Code(s): 838, 839, 840

Truck
behaviour
circuit:
short circuit or cur- Everything is if they outside the accepted
rent through the stopped at once, range.
High power con-
main contactor the parking brake
3:546 sumption or short • Check the connections and wir-
(Q10) exceeds is activated, and
circuit ing harness for short-circuit.
valid limit values. the main contac-
Maximum value = tor opens • Check that the component does
2.5A, continuous not seize or is jammed.
value = 1.5A
plying component
circuit:
peres of the component, com-
pare them to the setpoint values
Everything is if they outside the accepted
Hardware protec-
stopped at once, Components are range.
tion in T1 detects a
the parking brake using too much
3:547 short circuit in the • Check the connections and wir-
is activated, and power or wiring is
output “High Side ing harness for short-circuit.
the main contac- short circuited.
driver”
tor opens • Check that the component does
not seize or is jammed.
plying component
© TMHE 8 – 27 T Code(s): 838, 839, 840

Truck
behaviour
circuit:
short circuit or cur- Everything is if they outside the accepted
rent through the stopped at once, range.
High power con-
main contactor the parking brake
3:548 sumption or short • Check the connections and wir-
(Q10) exceeds is activated, and
circuit ing harness for short-circuit.
valid limit values. the main contac-
Maximum value = tor opens • Check that the component does
2.5A, continuous not seize or is jammed.
value = 1.5A
plying component
motor
2: Low power ing sensor wires.
consumption
or break
2: Check wiring and component
after the break
Everything is
The motor control stopped at once, • Disconnect the battery
detects missing the parking brake • Visually inspect the wiring har-
3:549
phases to the is activated, and ness
motor the main contac-
tor opens • Using instruments, check that
there is no break in any wire
peres of the component, replace
it if the setpoint values are out-
side the accepted range.
• Reconnect the battery. Measure
and check the voltage for the ac-
tivated functions.
3: Replace T1
© TMHE 8 – 28 T Code(s): 838, 839, 840

Truck
behaviour
1: Low power 1: Check wiring and component
consumption after the break
or break
• Visually inspect the wiring har-
Everything is
ness
The amperage is
stopped at once, • Using instruments, check that
below the limit
the parking brake there is no break in any wire
3:563 value 100mA on
is activated, and
the output to brake • Check the ohms and the am-
the main contac-
(Q1) peres of the component, replace
tor opens
tivated functions.
consumption after the break
or break
Everything is
ness
The amperage is
stopped at once, • Using instruments, check that
below the limit
the parking brake there is no break in any wire
3:564 value 100mA on
is activated, and
the output to main • Check the ohms and the am-
the main contac-
contactor (Q10) peres of the component, replace
tor opens
tivated functions.
© TMHE 8 – 29 T Code(s): 838, 839, 840

Truck
behaviour
consumption after a break (main contactor,
or break lowering valve, brake, pump
contactor)
2: Short circuit in
power stage • Disconnect the battery
Everything is ness
The transistor regu-
stopped at once,
lator's output for • Using instruments, check that
the parking brake
3:582 power supply has there is no break in any wire
is activated, and
the wrong voltage
the main contac- • Check the ohms and the am-
level.
tor opens peres of the component, replace
tivated functions.
2: Replace T1
Everything is 1: Defective 1: Replace T1
Internal transistor stopped at once, motor control
regulator voltage the parking brake
3:583
supply has not is activated, and
been switched on. the main contac-
tor opens
1: Broken wiring 1: Check wiring after the break.
2: Defective • Disconnect the battery
component
• Using instruments, check that
3: Change in sur- there is no break in any wire.
face friction
combined with
with the functions activated
slippage
The drive is 2: Check the rotational speed
The change
stopped immedi- sensor
3:590 exceeds 1000 rpm
ately with the
in 20 ms • Disconnect the B11. Check that
parking brake
there are no metal fragments on
B11 sensor points.
• Check that the toothed wheel on
the motor axle is clean, intact
and properly mounted.
3: Drive carefully if there is a risk
of slipping
© TMHE 8 – 30 T Code(s): 838, 839, 840

Truck
behaviour
Internal electrical The drive is 1: Defective 1: Replace T1
fault. stopped immedi- motor control
3:592
Sensor offset is too ately with the
high parking brake
1: Intensive use 1: Intensive use of the truck. Let
of the truck the truck cool down.
reduced or the
temperature
sensor is
defective.
properly.
The drive is • Check that the fans work when

The motor temper- the speed control is activated
stopped immedi-
3:597 ature exceeds (fans behind T1 and motor fan)
ately with the
+180°C.
parking brake • Check that the fan on charger
T14 works when the charging
ble is connected
Lifting/lowering 1: Control manip- 1: Let go of the control, and wait
control is not in ulated for four seconds
neutral position at
Blocked lifting/ 2: Check
start-up. Lifting is
4:001 lowering move-
prevented until the • wiring in the handle
ment
lifting/lowering con-
troller is back in the • the potentiometer. If defective,
neutral position. replace the potentiometer.
© TMHE 8 – 31 T Code(s): 838, 839, 840

Truck
behaviour
1: Control manip- 1: Let go of the control, and wait
ulated for four seconds
Signal from the Creep speed,
sensilift potentiom- blocked lifting/ 2: Check
4:101
eter detects abnor- lowering move- • wiring in the handle
mal values. ment
• the potentiometer. If defective,
replace the potentiometer.
1: Incorrect value 1: Check parameters
for parameter
Signal from the
1102
sensilift potentiom- Creep speed, are set according to the truck
eter detected even blocked lifting/ 2: Error in configuration.
4:102 hydraulic con-
though parameter lowering move- • Check that other parameters
1102 does not have ment trols
are set correctly.
the value 4.
2: Replacement of the hydraulic
control.
Pump motor cur-
Creep speed,
1: Defective • Replace T1
rent feedback power supply
blocked lifting/
4:125 remains zero when to the motor
lowering move-
the pump motor control.
ment
operates.
Excessive pump
Creep speed,
1: Defective • Replace T1
motor current feed- power supply
blocked lifting/
4:126 back at start-up to the motor
lowering move-
and in the standby control.
ment
mode.
1: Wire break 1: Check wiring after the break.
between T1
and the pump
motor • Using instruments, check that
2: The pump
motor • Measure and check the voltage
Pump motor volt- The main contac-
4:521
age too low. tor opens 2: Check the pump motor
ing sensor wires.
nected to the chassis. Replace if
the motor is not isolated
© TMHE 8 – 32 T Code(s): 838, 839, 840

Truck
behaviour
1: Wire break 1: Check wiring after the break.
between T1
and the pump
motor • Using instruments, check that
2: The pump
motor • Measure and check the voltage
Pump motor volt- The main contac-
4:522
age too high. tor opens 2: Check the pump motor
ing sensor wires.
nected to the chassis. Replace if
the motor is not isolated
The transistor 1: The transistor 1: Inspect the connections and
regulator output regulator out- wiring harness.
to the lowering Everything is put to the low-
stopped at once, • Disconnect the lowering valve
valve has short- ering valve
the parking brake and try restarting the truck.
4:540 circuited. has short-cir-
is activated, and cuited. 2: If the error remains, replace
the main contac- the lowering valve of the T1
tor opens 2: Internal short-
circuit in the
motor control.
The transistor Everything is
stopped at once, • Disconnect the battery
regulator output
the parking brake • Using instruments, check that
4:541 to the lowering
is activated, and there is no break in any wire.
valve has short- the main contac-
circuited with B-. tor opens • Measure and check the voltage
2: Lowering • Disconnect the battery
Everything is valve
The transistor regu- stopped at once, • Using instruments, check that
lator output to the the parking brake there is no break in any wire.
4:560
lowering valve is is activated, and
open. the main contac-
tor opens with the functions activated
2: Check the lowering valve sole-
noid
© TMHE 8 – 33 T Code(s): 838, 839, 840

Truck
behaviour
1: Collision 1: Resetting truck after collision
Collision sensor 2: Parameters 2: Check parameters
has registered colli- 105 and 106
sion levels outside • Check that factory parameters
8:001 Creep speed set too low.
set limit values as are set according to the truck
defined by parame- configuration.
ters 105 and 106.
are set correctly.
The truck was 1: 1:
intentionally taken
8:002 Creep speed
out of service via
I_site
1: Option argu- 1: Check parameters
ment error,
Argument error in Not influenced. • Check that factory parameters
parameters
option. Invalid con- The alarming are set according to the truck
8:003 1003 - 1042
figuration in one or option does not configuration.
more options. work.
are set correctly.
1: Option button 1: Check your option buttons
pressed dur-
Not influenced. • Check the function of the option
ing start-up
All option but- buttons via the built-in test
One or more option tons are non- mode, Service Information
buttons on A5 is functional until mode 9 or TruckCom.
8:004
activated at start- the option button
up. that is influenced
• If there is still a signal from a
is not influenced seemingly uninfluenced button,
any more. the button must be checked for
jamming or unwanted connec-
tion.
bus wiring or
connections
ance and connectors. Discon-
tion problem with resistance between (X41:3) and
the built-in charger (X41:4) is 54 - 66 ohms.
T14 at start-up
>24 kOhm
© TMHE 8 – 34 T Code(s): 838, 839, 840

Truck
behaviour
bus wiring or
connections
tion problem with resistance between (X41:3) and
the built-in charger (X41:4) is 54 - 66 ohms.
T14.
>24 kOhm
1: Battery not 1: Check the battery charger
connected to cables.
charger
• Disconnect the battery by dis-
T14 detects no bat- connecting the connector and
8:020 tery, voltage below Not influenced power cable from the charger.
valid level: 6V
• Measure the ohms on red and
black cable from T14 to X1. Re-
place the cables in case of
breakage.
T14 detects exces- 1: The battery is 1: Inspect the battery.
sively low battery defective
voltage when
charging. Voltage
below valid level:
19.8V
T14 detects exces- 1: The battery is 1: Inspect the battery.
sively high battery defective
voltage when
charging. Voltage
above valid level:
34.8V
1: Truck used in 1: Inform the client that the truck
T14 detects exces- cold environ- should be stored in normal
sively low tempera- ments. ambient temperatures to avoid
ture when unnecessary wear and tear of
charging. the battery and other compo-
nents.
© TMHE 8 – 35 T Code(s): 838, 839, 840

Truck
behaviour
reduced or the
temperature
sensor is
defective.
properly.
T14 has reduced the speed control is activated
the charging cur- (fans behind T1 and motor fan)
8:024 rent to 0A because Not influenced
• Check that the fan on charger
of high tempera-
ture. T14 works when the charging
ble is connected
1: No software 1: Update the truck software
compatibility
Internal error in • Update the truck software to the
T14 2: Defective latest version.
component
2: Replace the T14
1: Battery 1: Check parameters
parameters
The main charging • Check that factory parameters
109 and 110
time is exceeded are set according to the truck
incorrectly set.
8:028 by 5-11 hours Not influenced configuration.
depending of bat- 2: The battery is
tery capacity. defective
are set correctly.
© TMHE 8 – 36 T Code(s): 838, 839, 840

Truck
behaviour
parameters
109 and 110
Charged capacity are set according to the truck
incorrectly set.
8:029 exceeds battery Not influenced configuration.
capacity. 2: The battery is
defective
are set correctly.
1: Incorrect value 1: Check parameters
Communication for parameter
with charger T14 1101
8:030 exists, but factory Not influenced
parameter 1101 is
configuration.
not activated. • Check that other parameters
are set correctly.
1: No software 1: Update the truck software
Saving parameter compatibility
8:031 Not influenced • Update the truck software to the
in T14 failed.
latest version.
parameters
Wrong battery type 109 and 110
8:032 selected via param- Not influenced incorrectly set.
eters 109 and 110.
configuration.
are set correctly.
bus wiring or
connections
CAN communica- Creep speed, nect the battery. Check that the
tion problems blocked lifting/ resistance between (X41:3) and
8:110
between A5 and lowering move- (X41:4) is 54 - 66 ohms.
A36/A37 ment
>24 kOhm
© TMHE 8 – 37 T Code(s): 838, 839, 840

Truck
behaviour
bus wiring or
connections
CAN communica- Creep speed, nect the battery. Check that the
tion problems blocked lifting/ resistance between (X41:3) and
8:111
between A5 and lowering move- (X41:4) is 54 - 66 ohms.
A36/A37 ment
>24 kOhm
bus wiring or
connections
tion problems resistance between (X41:3) and
between A5 and (X41:4) is 54 - 66 ohms.
B90
>24 kOhm
1: Argument 1: Check parameters
error option
Argument error in Creep speed, • Check that factory parameters
option. Invalid con- blocked lifting/ are set according to the truck
8:123
figuration in one or lowering move- configuration.
more options. ment
are set correctly.
bus wiring or
connections
Creep speed, ance and connectors. Discon-
blocked lifting nect the battery. Check that the
CAN communica-
movement If resistance between (X41:3) and
8:130 tion error with li-ion
battery
CAN key con- (X41:4) is 54 - 66 ohms.
nected - creep
speed • Check that the CAN wiring har-
>24 kOhm
© TMHE 8 – 38 T Code(s): 838, 839, 840

Truck
behaviour
Temperature in the Creep speed, 1: 1: Let the battery cool down
8:131 li-ion battery is too blocked lifting
high movement
1: Regenerative 1: No action.
braking with
fully-charged
battery. • Check the voltage using the
Creep speed, built-in test procedure and com-
Current in the li-ion 2:
8:132 blocked lifting paring with value from external
battery is too high
movement volt meter
Li-ion battery tem- Creep speed, 1: 1: Move the truck to a warmer
8:133 perature below per- blocked lifting area
mitted level movement
Defective hard- Creep speed, 1: Defective sen- 1: Contact the battery manufac-
8:134 ware in the li-ion blocked lifting sor in the mod- turer.
battery movement ule.
1: Communica- 1: Contact the battery manufac-
Internal CAN prob- Creep speed, tion problem turer.
8:135 lem in the li-ion bat- blocked lifting between mod-
tery movement ules in the bat-
tery.
1: A module in 1: Restart the battery.
the battery has
Creep speed,
Overvoltage in the been switched
8:136 blocked lifting
li-ion battery
movement
off because its
voltage is too
high.
1: Some battery 1: Overvoltage, undervoltage,
Battery cells deacti- Creep speed, functions are temperature too high, temper-
8:137 vated by internal blocked lifting not working. ature too low. Let the battery
monitoring movement rest and then restart the bat-
tery.
© TMHE 8 – 39 T Code(s): 838, 839, 840

Truck
behaviour
1: Battery dis- 1: Charge the battery
charged
2: Voltage drop.
• Check the voltage using the
Creep speed, built-in test procedure and com-
Low battery voltage
8:138 blocked lifting paring with value from external
in the li-ion battery
movement volt meter
parameter
Wrong battery type Creep speed, 1045 has
8:139 selected via param- blocked lifting incorrect set-
eter 1045 movement
configuration.
ting.
are set correctly.
© TMHE 8 – 40 T Code(s): 838, 839, 840

8.8 Troubleshooting chart

The following section describes the type of errors that can occur together with
a description of the cause.
Troubleshooting is divided into groups according to truck symptoms:
• The truck cannot be driven.
• The truck can be driven but only at reduced speed
• The truck can be driven but behaves abnormally
• Defective hydraulic functions.
© TMHE 8 – 41 T Code(s): 838, 839, 840

8.8.1 The truck cannot be driven.
Symptom Influencing elements Possible cause

Mechanical brake cannot Sensor [B60] • Sensor in wrong position or
be applied. disrupted by metal
• Defective sensor
Tiller arm handle always "On" in Damaged wiring harness or
travel mode incorrect plus/minus current
supply
Motor control, input [T1:95]. Motor control defective
Mechanical brake cannot Sensor [B60] • Sensor in wrong position or
be released. cannot be normally actuated
• Break in sensor wiring har-
ness.
Motor control, input [T1:95] Motor control defective
Motor control, output [T1:90]
Corrosion Brake has seized due to
corrosion
Truck cannot travel after Sensor [B60] • Sensor in wrong position and
start-up although tiller arm affected by metal
handle was in raised
position.
Tiller arm handle always "On" in Damaged wiring harness or
travel mode incorrect plus/minus current
supply
Motor control, input [T1:95]. Motor control defective.
© TMHE 8 – 42 T Code(s): 838, 839, 840

8.8.2 Truck only travels at reduced speed

Speed always reduced Click-2-Creep function Click-2-Creep function activated
Turtle function Turtle function activated
Operator parameter 6 - speed Operator parameter 6 has not
been set to the maximum value
Pulse transducer [B11] Defective or disconnected pulse
transducer [B11]
Motor cable connections • One of the phases U, V, W
has been disconnected
• Broken wiring
Mechanical brake • Partially applied brake
• Incorrect gap.
© TMHE 8 – 43 T Code(s): 838, 839, 840

8.8.3 The truck can be driven but behaves abnormally

Truck travels in wrong Motor cable connections Incorrect U, V, W connections
direction.
Acceleration always Driver parameter 4 Value setting low.
reduced
Reversing braking always Service parameter 201 Value setting low.
reduced.
Neutral braking always Driver parameter 5 Value setting low
reduced
The truck cannot be Parameter 102. The Red off key Parameter 102 has been
switched off. on the keypad does not work. incorrectly set for the log-in unit
installed in the truck.
Speed always reduced Pulse transducer [B11] Defective or disconnected pulse
transducer [B11]
Motor cable connections • One of the phases U, V, W
has been disconnected
• Broken wiring
© TMHE 8 – 44 T Code(s): 838, 839, 840

8.8.4 The truck can be driven, but some functions do not work
Software compatibility
Ensure that the correct software for logic card [A5], motor control [T1] and
battery charger [A30] is installed on the truck. See section "8.1 General".
Hardware compatibility matrix

Make sure the correct software for the logic card [A5] and motor control [T1]
are installed on the truck by referring to the matrix below.
Motor control ACT[T1] not Motor control ACT[T1]

replaced replaced
ICH OK Warning 2.004. Use TruckCom

logic card [A5] not to download new backup values.
Open TruckCom, and select
replaced
“Copy configuration to
secondary unit: ACT”
ICH Error code 2.101. Use TruckCom Replace one node at a time and
logic card [A5] replaced to upload new backup values. implement the corresponding
Select “Copy configuration to measure. See 17.2 and 16.5.2
primary unit: ICH”
© TMHE 8 – 45 T Code(s): 838, 839, 840

8.8.5 Defective hydraulic functions
Symptom Influencing elements Possible cause/Remedy

The forks can be lowered but Low or no hydraulic pressure • Low oil level
not raised.
• Clogged suction filter
• Defective or incorrectly ad-
justed pressure limiting valve
• Defective hydraulic pump; re-
place the hydraulic unit
Pump contactor [Q25] does not • Measure current and voltage
close through pump contactor
[Q25].
For more information, see the
table below: Pump contactor
[Q25] does not close:
• Pump contactor [Q25] volt-
age/current normal
• No current or voltage through/
across the contactor coil
[Q25]
• Voltage across contactor coil
[Q25], but no current through
the coil.
Pump motor [M3] does not work • Hydraulic unit fuse [F1] has
blown; replace fuse.
following table Pump motor
[M3] does not work:
• Measure current and voltage
through and across the pump
motor [M3].
• Pump motor [M3] voltage/cur-
rent normal
across the motor [M3]
• Voltage across the motor
[M3], but no current through
the motor
Height switch [B61] does not • Inspect the switch and its con-
work nections
© TMHE 8 – 46 T Code(s): 838, 839, 840


Forks can be raised but not The proportional valve [Q4] for • Measure current and voltage
lowered. lowering the forks does not open through and across the valve
coil.
table below Solenoid valve
[Q4] for lowering the forks
does not open:
• Solenoid valve voltage/cur-
rent normal
across the solenoid valve coil
• Voltage across solenoid valve
coil, but no current through
the coil.
Forks can neither be raised Defective fuse [F50] 7.5 A Replace the fuse
nor lowered
Logic card [A5] faulty Replace the logic card
Defective motor control [T1] Replace the motor control
Factory parameter 1023 Check the parameter value
settings
Cont'd. Pump contactor [Q25] does not close

Pump contactor [Q25] Defective contact tongues Replace the pump contactor
voltage/current normal
No current or voltage Damaged wiring harness or Check the wiring harness for
through/across the contactor connections in the pump interruptions or short-circuits to
[Q25] coil contactor other electric components
Tiller arm Hall sensor for fork Replace the logic card [A5]
lifting defective
The motor control [T1], output Replace the motor control [T1]
107 “OUT.PUMP CONTACTOR”
defective
Motor control [T1], output 82 See the troubleshooting chart
“OUT. +24 V HIGH SIDE The truck cannot be driven
DRIVER” defective
© TMHE 8 – 47 T Code(s): 838, 839, 840

Cont'd. Pump contactor [Q25] does not close

Voltage across contactor coil Interruption in the pump Replace the pump contactor
[Q25], but no current through contactor coil [Q25]
the coil.
© TMHE 8 – 48 T Code(s): 838, 839, 840

Cont'd. Pump motor [M3] does not operate:

Pump motor [M3] voltage/ Mechanical fault in the pump Replace the hydraulic unit
current normal
No current or voltage through/ Damaged wiring harness or Check the wiring harness for
across the motor [M3] connections in the pump interruptions or short-circuits to
motor [M3] other electric components
Voltage across the motor [M3], Open circuit in the pump Replace the hydraulic unit
but no current through the motor motor [M3]
Cont'd. The solenoid valve [Q4] for lowering the forks does not open:
Solenoid valve [Q4] voltage/ Mechanical fault in the valve Replace the hydraulic unit
current normal [Q4]
Low or no current/voltage Damage to the solenoid valve Check the wiring harness for
through/across the solenoid [Q4] wiring harness or interruptions or short-circuits to
valve coil [Q4] connections other electric components
Tiller arm Hall sensor for fork Replace the logic card [A5]
lowering defective
The motor control [T1], output Replace the motor control [T1]
108 “OUT.LOWER VALVE”
defective
Motor control [T1], output 82 See the troubleshooting chart
“OUT. +24 V HIGH SIDE The truck cannot be driven
DRIVER” defective
Voltage across solenoid Break in the solenoid valve coil Replace the hydraulic unit
valve coil [Q4], but no current [Q4]
through the coil
© TMHE 8 – 49 T Code(s): 838, 839, 840

8.9 Built-in test function

The truck has a service information mode that is a useful aid for troubleshoot-
ing. To activate:
1. Connect the CAN service key to [X41] and log in.
2. The battery status symbol lights up.
3. Press the horn button [S18] repeatedly to select the desired mode in the
8 4 2 1 service information mode.
Note:
All truck functions work as normal when the service information mode is ac-
tive. Care should be taken when operating the truck and reading the display
at the same time.
Data Flashing symbol Description Resolution Unit Standard value

- BDI 10 % 0-100
Depending on bat-
tery type. Compare
1 Battery voltage 0.1 V
with the real battery
voltage
Battery voltage, the value
indicated in an approxi-
2 1 A 0-450A
mate value of motor and
pump voltages.
The set speed that is sig-
nalled to ACT from ICH. -12.5 - 12.5 km/h
3 Positive value in the drive 0.1 km/h (depending on truck
wheel direction. Negative type)
value in the fork direction.
Speed value from the
speed sensor. Positive -12.5 - 12.5 km/h
4 value in the drive wheel 0.1 km/h (depending on truck
direction. Negative value type)
in the fork direction.
Forks or support arms,
lifting or lowering com-
5 1 % 0-100%
mand. 100% shown for
on/off checked signals
6 N/A
7 N/A
8 N/A
© TMHE 8 – 50 T Code(s): 838, 839, 840

Data Flashing symbol Description Resolution Unit Standard value

Digital I/0 for ICH and
ACT. See description in
9 - - -
“Test mode “9” –” on
page 52
10 TBD - - -
Maximum value for colli-

sion sensor X and Y.
11 0.1 G 0 G - 10 G
“nonE” is shown if no
sensor exists.
SEU digital I/0. See
description in “Test mode
“12” – Expansion unit
12 - - -
SEU (option).” on
page 54 “nonE” is shown
if no SEU exists.
13 Steering angle 1 ° 0-90°
14 Drive motor temperature 1 °C ?
15 ACT temperature 1 °C ?
© TMHE 8 – 51 T Code(s): 838, 839, 840

8.10 Digital input/output status
8.10.1 Test mode “9” –
In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
1
6 7 2
5 3
8
1 2 3 4 4
Position:
1. Digital input of ICH [A5]
2. Digital input/output of ICH [A5]
3. Transistor regulator inputs
4. Transistor regulator inputs
1 – 8: Reference to segment
Digit 1, ICH digital in Digit 2, ICH digital in/out
Segment Description Segment Description
1 1 Option button 6 1 1 Rear button up
2 Option button 5 2 Rear button down
6 7 2 3 Option button 4 6 7 2 3 Front button up
4 Option button 1 4 Front button down
5 3 5
6
Option button 2
Option button 3
5 3 5
6
Main contactor
Horn input
8 7 ICH address (node ID) 8 7 Brake output
4 8 -
4 8 Pump
Digit 3, ICH digital in Digit 4, ICH digital in

Seg-
Segment Description Description
ment
Top position sensor not
1 1
active (B61) 1 1 Input 9
Steering arm active

6 7 2 2
(B60) 6 7 2 2 Input 10
Operator on platform
3 3 Input 11
[B119]
5 3 4 Input 4 5 3 4 Input 12
8 5 Input 5 8 5 Input 13
4 6 Platform up (B120) 4 6 Input 14
7 Gate up (121) 7 Motor encode, channel A
8 Gate down (B122) 8 Motor encode, channel B
© TMHE 8 – 52 T Code(s): 838, 839, 840

8.10.2 Test function “10” – Logic card
Function Pos 1 Pos 2 Pos 3 Pos 4

- A * * * Not assigned
- B * * * Not assigned
- C * * * Not assigned
Front fork lift button [A5:S19] D * * * Lit: Button depressed
Front fork lowering button Lit: Button depressed
E * * *
[A5:S20]
Rear fork lift button [A5:S21] F * * * Lit: Button depressed
Rear fork lowering button Lit: Button depressed
G * * *
[A5:S22]
Sound signal control [S18] H * * * Lit: Button depressed
Outermost option button, right Lit: Button depressed
* A * *
side [S116]
Centre option button, right side Lit: Button depressed
* B * *
[S115]
Innermost option button, right Lit: Button depressed
* C * *
side [S114]
Outermost option button, left Lit: Button depressed
* D * *
side [S113]
Centre option button, left side Lit: Button depressed
* E * *
[S206]
Innermost option button, left Lit: Button depressed
* F * *
side [S111]
- ‘ G * * Not assigned
- * H * * Not assigned
A
F G B
E C
D H
© TMHE 8 – 53 T Code(s): 838, 839, 840

8.10.3 Test mode “12” – Expansion unit SEU (option).
In this mode, the digital inputs and outputs are tested by checking specific
segments on the display according to the following tables.
1
6 7 2
5 3
8
1 2 3 4 4
Position:
1. SEU 0 inputs
2. SEU 0 outputs
3. SEU 1 inputs
4. SEU 1 outputs
1 – 8: Reference to segment
Digit 1, SEU 0 digital in Digit 2, SEU 0 digital out

1 1 In 1 1 1 Out 1
2 In 2 2 Out 2
6 7 2 3 In 3 6 7 2 3 Out 3
4 In 4 4 Out 4
5 3 5
6
In 5
In 6
5 3 5
6
8 7 In 7 8 7
4 8 In 8
4 8
Digit 3, SEU 1 digital in Digit 4, SEU 1 digital out

1 1 In 1 1 1 Out 1
2 In 2 2 Out 2
6 7 2 3 In 3 6 7 2 3 Out 3
4 In 4 4 Out 4
5 3 5
6
In 5
In 6
5 3 5
6
8 7 In 7 8 7
4 8 In 8
4 8
© TMHE 8 – 54 T Code(s): 838, 839, 840

8.11 Built-in test function for the tiller arm

1: Make sure the battery is connected.
2: Check that the truck is switched off. Press the OFF switch
3: Connect the CAN key or enter the PIN code. Note: Do not press the ON
button.
4: Press and then release the horn button. “Info“ is shown on the display.
5: Press and release the horn button to select the "Info" menu.
6: Turn the speed control several times until “tESt” is shown on the display.
7: Press the horn button and release it to enter the test mode.
8: The first one you arrive at is the display test. Press on the button/function
you want to test to proceed. In this mode, the 2 LEDs on the keypad
flash.
8.11.1 Display test

The digital display [A6] can be tested to verify all the segments of the display
function correctly. A moving 8 tests all the segments of the display.
8.11.2 Speed control

The Hall elements are tested by moving the speed control all the way back
and forth. Follow these steps to test the Hall elements:
Move the rocker from the neutral position to begin the test. This is visualised
as number X Y when the rocker is moved in the fork direction and X-Y when
the rocker is moved in the drive wheel direction. X is the total number of Hall
elements that are affected by the magnet and Y is the number of existing Hall
elements. At full movement in both directions 9-9 or 9 9 is shown when all Hall
elements are OK.
8.11.3 Safety reversing

Press the button for safety reversing “Er 1” is shown in the display
8.11.4 Controls for lifting/lowering

Press a button for lifting / lowering in order to start the test. “L1”, “L2”, “L3” or
“L4” is shown in the display depending on which button has been pressed.
8.11.5 Sensilift
Move the sensilift rocker from the neutral position to begin the test. The ana-
logue value from the sensilift potentiometer is shown in mV.
© TMHE 8 – 55 T Code(s): 838, 839, 840

8.11.6 Keypad
Press a number to start testing the keypad. “b1” up to “b11” is shown in the
display depending on which button is pressed. The numbers 0-9 are shown
as “b0” to “b9”. The red button “b10” and the green button “b11”
9: Switch off the truck by pressing the OFF button or return to the previous
menu by pressing the horn button.
© TMHE 8 – 56 T Code(s): 838, 839, 840

8.12 Checking the built-in battery charger

This checklist must be filled in and sent in together with the replaced charger.
Applies to the following part numbers:

7513327
7513328
7539122
7539123
The unit must not be opened under any circumstances.

• Connect the charger to mains voltage and ensure the battery connector is
connected.
Check Yes No
1 Are all of the charger's connectors properly
connected?
2 Does the fan blow air out of the charger? (it
should begin running at start-up)
3 Does battery voltage increase when the charger
is connected to mains voltage?
(Measure across the battery terminals)
4 Are the parameter settings for the battery set as
specified in the repair manual?
5 If any parameter setting was incorrect, does it ---------
have the correct setting now?
6 Is the correct software completely downloaded?
If not, follow the emergency downloading
instructions found in the TruckCom manual.
If you answered Yes to all of the questions, the charger is functioning properly
and does not require replacement.
If not, fill in the rest of the checklist on the next page.
© TMHE 8 – 57 T Code(s): 838, 839, 840

This part of the checklist is intended to help us in our improvement

work.
Check Yes No
1 Is there any evidence of moisture on the inside
or outside?
(Investigate for interior moisture through the
perforated sides.)
2 Has the truck been used in an environment with
a temperature below 0° Celsius?
3 Has the truck been used outdoors?
4 Are there signs of mechanical damage?
5 Has the truck travelled over uneven floors or
loading ramps?
6 Are there any error codes? If yes, please specify.
© TMHE 8 – 58 T Code(s): 838, 839, 840

Repair manual: Chassis 0000 Model(s): LWE140, 160, 180, 200, 250.
9. Chassis 0000
9.1 General
To gain access for certain inspection items, it may be necessary to disassem-
ble the drive unit from the fork frame.
E
Pos. Description
A Cylinder locking
B Mounting hole
C Axle 2
D Stop screw 2
E Nut 2
© TMHE 9– 1 T Code(s): 838, 839, 840

9.2 Fork chassis 0380
9.2.1 Overview
D
K
G
F
L
H
I
J
Pos. Description Pos. Description

A Lock pin J Bushing
B Bushing I Torsion tube
C Shaft L Bushing
D Screw M Bushing
E Grease nipple N Spring pin
F Bushing O Shaft
G Spring pin P Shaft
H Shaft Q Stop screw
I Push rod R Nut
© TMHE 9– 2 T Code(s): 838, 839, 840

9.3 Disassemble the drive unit from the fork frame

Proceed as follows to separate the fork frame from the drive unit:
1. Make sure the truck is parked on a level surface.
2. Remove the covers and the battery door.
The top cover is secured with Velcro tape. Be careful when detaching 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. Place a jacking block under the rear edge of the drive unit (Use identical
block sizes when supporting the truck to make sure it is level)
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.
Install in reverse order.
Note:
Be careful when reassembling so that no cables are crushed.
© TMHE 9– 3 T Code(s): 838, 839, 840

9.4 Removing the platform

1. Apply a load on the platform and loosen the upper dampening stop
together with the spring cover plate.
2. Disassemble the platform from the truck by loosening the four bolts.
3. Put the platform on the floor behind the truck with the spring facing you
and placing the other edge under the truck's foot guard.
4. Loosen all 8 screws securing the bracket, which the spring clamp is
pushing against.
© TMHE 9– 4 T Code(s): 838, 839, 840

Note: Pay utmost attention when working with tensioned springs.

5. Relieve the spring using a crowbar or a large screwdriver and carefully
remove the bracket.
6. Pull out the axle and replace the part(s) that should be replaced.
7. Install in reverse order.
© TMHE 9– 5 T Code(s): 838, 839, 840

9.5 Replacing the castor wheel bracket damper

1. Loosen the nuts at the ends of the damper
2. Pull off the damper from the threaded studs

3. Fit the new damper and refit the nuts
9.6 Replacing the castor wheel bracket springs and cylinder

1. Lift the rear end of the truck using a jack to release the pressure from the
cylinder.
2. Disconnect the hydraulic connection to the cylinder using a 14 mm
wrench
© TMHE 9– 6 T Code(s): 838, 839, 840

3. Unscrew the cylinder bracket using 5 mm and 10 mm Allen keys
4. Dismantle the bracket from the cylinder
5. Replace the cylinder and/or the spring
6. Reassemble in reverse order
© TMHE 9– 7 T Code(s): 838, 839, 840

© TMHE 9– 8 T Code(s): 838, 839, 840

Repair manual: Electric drive motor 1700 Model(s): LWE140, 160, 180, 200, 250.
10. Electric drive motor 1700

10.1 Overview
b
a
c
e
Pos. Description
A Speed sensor
B Cover
C Motor: LWE140/160/180 1,0 kW
LWE200/250 1,5 kW
D Lift cylinder
E Temperature sensor
© TMHE 10 – 1 T Code(s): 838, 839, 840

10.2 Removing the motor from the truck

1. Remove the covers.
2. Lift the drive unit using a jack and secure the truck with trestles placed
under the drive unit so that the drive wheel is freely suspended.
3. Cut off the cable ties of the cable duct on the transistor regulator side and
disconnect cable connections X5 and X65.
4. Unscrew the retaining screws of the steering console and remove the
steering console and the tiller arm.
5. Unscrew the retaining screws of the brake and disconnect cable
connection Q1.
6. Remove the brake.
7. Remove the speed sensor Page 10–6 and wire connection B1.
8. Disconnect the motor cables and unscrew the motor retaining screws.
9. Lift out the motor from the truck.
Note:
Cover the drive gear to prevent loose items from falling into the drive gear af-
ter the drive motor has been removed.
Install the motor in the reverse order.

See section "10.7 Drive motor tightening torques".
Note:
Mount the drive motor into place with the 4 screws. The screws must be tight-
ened crosswise and in two stages. In other words, do not tighten to full
torque during the first stage. See section "10.7 Drive motor tightening tor-
ques".
© TMHE 10 – 2 T Code(s): 838, 839, 840

10.3 Removing the toothed wheel

• Remove the motor from the truck. Page 10–2
Note: Place the motor on a working surface and make sure that it is secured
and cannot fall over.
1. Remove the circlip
2. Remove the brake hub
3. Remove the key
© TMHE 10 – 3 T Code(s): 838, 839, 840

4. Remove the toothed wheel

© TMHE 10 – 4 T Code(s): 838, 839, 840

10.4 Removing motor bearings

• Remove the toothed wheel Page 10–3
6. Remove the circlip from above
7. Carefully knock out the stator
8. Remove the circlip inside the motor
© TMHE 10 – 5 T Code(s): 838, 839, 840

9. Knock out the bearing

10.5 Removing the RPM sensor

• Remove the hood
1: Undo the screw and pull the RPM sensor straight out. Disconnect con-
nector B11.
2: Install in reverse order.
© TMHE 10 – 6 T Code(s): 838, 839, 840

10.6 Installing the temperature sensor

1. Cut off the wiring to the broken temperature sensor, and splice on the
new one
2. Position the new temperature sensor on the motor.
3. Carefully clean the area and make sure all surfaces are dry.
4. Apply plastic steel by pushing out a string that is half the length of the
curing agent compared to the putty, then carefully mix the two (be careful
not to mix a larger amount than will be used in 5 minutes).
5. Apply a layer of plastic steel, at least 4 mm thick, and make sure the
repaired surface has an overlap of at least 2 cm.
6. Secure the steel plastic with masking tape and allow it to cure.
7. Remove the masking tape.
The temperature sensor should now be completely covered by plastic
steel.
8. Following curing, it is recommended to apply another layer of plastic
steel.
© TMHE 10 – 7 T Code(s): 838, 839, 840

10.7 Drive motor tightening torques

The drive motor tightening torques are depicted in the figure below:
3.5Nm
T30
4,5 + 0,5 Nm
10 mm
10,5 + 1,5 Nm
T30
© TMHE 10 – 8 T Code(s): 838, 839, 840

10.8 Cleaning
Keep the motor as clean as possible since this is a decisive factor for correct
operation. Regularly inspect the motor and motor compartment for build-up
of dust, oil and other contaminants.
Dirty and/or greasy components should be cleaned with a rag moistened with
solvent. Use a rag of lint-free cloth material. Do not use too much solvent as
it could penetrate into the motor parts.
After cleaning, dry the components thoroughly. The easiest way is by heating.
Note:
Windings and insulation must not be heated over 125°C and not for longer
than 6 hours.
© TMHE 10 – 9 T Code(s): 838, 839, 840

© TMHE 10 – 10 T Code(s): 838, 839, 840

Repair manual: Drive gear 2550 Model(s): LWE140, 160, 180, 200, 250.
11. Drive gear 2550

11.1 General
The drive gear is a two-stage angle gear that is integrated with the motor and
brake assembly in a complete drive unit. The drive gear is fitted to the chassis
with bolts. At the top edge of the gear, the steering bearing and a gear ring
for the steering motor (option) are fitted.
These service instructions cover descriptions of service performed on site at
the customer. A complete reconditioning of the drive gear must be performed
in the workshop by trained technicians.
© TMHE 11 – 1 T Code(s): 838, 839, 840

11.2 Overview
Description Value
Gear ratio 29.85
Oil quality 0.8 litres
Drive wheel Ø 230
a e
Pos. Description Notes

a Transmission housing
b Motor bearing and packing box
c Steering bearings
d Seal and cover ring
e Stud bolt M12x1.5
© TMHE 11 – 2 T Code(s): 838, 839, 840

11.3 Removing the drive 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 covers.
5. Unscrew the retaining screws of the steering console and remove the
steering console and the tiller arm.
6. Disassemble the speed sensor and disconnect the wire connectors Q1
and B1.
7. Disconnect the motor cables and unscrew the motor retaining screws.
8. Lift out the motor from the truck.
9. Insert a plug in the hole in the gear housing to prevent oil leakage when
the gear is removed from the truck.
10. Unscrew the retaining screws of the gear box.
11. Lay down the gear and move it out under the forks.
Put a wooden block under the gearbox to facilitate reassembly.
© TMHE 11 – 3 T Code(s): 838, 839, 840

11.4 Fit grease nipples, steering bearings (option)
Step 1
Step 2
Step 3
1: Clean the surface, remove all dirt from the recess for the grease nipples.
2: Unscrew the stop screws
3: Screw in the grease nipples using an extension piece, 2 each
© TMHE 11 – 4 T Code(s): 838, 839, 840

11.5 Lubricate the steering bearing (Option)
1: Turn the steering wheel to the end position.

2: Press in some grease, not so much that the seal lifts, check the seal at
the grease nipple position.
3: Turn the wheel about 15 degrees, press in some more grease, continue
to the other end position.
4: Do the same with the other grease nipple to lubricate the entire bearing.
© TMHE 11 – 5 T Code(s): 838, 839, 840

11.6 Checking and changing the oil
11.6.1 Draining oil
Step 1 Step 2 Step 3 T=20 Nm
1: Undo and remove the oil plug on the lower part of the gear housing.
2: Drain all old oil into a suitable receptacle.
3: Clean away dirt and metal shavings from the oil plug before fitting.
© TMHE 11 – 6 T Code(s): 838, 839, 840

11.6.2 Checking/refilling oil
Step 1 Step 2 Step 3
1: Remove the oil filler plug on the upper part of the gear housing.
2: Top up with oil up to the lower edge of the hole to reach the correct level.
3: Screw in the plug.
© TMHE 11 – 7 T Code(s): 838, 839, 840

11.7 Replacing the wheel hub seal
Removing the seal
1: Remove the cover ring using a screwdriver or similar.

2: Remove the seal using a screwdriver or similar.
© TMHE 11 – 8 T Code(s): 838, 839, 840

Fitting the seal
Step 1 Step 2
1: Fit a new seal. Tap lightly to get it into the right position.
2: Fit a new cover ring. Tap it lightly into place.
© TMHE 11 – 9 T Code(s): 838, 839, 840

11.7.1 Replacing studs

The drive wheel is fixed to the hub with five studs, conical washers and nuts.
Loctite XXX
Step 1 Steps 2, 3 T=35 Nm
1: Remove the damaged studs.

– Use a stud tool to remove any studs with damaged threads.
– For broken studs, there are two methods:
Method 1: Drill a hole in the centre of the stud and remove it using a bolt
extractor.
Method 2: If the stud will not come loose with a bolt extractor, it will have
to be drilled out
– Drive a centre punch as close to the centre of the stud as possible
– Drill a pilot hole through the stud using a 5 mm bit
– Drill out the screw with a drill.
– Try to remove the stud remains using pliers, etc. If that does not work,
remove the remains by clearing the threads with a tap.
2: Apply Loctite® 270 to the stud thread.

3: Use the stud tool to fit the new stud and tighten to 35 Nm.
© TMHE 11 – 10 T Code(s): 838, 839, 840

Repair manual: Brake system/Wheels C3000 Model(s): LWE140, 160, 180, 200, 250.
12. Brake system/Wheels C3000

12.1 Brake system - C3100
12.1.1 Description
The truck has three different types of brake:
• travel brake,
• parking brake,
• emergency brake.
Travel brake
• Regenerative motor braking using the drive motor.
Parking brake
The brake [Q1] is a single stage electromechanical spring-loaded brake that
is released when the magnetic coil is energised. This brake serves as a park-
ing brake and emergency brake.
The parking brake is activated/is active as follows:
• The parking brake is applied automatically when the truck stops during op-
eration. The brake is released when the truck moves off.
• The parking brake remains active after the main power has been switched
on.
Emergency brake
Emergency braking of the truck takes place in the event of a fault with the
steering system or a serious fault in the electrical system.
The parking brake on the drive motor is the main emergency brake.
Motor braking can operate during emergency braking provided there is a sup-
ply voltage.
© TMHE 12 – 1 T Code(s): 838, 839, 840

12.2 Parking brake 3180

In normal work environments, the brake should not require any maintenance.
DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function being
partly or completely lost.
Only the actions described in this section may be carried out on the parking
brake.
12.2.1 Overview
I
A
C F
J D
G
E
Pos. no. Description

A Circlip
B Complete brake assembly
C Screw
D Key
E Hub
F Brake disc
G Flange
H Dust guard
I Cable grommet
J Dust guard
© TMHE 12 – 2 T Code(s): 838, 839, 840

12.2.2 Emergency release of the parking brake

Note:
An emergency release of the brakes should only be performed when the
truck needs to be moved in connection with work for service and repairs.
A
The brakes on the truck can be manually released by screwing two screws
(M5) into the holes (A). The screws should be 30-35 mm long.
Note:
Remember to remove the screws before operating the truck again.
© TMHE 12 – 3 T Code(s): 838, 839, 840

12.3 Removing the parking brake

DANGER!
Risk of brake function being lost.
When work is done in the brake system, there is a risk of brake function being
partly or completely lost.
• Truck switched off and the battery disconnected
• Motor compartment open
1. Remove the steering yoke from the truck together with the tiller arm (see
the repair manual). Note the position of the conduit entry so that refitting
is done correctly.
2: Unscrew the retaining screws of the brake and disconnect the cable
connection.
© TMHE 12 – 4 T Code(s): 838, 839, 840

3. Remove the brake unit from the truck. Note the position of the brake so
that refitting is done correctly.
© TMHE 12 – 5 T Code(s): 838, 839, 840

12.4 Fitting the parking brake
Steps 1 and 2
T=5Nm
1. Torque tighten the brake retaining screws to 5 Nm.

2. Fit the connector Q1
Step 3
T=23Nm
3. Fit the tiller arm and the steering yoke and tighten the mounting bolts to
23Nm
Make sure the wire grommet is mounted securely to the brake and placed
according to your notes.
• Connect the battery and close the motor compartment cover.
• Start the truck and check that the brake works correctly.
© TMHE 12 – 6 T Code(s): 838, 839, 840

12.5 Checking the air gap

• Remove the parking brake
Steps 1,2 and 3

Spacing=Min 0.2mm
1: Place the parking brake on a workbench with the magnet housing facing
downwards.
2. Clean the brake using compressed air. Clean from the inside outwards.
3. Repeat the cleaning as necessary until a 0.2 mm feeler gauge can be
inserted. If there are particles that cannot be cleared away with
compressed air, these may be carefully scraped away.
Measure the air gap between the magnet housing of the brake unit and
the movable pressure disc. Measuring must be done around the entire
pressure disc, both on the inside and the outside.
Note:
It is extremely important that an air gap of min. 0.2 mm is maintained all
around the brake. If the prescribed measurement cannot be maintained, the
brake must be replaced
© TMHE 12 – 7 T Code(s): 838, 839, 840

12.6 Drive wheel 3530
12.6.1 Replacing the drive wheel

1. Raise the forks and lift the truck (approx. 100 mm).
2. Disassemble 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.
© TMHE 12 – 8 T Code(s): 838, 839, 840

12.7 Castor wheels 3540
12.7.1 Overview
A
B
C
L M
K J

A Circlip H Screw
B Washer I Spacer
C Screw J Spacer
D Bracket I Warehouse
E Nut L Guard
F Warehouse M Nut
G Circlip
© TMHE 12 – 9 T Code(s): 838, 839, 840

12.7.2 Castor wheel mounting

11
12
13
14
15
21
20
19
18
17
16

11 Nut 17 Screw
12 Steering 18 Washer
13 Spring 19 Bracket
14 Steering 20 Bushing
15 Cradle 21 Shims, max 1mm gap.
16 Screw Add as needed.
© TMHE 12 – 10 T Code(s): 838, 839, 840

12.7.3 Replacing the castor wheel

DANGER!
Risk of crushing since a poorly supported truck could fall down.
1. Secure the truck in a safe manner.
2. Disconnect the truck battery.
3. Unscrew the castor wheel.

4. Refit the castor wheel and its four fastening screws and washers.
5. Connect the battery.
6. Remove the support trestles.
© TMHE 12 – 11 T Code(s): 838, 839, 840

12.7.4 Disassembling the 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.
12.8 Spring replacement
12.8.1 Removing springs

1. Loosen the upper locking nuts.
2. Lift the drive unit so that the springs are released from the upper bracket.
3. Loosen the lower locking nut on the spring that is to be changed.
Note:
The spring is pre-tensioned, take care when loosening the lower locking nut.
12.8.2 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 locking nut and washer.
Use a short sleeve in order to screw the lower locking nut tight whilst
pressing the spring together.
3. Screw down the lower locking nut so that the distance between the edge
of the washer and the top of the screw is 15 mm.
4. Make sure that the springs are sitting correctly in the upper fasteners
when the drive part is lowered.
5. Screw the upper locking nuts tightly.
© TMHE 12 – 12 T Code(s): 838, 839, 840

12.9 Support arm wheel 3550
12.9.1 Overview
Pos. Description
a Screw
b Bracket
c Bogie wheel
d Single wheel
e Shaft
f Circlip
© TMHE 12 – 13 T Code(s): 838, 839, 840

14
13
1 e
e=156 mm
13 14
2 e
14
e=180 mm 25
Pos. Description
13 Shaft
14 Pin
25 Shaft
Pos. Description
1 LWE140/160
2 LWE180/200/250
© TMHE 12 – 14 T Code(s): 838, 839, 840

12.10 Climber wheels
12.10.1 Overview
C
D
G
H
K
I
J

A Screw, K6S 8x12 G Wheel, assy
B Screw, MF6S 8x35 H Wheel bracket
C Sleeve I Shaft
D Climber wheels J Wheels
E Slide pad I Spring pin
F Lock nut M8
© TMHE 12 – 15 T Code(s): 838, 839, 840

© TMHE 12 – 16 T Code(s): 838, 839, 840

Repair manual: Tiller arm 4000 Model(s): LWE140, 160, 180, 200, 250.
13. Tiller arm 4000

13.1 Overview
T
B
E
S
D I
F J
R G
H K
Q
L
P M
N
O
V
© TMHE 13 – 1 T Code(s): 838, 839, 840


A Tiller arm: M Indicator sleeve
B Rubber buffer N Plate
C Cylindrical bolt O Yoke
D Gas strut P Cable clamp
E Circlip Q Screw
F Rubber buffer R Yoke
G Bushing S Screw
H Threaded insert T Cover
I Stop screw U Cover
J Holder V Cable clamp
K Safety sensor B60 W Cable clamp screw
L Shaft
© TMHE 13 – 2 T Code(s): 838, 839, 840

13.2 Removing the tiller arm

2. Remove the cover (T).
3. Unscrew the retaining screws of the yoke (R).
4. Detach the cable clamp (P) by pressing on the clamp with your thumbs
and lifting it upwards. Pull the cable clamp out through the hole in the
steering console.
Note:
Do not try to prise away the cable clamp with a screwdriver.
13.3 Replacing the gas spring

1. Remove the cover (T).
2. Remove the cable clamp retaining screw (W)
3. Unscrew the adjusting screw (Q).
4. Remove the locking mechanism (E) from the gas strut lock shaft (C)
5. Detach the gas strut lock shaft (C).
6. Remove the gas strut.
Note:
Pay attention during assembly and make sure no cables are pinched.
© TMHE 13 – 3 T Code(s): 838, 839, 840

13.4 Replacing the safety sensor
13.4.1 Disassembly
1. Remove the gas strut. See section "13.3 Replacing the gas spring".
2. Unscrew the stop screw (I) of the shaft (L). See figure.
3. Turn the shaft (L) until the back of the indicator sleeve (M) becomes
accessible.
4. Loosen the indicator sleeve (L).
To prevent damage to the sleeve, pry the indicator sleeve loose from both
sides at the same time.
5. Tap out the shaft (L).
Note:
Make sure that the handle does not drop down and damage the cables.
6. Remove the cable clamp retaining screw (W).
7. Remove the sensor retaining screw (S).
8. Detach contact B60 from the sensor (K).
9. Remove the sensor.
13.4.2 Assembly
1. Fit the sensor (K)

2. Attach connector B60 to the sensor.
3. Apply Loctite to the sensor retaining screw (S) or replace it. Fasten the
screw.
4. Fasten the cable clamp retaining screw (W).
Note:
The cable must be routed to the right of the sensor (K), towards the spring
pin.
5. Screw the stop screw (I) into the shaft (L). See figure.
6. Fit the gas spring. See section "13.3 Replacing the gas spring".
7. Check for correct operation of the safety sensor.
© TMHE 13 – 4 T Code(s): 838, 839, 840

13.5 Electrical steering system – 4000
13.5.1 Tiller arm handle C4110
13.5.2 Overview
f i
j
a a
b
e k
c d
© TMHE 13 – 5 T Code(s): 838, 839, 840

Pos. Description
a Cover
b Plug
c Wiring harness
d Cover
e Butterfly switch
f Horn button
g Button "lifting/lowering"
h Display
i Horn button
j Switch "horn"
k Display
l Electronic card "A5"
m Stomach button
n Speed control
© TMHE 13 – 6 T Code(s): 838, 839, 840

13.5.3 Replacing the keypad C9420

Removing the keypad
Detach the keypad and disconnect it from the logic card

Fitting the keypad
Connect the keypad and screw it in position
© TMHE 13 – 7 T Code(s): 838, 839, 840

13.5.4 Replacing the upper cover C4110
Removing the upper cover
Step 1 Step 2
• Remove the keypad. Page 13–7

1: Remove the screws holding the upper cover and keep hold of the upper
cover to prevent damage to the cable to the logic board
2: Disconnect the CAN connection to the logic card
© TMHE 13 – 8 T Code(s): 838, 839, 840

Fitting the upper cover
x5
Step 1 Step 2
2 3
x4
4 1
Step 3 Step 4
1: Connect the CAN bus connection to the logic card

2: Press together the upper and the lower parts, and turn the screws five complete
turns. Start with the left side, and then proceed with the right side.
3. Turn the screws crosswise as depicted below a further four complete turns (a
total of nine turns, which corresponds to 1 Nm).
4. Check that there is no space between the tiller arm and the steering head.
5: Make sure that the control can be moved back and forth without difficulty, and
that the control returns to the neutral position.
If the control shows signs of being difficult to move: Re-adjust the screws
according to step 3.
Fit the keypad. Page 13–7
© TMHE 13 – 9 T Code(s): 838, 839, 840

13.5.5 Replacing the tiller arm handle
Removing the tiller arm handle
• Remove the upper cover. Page 13–8

1: Remove the cable bracket/handle in the tiller arm.
Fitting the tiller arm handle
T=12Nm
1: Fit the handle/cable bracket.

Note: Mount the wiring harness so that it does not get pinched.
• Fit the upper cover. Page 13–9
© TMHE 13 – 10 T Code(s): 838, 839, 840

13.5.6 Replacing the logic card
Removing the logic card
• Remove the upper cover. Page 13–8

Warning!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure you take the necessary steps to prevent static electricity, ESD
protection, before starting work on the steering module.
1: Remove the screws holding the cover to the logic card and carefully lift
away the cover.
Hint: Hold a finger between the cover and the shaft for the speed control
buttons to prevent the speed control assembly from falling down.
2: Pull out the logic card, and pull off the connectors.
© TMHE 13 – 11 T Code(s): 838, 839, 840

Fitting the logic card
Steps 1, 2 Step 3 Step 3
1: Fit the new logic card in place and connect it.

2: Check the cable connection on the logic card and that the connectors are
correctly connected.
3: Fit the cover in place and screw it down. Make sure the conduit entry is
intact and correctly positioned.
• Fit the upper cover. Page 13–9
© TMHE 13 – 12 T Code(s): 838, 839, 840

13.5.7 Checking the handle

Test drive the truck and check the functions of the handle Page 8–55
13.5.8 Update the software

If a new logic card without software has been installed, use TruckCom to
download software and reset the parameters.
See the TruckCom manual.
© TMHE 13 – 13 T Code(s): 838, 839, 840

13.5.9 Replacing the signal button/switch
Step 3 Step 4
• Remove the stomach button Page 13–17

1: Remove the screws to the wire fittings.
2: Remove the connectors to the logic card
3: Remove the horn button, use a screwdriver to carefully prise it off the clip
fasteners.
4: Remove the switch by pulling it straight up.
• Install in reverse order.
© TMHE 13 – 14 T Code(s): 838, 839, 840

13.5.10 Replacing the lift/lower button

1: Remove the speed control
2: Use a screwdriver and carefully press down the button fitting
3: Pull the button straight out, compress the spring when removing it
• Reassemble in reverse order
© TMHE 13 – 15 T Code(s): 838, 839, 840

13.5.11 Replacing the sensilift
Step 1 Step 2

1: Remove the button, use a screwdriver to carefully prise it loose
2: Pull it straight up
• Reassemble in reverse order
© TMHE 13 – 16 T Code(s): 838, 839, 840

13.5.12 Replacing the stomach button
Step 1 Step 1
• Remove the upper cover Page 13–8

1: Remove the screws holding the cover/stomach button over the logic card
and carefully lift away the cover.
Hint: Hold a finger between the cover and the shaft for the speed control
buttons to prevent the speed control assembly from falling down.
Note: The stomach button must not be replaced by itself, the complete cover
and button must be replaced as a unit.
© TMHE 13 – 17 T Code(s): 838, 839, 840

13.5.13 Changing the position of the controls - support arm lift/

fork lift
1. Pry off the lift control buttons using a thin screwdriver and switch the
positions with the rear buttons.
2. Make sure the lips catch when the new buttons are inserted.
3. Connect a PDA or PC and use TruckCom to change parameter 1023 to 2.
4. Start the truck and make sure the change is correct.
© TMHE 13 – 18 T Code(s): 838, 839, 840

Repair manual: Electric components-5000 Model(s): LWE140, 160, 180, 200, 250.
14. Electric components-5000

14.1 Li-ion battery (Hoppecke)
14.1.1 Resetting/restarting the battery

If error codes are generated or the battery lamp does not light with a steady
green glow, the battery can be restarted.
1: Disconnect the battery yoke

Note: the yoke must be removed from the battery.
2: Disconnect the CAN connector X111.

3: Wait until the light goes out.
4: Connect the CAN connector.
5: Wait until the lamp on the battery shows steady green.
6: Reconnect the battery yoke.
14.2 Inspecting the battery

1: Check that a green lamp is lit on the battery. This indicates that
everything is OK.
2: Check the attachment of the brackets.
3: Check electrical connections on the CAN wiring harness.
4: Check the attachment of the battery lock.
5: Check that the covers have been refitted properly.
© TMHE 14 – 1 T Code(s): 838, 839, 840

14.3 Replacing the wiring harness
A
B
X5
C
X21
X60
Pos. Description
A Connector clamp
B Connector, female part
C Bracket
D Connector, male part
Proceed as follows when replacing the wiring harness:

1. When prying the X connectors apart, press in the connector lock (A) of
the female part (B) and pull upwards.
2. Disconnect the female part (B) of the connector from the male part (D).
3. Then disconnect the male part (D) by pulling it downwards.
The bracket (C) remains on the connector panel.
© TMHE 14 – 2 T Code(s): 838, 839, 840

14.3.1 Replacing the transistor regulator wiring harness
Keep the following in mind if it becomes necessary to disconnect the connec-

tor (A) of the transistor regulator:
• First press down on the bracket clamp (B).
• Then lift up the connector lever (C).
© TMHE 14 – 3 T Code(s): 838, 839, 840

14.4 Replacing the transistor regulator

Note:
This action requires access to TruckCom!
D C

2. Cut off the cable ties of the cable duct on the transistor regulator side.
3. Disconnect the connectors (A) from the connector bracket.
4. Undo the screws (D) and move the connector bracket aside.
5. Disconnect all cables and connectors from the transistor regulator.
6. Loosen the fastening nuts (B) of the fixing plate.
7. Remove the transistor regulator.
Angle out the top edge of the fixing plate and turn it in the drive wheel
direction in order to remove it from the truck.
8. Unscrew the transistor regulator from the fixing plate (C).
Assembly is done in reverse.
After installation of the new transistor regulator, the truck will display error
code 2.004.
© TMHE 14 – 4 T Code(s): 838, 839, 840

1. Connect TruckCom.
2. Select “Copy truck configuration”.
Select “Copy configuration to secondary unit: ACT”
14.5 Lift height limitation sensor [B61]
14.5.1 Replacing sensor [B61]
Location of lift height limitation sensor [B61] in the truck

1. Disconnect the truck battery.
2. Disconnect the sensor’s electrical connection (a)
3. Mark (e.g. with tape) the position of the sensor bracket (b).
© TMHE 14 – 5 T Code(s): 838, 839, 840

d
b
c
4. Undo the screws (c) of the sensor bracket (Torx T30) (wrench 9 mm).
5. Remove the bracket together with the sensor to gain access to the two
screws (d).
6. Unscrew the sensor (Torx T20) (wrench 7 mm) and discard the locking
nuts.
7. Screw the new sensor into place with new locking nuts. The screws (d)
should only be tightened enough that the sensor is secured firmly with no
play.
8. Align the bracket with the marking
9. Screw the sensor bracket (b) into place and remove any marking.
10. Connect the sensor’s electrical connection (a).
11. Connect the truck battery.
12. Test the function of the sensor.
13. If necessary, adjust the sensor. See section "14.5.2 Adjusting the sensor
[B61]".
© TMHE 14 – 6 T Code(s): 838, 839, 840

14.5.2 Adjusting the sensor [B61]
1. Undo the screws securing the sensor bracket (Torx T30) (wrench 9 mm)
so that bracket position can be adjusted.
2. Adjust the sensor as high as possible without allowing the forks to run
again the mechanical stop. Slide the brackets upwards or downwards to
find the correct position.
3. Fasten the bracket (Torx T30) (wrench 9 mm).
© TMHE 14 – 7 T Code(s): 838, 839, 840

© TMHE 14 – 8 T Code(s): 838, 839, 840

Repair manual: Hydraulic system 6000 Model(s): LWE140, 160, 180, 200, 250.
15. Hydraulic system 6000

15.1 General
Always take the following safety precautions prior to commencing work on
the truck's hydraulic systems:
• Slowly depressurise system pressure.
• Use paper or a stiff piece of cardboard when checking for possible oil
leaks. Do not use your hand.
• Be careful since the oil in the transmission and hydraulic systems can be
scalding hot.
DANGER!
Risk of burns if hot transmission oil or hydraulic oil gets onto the skin. Allow
the truck to cool down before changing the oil.
© TMHE 15 – 1 T Code(s): 838, 839, 840

15.2 Hydraulic hygiene

Note:
Risk of malfunction.
If impurities get into the hydraulic system, there is a risk of malfunctions in
part or all of the hydraulic system. There is also a risk of severe damage to
components.
For all work on the hydraulic system, the following instructions must be fol-
lowed.
Note:
Use only new and clean oil when refilling the hydraulic oil system. If the oil is
contaminated, the hydraulic components will suffer damage.
15.2.1 Washing
Hydraulic components, including hydraulic hoses and pipes, must be cleaned
with a filtered washing fluid using a method suitable for the components con-
cerned.
The washing fluid must have purity code 19/16/13 in accordance with
ISO4406:1999 or 16/13 in accordance with ISO4406:1987.
Blowing clean with dry filtered air may be done when this is the only practical
method to carry out cleaning.
15.2.2 Packaging
After cleaning, all openings must be sealed with protective plugs. Connecting
surfaces must be protected against handling damage and dirt penetration.
Completely dry components can be packed in plastic bags or boxes with lids.
The packaging (protective plugs, masking, plastic bag, etc.) must not be re-
moved until immediately before the component is to be fitted in a workplace
suitable for handling hydraulic components.
Tape must never be used without cleaning afterwards.
Protective plugs must be stored in plastic bags or boxes with lids until they
are used.
After use, discard the plugs and plastic bags.
15.2.3 Handling
Hydraulic components must be handled and transported with the greatest
care.
Transportation packaging must be used throughout the entire handling chain.
This packaging must be clean and free from dust, etc.
© TMHE 15 – 2 T Code(s): 838, 839, 840

15.2.4 Storage
Hydraulic components must be handled and stored so that:
• no rusting can occur
• dust and dirt particles are shielded out
• no mechanical deformation can occur
15.2.5 Work procedures

When working on the hydraulic system, great cleanliness must be observed
so that no impurities can enter the system.
No work that generates particles may be carried out in the same workplace
or close to where work is being carried out on the hydraulic system.
The service technician must ensure that the components to be used are care-
fully deburred and cleaned.
Couplings for pipe ends or other openings must never be removed until the
part is to be fitted to the receiving component.
Note:
All hydraulic components that have not been cleaned, e.g. pipe couplings and
nipples, must be blown clean before fitting.
© TMHE 15 – 3 T Code(s): 838, 839, 840

15.3 Hydraulic system components for LWE140, LWE160,

LWE180
B
A
Pos. Description
A Pump motor
B Screw
C Pressure limiting valve
D Magnetic valve, fork lowering
E Tank (suitable oil volume 0.8 l)
F Filler pipe
© TMHE 15 – 4 T Code(s): 838, 839, 840

15.4 Hydraulic system components for LWE200 and LWE250
A
B
Pos. Description
A Pump motor
B Screw
C Pressure limiting valve
D Tank (suitable oil volume 0.5 l)
E Filler pipe
F Magnetic valve, fork lowering
© TMHE 15 – 5 T Code(s): 838, 839, 840

15.5 Installing the hose coupling

1. Remove the dust guard.
Use the disassembly tool to remove the dust guard from the female part.
Note:
Foreign objects in the female part could cause damage.
2. Slide on the assembly stopper.
Slide the assembly stopper into position on the male part.
3. Connect the male and female parts by pushing them together.
By turning the male part during assembly, less force is required to
connect the two parts.
Note:
Do not connect the male part unless the assembly stopper has been mounted
since this otherwise could result in unintentional separation.
4. Complete the connection until the assembly stopper has contact with the
female part.
Note:
Check that there is no play between the assembly stopper and the female
part.
5. Try to pull apart the coupling to make sure the male part is properly
locked.
© TMHE 15 – 6 T Code(s): 838, 839, 840

15.6 Hydraulic connections 6230
15.6.1 Quick change connector
Connecting 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.
© TMHE 15 – 7 T Code(s): 838, 839, 840

15.7 Adjusting the pressure limiting valve
1
2
The truck must be able to handle the rated load on the forks.
Place a rated load on the forks and verify that the truck is able to lift it.
If the truck cannot lift the rated load:
Note:
It is not necessary to restore the closing seal after adjustment.
1. a) Pry off the white sealing cap (1) attached to the pressure limiting valve
using a screwdriver. No longer used.
1. b) Scrape away the marking paint sealing the valve.
2. Loosen the locking nut (2) by screwing it anticlockwise.
3. Adjust the adjusting screw (3) clockwise until the truck is able to lift the
load without problems.
4. Screw the locking nut (2) clockwise.
Once the truck manages to lift the rated load, apply an additional 100 kg on
the forks. Verify that the truck cannot lift the load.
If the truck is able to lift 100 kg more than its rated load:
1. a) Pry off the white sealing cap (1) attached to the pressure limiting valve
using a screwdriver.
1. b) Scrape away the marking paint sealing the valve.
2. Loosen the locking nut (2) by screwing it anticlockwise.
3. Screw the adjusting screw (3) anticlockwise until the truck cannot lift the
load.
4. Screw the locking nut (2) clockwise.
© TMHE 15 – 8 T Code(s): 838, 839, 840

15.8 Disassembling the hydraulic unit

Before commencing any work on the hydraulic unit, make sure the forks have
been fully lowered.
2
1
3
1. Detach the hydraulic hose (1); see the quick coupling section 18.5.1 for
more information.
2. Disconnect the motor cables (2) using a wrench, no. 13.
3. Disconnect the lowering valve connector (3).
4. Loosen the hydraulic unit bracket (4) and lift out the unit from the truck.
5. Loosen the screw (5) to be able to disassemble the tank from the motor
and lift the motor away from the tank.
© TMHE 15 – 9 T Code(s): 838, 839, 840

6. Loosen the locking ring (6) attached to the oil strainer (7).
7. Remove and clean the strainer, then reattach it in the correct position.
8. Change the oil and clean the tank.
9. Reassemble everything in reverse order.
© TMHE 15 – 10 T Code(s): 838, 839, 840

15.9 Hydraulic unit tightening torques

The hydraulic unit tightening torques are depicted in the picture below:
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
© TMHE 15 – 11 T Code(s): 838, 839, 840

© TMHE 15 – 12 T Code(s): 838, 839, 840

Repair manual: Mast C7000 Model(s): LWE140, 160, 180, 200, 250.
16. Mast C7000
© TMHE 16 – 1 T Code(s): 838, 839, 840

Repair manual: Mast C7000 Model(s): LWE140, 160, 180, 200, 250.
© TMHE 16 – 2 T Code(s): 838, 839, 840

Repair manual: Peripherals C8000 Model(s): LWE140, 160, 180, 200, 250.
17. Peripherals C8000
© TMHE 17 – 1 T Code(s): 838, 839, 840

Repair manual: Peripherals C8000 Model(s): LWE140, 160, 180, 200, 250.
© TMHE 17 – 2 T Code(s): 838, 839, 840

Repair manual: Accessories Model(s): LWE140, 160, 180, 200, 250.
18. Accessories
18.1 Spider expansion unit
The spider expansion unit, called SEU, allows the main logic card to handle
a greater number of inputs and outputs. The SEU does not have its own truck
controller logic, which means that a defective SEU can be replaced without
the replacement affecting any truck functions.
The SEU is used for modification of the truck to meet special customer re-
quirements. .
Electronic
card
Truck Log
System
Spider
Extra/Customised
Expansion
function(s)
Unit
CAN bus
Pump
controller
CAN service
connector
Motor
Controller
The picture above shows how the SEU is used to allow a greater number of
functions to be controlled via the CAN bus. SEU has a 42-pin, multi-pin con-
tact that manages all inputs, outputs, CAN and power supply signals.
© TMHE 18 – 1 T Code(s): 838, 839, 840

18.2 TLS - Truck log system

See the separate manual that is included with the truck log system.
18.3 ID unit
See the separate manual that is included with the software.
18.4 I_Site
I_Site is a system that collects data from the trucks.
I_Site is available in two different versions:
• I_Site including a DHU/DHU2 and an antenna.
• I_Site including a DHU/DHU2 and an antenna and a collision sensor.
The data handling unit (DHU) receives data from the truck and transfers it to
a central server at a set interval. The data is then accessible to users with an
authorised code via a website. No hardware installation is required at the cus-
tomer site. Communication is via the GSM 900/1800 network for the DHU.
DHU2 is also approved for UMTS FDDI/ VIII 900/ 1900/ 2100 MHz.
Reports can be viewed showing information such as the following:
• Truck usage
• Operator utilisation
• Battery consumption and charging behaviour
• Hour meter readings
If the system includes a collision sensor, the following collision data can be
viewed:
• Operator involved in collision
• Severity of collision
• Error codes generated by a collision
• When the collision occurred and how long the truck had been in use before
the collision
Collision sensitivity and the post-collision resetting procedure can be pro-
grammed separately for each individual truck.
For instructions on installation, configuration, setup and troubleshooting, see
the separate I_Site manual.
© TMHE 18 – 2 T Code(s): 838, 839, 840

18.5 DC/DC converter

The truck can be equipped with a DC/DC converter to supply power to equipment
such as a PC, scanner, etc. The converter on the input side is protected against
polarity reversal, short circuit and thermal overload. The chassis is not live, and
the in/outputs are galvanically separated. The output sits on the E-bar profile.
18.6 Collision sensor

If a collision sensor is installed on the CAN bus, this registers when the truck
bumps against something. If an impact exceeds a certain level, specified by
parameters 105 and 106, this is counted as a collision.
© TMHE 18 – 3 T Code(s): 838, 839, 840

18.7 Built-in battery charger

Note:
If retrofitting the built-in battery charger, TruckCom is required to be able to
set all necessary parameters. TruckCom is not needed if replacing an exist-
ing charger. When installing the charger, torque tighten nuts (A) to max. 1.6
Nm.
If the truck is factory-fitted with a battery, the battery charger is adjusted to
suit the battery.
If the truck is delivered from the factory without a battery, the customer/tech-
nician must set the right parameters based on battery type and size
18.7.1 Technical data
Designation SMCO 24/30

Dimensions, 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
© TMHE 18 – 4 T Code(s): 838, 839, 840

18.7.2 Charging the battery

To start charging, open the battery compartment cover and connect the
charger connector to a wall outlet.
Note:
Prior to commencing charging, switch off the truck and disconnect all other
electrical connections to the truck.
When the truck is charging, the following is indicated on the display:
Main charging
During the charging process, lines appear sequentially from left to right as the
battery is charged. The battery symbol and the OFF button flash.
Equalising charging
Four lines at the left in the display light continuously while four lines on the
right appear sequentially. The battery symbol and the OFF button flash.
Charging completed
The battery capacity value and unit (Ah) appear alternately in the display. The
battery symbol is lit continuously, while the OFF button flashes.
Disconnect the contact from the wall socket once the battery has been
charged. The OFF button then lights continuously. The truck is now ready for
use.
© TMHE 18 – 5 T Code(s): 838, 839, 840

© TMHE 18 – 6 T Code(s): 838, 839, 840

Repair manual: Instructions for disposal Model(s): LWE140, 160, 180, 200, 250.
19. Instructions for disposal

19.1 General
The disposal instructions were developed to support our company's objective
of protecting the environment. By recycling materials, resources can be uti-
lised more efficiently, while reducing emissions.
The instructions below indicate the proper sorting category for the materials
used in the various truck components. To achieve optimum sorting, all com-
ponents should be disassembled to a level corresponding to the sorting cat-
egories.
19.2 Marking of plastics
19.2.1 General marking of products and packaging

Markings on plastics consist of three arrows, a number and usually also a
designation of the plastic material used. This example shows 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 – Other
© TMHE 19 – 1 T Code(s): 838, 839, 840

19.2.2 Marking according to the manufacturer’s standards

Standards: 58-02-001, 58-02-003 and 58-02-004.
A few examples of markings are given here. For more information, please re-
fer to the standards above.
The product material and trade name of each item are indicated between ar-
rows. 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 carbonate
plastic:
>ABS+PC<
Filled or reinforced materials
Polypropylene with 30% mineral powder:
>PP-MD30<
© TMHE 19 – 2 T Code(s): 838, 839, 840

19.3 Pressure vessels

Pressure vessels sent for recycling/destruction must have been depressur-
ised beforehand and, if possible, opened.
Examples of existing pressure vessels are gas dampers and accumulators
used in hydraulic systems.
19.3.1 Gas dampers

WARNING!
Gas dampers have extremely high internal pressure. To prevent injury, al-
ways follow the instructions of the manufacturer.
Wear safety goggles when disassembling springs.
To allow the gas to escape, only open and disassemble gas dampers as rec-
ommended 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 bottom.

2: Drill or cut a hole in the recess at the piston rod end.
© TMHE 19 – 3 T Code(s): 838, 839, 840

19.4 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)
• Wires
• Hazardous waste
• Complex materials - large amounts in several categories but non-combus-
tible and not hazardous
• Combustible material, including small plastic and rubber parts
• Please return batteries to the manufacturer.
Component Category Comments
Chassis Iron/steel
Iron/steel
Inspection covers, sheet metal
Handle: >ABS<
Sort according to the material mark-
Inspection covers, plastic Plastic
ing
Forks and frames Iron/steel
Iron/steel, including any gas damp-
Operator's platforms ers Be sure to depressurise dampers
Mats, cushions: combustible
Roofs and overhead guards Iron/steel
Iron/steel
Gates and operator protective
Plastic handles: >PA<
devices
Crush protectors: >PMMA<
Oil
Hydraulic hoses: Oil-polluted mate-
Ensure that the system has been
rial
depressurised.
Oil tank: >PP<
Hydraulic unit Carefully drain all oil.
Motor, valves: Electronic compo-
Any accumulators should be emp-
nents
tied of gas and if possible opened.
Pump: Iron/steel
Accumulator: Iron/steel
Motor: Electronic components
Travel motors Wires
Parking brake: Hazardous waste
Iron/steel Carefully drain all oil
Drive gears
Oil Hazardous waste
If the tread and hub cannot be sepa-
Tread: Plastic according to marking
Wheels rated, then sort the wheel as com-
Hub: Iron/steel
plex material
© TMHE 19 – 4 T Code(s): 838, 839, 840

Component Category Comments

Electronic components
Tiller arms Wires Be sure to depressurise dampers
Iron/steel, also gas dampers
PCBs, transistor regulators, Expan-
sion unit SEU, contactors: Electronic
Electrical system Hazardous waste
components
Wires
Small batteries Hazardous waste
Hazardous waste.
Because of the chemical content in
fluorescent tubes, do not break
Fluorescent tubes them.
Obsolete fluorescent tubes must be
packaged and transported according
to local regulations.
Mast beams, rollers, cylinders,
hydraulic pipes: Iron/steel
Hydraulic hoses: Oil-polluted ()
Wires Oil-polluted components should be
Mast
Sensors/switches: Electronic com- handled as hazardous waste
ponents
Plastic components: According to
marking or as combustible waste
Electronic components
Chargers and connectors
Wires
© TMHE 19 – 5 T Code(s): 838, 839, 840

© TMHE 19 – 6 T Code(s): 838, 839, 840

Repair manual: Electrical components and wiring diagrams Model(s): LWE140, 160, 180, 200, 250.
20. Electrical components and wiring diagrams

20.1 Electric components
The table below shows a summary of the major electric components of this
truck.
Symbol Description Function Remarks

A5 Logic card Tiller arm logic card
A30 Battery charger On-board battery charger Option
B1 Temperature Drive motor temperature sensor

sensor
B11 Pulse transformer Speed sensor
B60 Inductive switch Mechanical activation of the
brake
B61 Inductive switch Lift height limitation
B90 Collision sensor Option
F1 Fuse Main fuse 150 A

F50 Fuse Operating circuit A5 7.5 A
F51 Fuse Operating circuit T1 7.5 A
F52 Fuse Optional equipment Option
G1 Battery 24 V
G10 Battery Li-ion 24 V
K110 Data Handling Unit Data handling unit Option

(DHU)
M1 Motor Truck traction

M3 Motor Pump motor
P4 Horn
P6 Display Truck function display
Q1 Electromechanical Mechanical brake

brake
Q4 Solenoid valve Fork lowering
© TMHE 20 – 1 T Code(s): 838, 839, 840

Q10 Contactor Main contactor

Q25 Contactor Pump motor
S18 Switch Horn button

S21 Switch Emergency switch off
S206 Switch Turtle function Option
S111 Switch Option button Option
S223 Keypad/Smart card Login with PIN code
T1 Transistor
regulator
T7/T8 DC/DC converter T7=24V/12V Option
T8=24V/24V
T20 Antenna Antenna, T.W.I.S
X1 Connector Battery
X21 Port DC/DC converter Option
X40 Port CAN communication (Extra I/O)
X41 Port CAN communication (External)
X65 Port Tiller arm:
© TMHE 20 – 2 T Code(s): 838, 839, 840

P6
S113 S116
S206 S115
S111 S114
S18:1 S18:2
S223
B60
X41
© TMHE 20 – 3 T Code(s): 838, 839, 840

S21
X1
G1
T7/T8
F50, F51, F52

F1 Q25
Q10
X21
X40
B90
T1
A30
© TMHE 20 – 4 T Code(s): 838, 839, 840

20.2 Wiring diagram
20.2.1 List of symbols
Table 1: List of symbols

Symbol Description Symbol Description
Truck battery. Emergency switch off NC
Fuse Switch, pressure (weight)

operated
Horn Sensor, inductive NO
Motor, AC1 Sensor, inductive NC
Contactor Variable resistance

(potentiometer)
Brake coil (normally applied) Push switch NO
Coil for the hydraulic solenoid Multi-pin connector

valve
Pressure sensor, analogue NO = Normally open

P NC = Normally closed
1. AC = Alternating Current
© TMHE 20 – 5 T Code(s): 838, 839, 840

20.2.2 General wiring 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
0VDC T7/T8
40
CAN HIGH/LOW 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 CAN HIGH/LOW Hall SAFETY CAN HIGH/LOW
20 (1) +24V DC REVERSE RED (+) POS. VOLT.
40 (2) 0V DC 20 (X3) +24V DC A2:S19 BLACK (-) NEG. VOLT.
Hall FORK
OPTION
40 (X3) 0V DC
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
S206 K110
(X2:1/3) TURTLE CAN HIGH (X3) 119 ANTENNA
CAN LOW (X3) 120 OPTION
KEYBOARD /
SMART CARD (X11) (X12)
DISPLAY
S223 P6
© TMHE 20 – 6 T Code(s): 838, 839, 840

20.2.3 Wiring diagram
1/10 PROD I
236994
© TMHE 20 – 7 T Code(s): 838, 839, 840

2/10 PROD I
236994
© TMHE 20 – 8 T Code(s): 838, 839, 840

3/10 PROD I
236994
© TMHE 20 – 9 T Code(s): 838, 839, 840

4/10 PROD I
236994
© TMHE 20 – 10 T Code(s): 838, 839, 840

5/10 PROD I
236994
© TMHE 20 – 11 T Code(s): 838, 839, 840

6/10 PROD I
236994
© TMHE 20 – 12 T Code(s): 838, 839, 840

7/10 PROD I
236994
© TMHE 20 – 13 T Code(s): 838, 839, 840

8/10 PROD I
236994
© TMHE 20 – 14 T Code(s): 838, 839, 840

9/10 PROD I
236994
© TMHE 20 – 15 T Code(s): 838, 839, 840

10/10 PROD I
236994
© TMHE 20 – 16 T Code(s): 838, 839, 840

Repair manual: Hydraulics chart Model(s): LWE140, 160, 180, 200, 250.
21. Hydraulics chart

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, fork lowering
C Flow regulator valve
D Air filter
E Filter
F Pump
M3 Pump motor
G Pressure limiting valve, max. 230 Bar
H Non-return valve
T Tank
© TMHE 21 – 1 T Code(s): 838, 839, 840

Repair manual: Hydraulics chart Model(s): LWE140, 160, 180, 200, 250.
© TMHE 21 – 2 T Code(s): 838, 839, 840

Repair manual: Tools Model(s): LWE140, 160, 180, 200, 250.
22. Tools
22.1 MQS contacts
Tools Number Use

257841 MQS Basic toolbox.
The box contains:

1 set pliers with tools
25 x splice sleeves 0.5-1.5 mm2
2x complete 2, 3, 4, 6, 8 and 12-pin
connectors (male and female) with
prewired cables and splicing sleeves.
Please use to replace damaged
connectors on the truck.
© TMHE 22 – 1 T Code(s): 838, 839, 840

Tools Number Use

257842 MQS refill box.
Use to refill the “MQS 257843
Complete toolbox”.
The refill box contains:

200 x sleeves 0.2-0.5 mm2
200 x sleeves SWS 0.2-0.5 mm2
400 x sleeves SWS 0.5-0.75 mm2
100 x sleeves S"Clean body" 0.5-0.75
mm2
200 x pins SWS 0.2-0.5 mm2
400 x pins SWS 0.5-0.75 mm2
1200 x seals
200x blind plugs
257843 MQS Complete 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
Puller for 2, 3, 4, 6, 8 and 12-pin male

and female connectors.
© TMHE 22 – 2 T Code(s): 838, 839, 840

22.2 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 Use

151080 (PT) Removal tool for pins/
sleeves
213296 (JPT) Removal tool for pins/

sleeves
213298 (MPT) Removal tool for pins/

sleeves
1=163787 (JPT) Crimping tool (sleeves only)

2=163788 (JPT)
1=213336 (MPT)
2=213337 (MPT)
1
2
1=213336 (JPT) Crimping tool for fitting pins
2=213549 (JPT) For 0.5–2.5 mm2
1
2
© TMHE 22 – 3 T Code(s): 838, 839, 840

22.2.1 AMP connectors, Multilock series 040
Figure Number Use

213130 Pin removal tool
213129 Crimping tool for pins
22.3 Molex connectors
16
9
8
1
Figure Number Use

156937 Crimping tool for pins
156936 Crimping tool for fitting

sleeves/pins
© TMHE 22 – 4 T Code(s): 838, 839, 840

22.4 Grease guns
Figure Number Use

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-handed grease gun with angled

fif
discharge pipe and nozzle.
755152 Two-handed grease gun with hose

and nozzle.
755145 Lubricating hose 450 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 necked nipples. Fits grease
guns with hose and discharge pipe.
© TMHE 22 – 5 T Code(s): 838, 839, 840

22.5 Other tools
Figure Number Use

7516708 Service key (CAN)
1=7521083
1 2=163793
Service instrument
2 (CASTOR USB)
for programming
1=163793 Service instrument for

2=163792 program changes
© TMHE 22 – 6 T Code(s): 838, 839, 840

Figure Number Use

08-13022 Drive gear puller
© TMHE 22 – 7 T Code(s): 838, 839, 840

© TMHE 22 – 8 T Code(s): 838, 839, 840

Repair manual: Oil and grease specification Model(s): LWE140, 160, 180, 200, 250.
23. Oil and grease specification

23.1 General tightening torques
Millimetre threads M3 to M24. The following applies in the case of good con-
ditions, e.g. steel against steel.
Galvanised, Untreated,
not oiled screws oiled screws
Strength class: Strength class:
Dimension
8.8 10.9 12.9 8.8 10.9 12.9
1.1 1.6 2.0 M3 1, 2 1.7 2.1
2.8 3.8 4.7 M4 2.9 4.0 4.9
5.5 7.7 9.3 M5 5.7 8.1 9.7
9.5 13 16 M6 9.8 14 17
23 32 38 M8 24 33 40
45 62 76 M10 47 65 79
78 109 130 M12 81 114 136
123 174 208 M14 128 181 217
189 266 320 M16 197 277 333
370 519 623 M20 385 541 649
638 898 1075 M24 665 935 1120
Tightening torque ‘T’ (Nm)

Note:
Experience has shown that if the torque wrench is adjusted to the values for untreated
screws, the correct torque value for galvanised screws will also be obtained. Do not
tighten more than the values indicated in the table, otherwise the screws can be de-
stroyed.
© TMHE 23 – 1 T Code(s): 838, 839, 840

Repair manual: Oil and grease specification Model(s): LWE140, 160, 180, 200, 250.
23.2 Oil and grease specification
Specification Use
Lubricant type
> -15°C < -15°C
S213366 S213366
A Grease Bearings and bushes
Q8 Rubens WB Q8 Rubens WB
Synthetic hypoid gear oil
C Transmission oil SAE 75W-90 Gears
Class API-GL5
D Grease See table below See table below Chains
Grafloscon Grafloscon
E Grease Gear ring
A-G1 (Klüber) A-G1 (Klüber)
F Grease Gletmo 805 Gletmo 805 Beams, rib
F Grease Rembrandt EP2 Rembrandt EP2 Beams, flanges
Castrol Spheerol LC2
G Grease Steering bearings
Castrol Tribol 4020/460-2
H Grease Klüberplex BEM 34-132 Steer axle/steering damper
Ambient
Pos. Viscosity class Use
temperature
ISO VG 32
B 0 °C-40 °C ISO 6743-4 category HM Hydraulic system
DIN 51524 part 2 = HLP
ISO VG 27.5
B -35 °C-40 °C ISO 6743-4 category HV Hydraulic system
DIN 51524 part 3 = HVLP
Ambient
Pos. Viscosity class Recommended products*
temperature
> -40°C
D VG 15 Klüberoil 4UH 1-15, Klüber Lubrication
< -30°C
> -30°C Klüberoil 4UH 1-68N, Klüber Lubrication
D VG 68
< +5°C Anticorit LBO 160 TT, Fuchs DEA
Klüberoil 4UH 1-150N, Klüber Lubrication
> +5°C
D VG 150 Anticorit LBO 160, Fuchs DEA
< +45°C Rexoil, Rexnord Kette
> +45°C
D VG 220 Klüberoil 4UH 1-220N, Klüber Lubrication
< +80°C
* Equivalent products from another manufacturer may be used.
© TMHE 23 – 2 T Code(s): 838, 839, 840

Repair manual: Technical data Model(s): LWE140, 160, 180, 200, 250.
24. Technical data

24.1 LWE140, LWE160, LWE180, LWE200, LWE250
Model LWE140, LWE200,

LWE160, LWE250
LWE180
Truck traction
Type Iskra AML7108 Iskra AML7109
Power, kW 1.0 1.5
Duty cycle S2-60 min S2-60 min
Weight, kg 9.0 10.5
Brakes
Type Warner PK10 Warner PK10
Braking force, Nm 15 15
Power, W 51/13 51/13
Resistance, coil, Ω 10.5-12.0 10.5-12.0
Nominal gap in actuated position, 0.2-0.55 0.2-0.55
mm
Minimum thickness of brake disc, 7.9 7.9
mm
Thickness of new brake disc, mm 8.2 8.2
Transmission/gear mechanism
Oil volume, litres 0.8 0.8
Oil type Synthetic Synthetic
Normal temperature, <-15°C API GL-5 API GL-5
SAE 75W-90 SAE 75W-90
© TMHE 24 – 1 T Code(s): 838, 839, 840


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, wheel bolts, 81±19 81±19
Nm
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/castor wheel, mm 85 85
Axle pressure without load, kg 150 150
Axle pressure at rated load, kg 150 150
Hydraulic system
Power, kW 1 1.4
Min. 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, 135-160, 165-190, 205-230
150-175
Pump flow, litres/minute 4.5-6.0 6.0-10.0
Usable tank volume, litres 0.5 0.5
Oil type Hydraulic oil Hydraulic oil
Normal temperature ISO-HM32 ISO-HM32
< -15oC ISO-HV32 ISO-HV32
Fuses
Drive motor circuit, A 125 125
Pump motor circuit, A 125 125
Control circuit, A 7.5 7.5
© TMHE 24 – 2 T Code(s): 838, 839, 840


LWE160, LWE250
LWE180
Battery compartment, Batteries
Weight, kg 120-175, 209-285,
120-235, 209-285
180-285
Truck travel speeds
Unloaded, km/h 6.0 6.0
Unloaded, m/s 1.7 1.7
With rated load, km/h 6.0 6.0
With rated load, m/s 1.7 1.7
Lifting/lowering speed
Lifting 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
Gradient capability
With rated load, % 8, 8, 9 9, 8
Dimensions
Short 1628 -
Medium 1685 1685
Long 1735 1735
Lift height 205 205
Weight
Truck without battery, min/max 280-300, 310-405,
280-310, 310-405
310-405
© TMHE 24 – 3 T Code(s): 838, 839, 840

© TMHE 24 – 4 T Code(s): 838, 839, 840

stronger together
TOYOTA MATERIAL HANDLING EUROPE, MANAGING THE TOYOTA AND BT MATERIALS HANDLING BRANDS IN EUROPE.

LWE160

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Repair manual 7588852-040

LWE140, 160, 180, 200, 250.

www.toyota-forklifts.eu stronger together

© TMHE T Code(s): 838, 839, 840

© TMHE 1– 1 T Code(s): 838, 839, 840

5.3 Service parameters, travel functions ......................................................... 5–17

© TMHE 1– 2 T Code(s): 838, 839, 840

7.2.6 Cleaning the motor compartment ................................................... 7–2

© TMHE 1– 3 T Code(s): 838, 839, 840

10.6 Installing the temperature sensor ............................................................ 10–7

© TMHE 1– 4 T Code(s): 838, 839, 840

13.5.3 Replacing the keypad C9420 ..................................................... 13–7

© TMHE 1– 5 T Code(s): 838, 839, 840

18.5 DC/DC converter ..................................................................................... 18–3

© TMHE 1– 6 T Code(s): 838, 839, 840

© TMHE 2– 1 T Code(s): 838, 839, 840

2.2 Warning levels and symbols

© TMHE 2– 2 T Code(s): 838, 839, 840

Symbol Measure Symbol Measure

Visual inspection of condi-

Check of fluid level and Check that bolts, nuts, etc.

Listening for noise. Lubrication, application.

Check of functions. Calibration

© TMHE 2– 3 T Code(s): 838, 839, 840

Symbol Measure Symbol Measure

An example of another type of pictogram is “Cut cable ties”:

© TMHE 2– 4 T Code(s): 838, 839, 840

3. General safety rules

3.1 Work safety

© TMHE 3– 1 T Code(s): 838, 839, 840

© TMHE 3– 2 T Code(s): 838, 839, 840

3.2 Electrical system

© TMHE 3– 3 T Code(s): 838, 839, 840

3.3 Safe lifting

© TMHE 3– 4 T Code(s): 838, 839, 840

3.4 Truck modifications

© TMHE 3– 5 T Code(s): 838, 839, 840

© TMHE 3– 6 T Code(s): 838, 839, 840

4. Operation and connection sequences

© TMHE 4– 1 T Code(s): 838, 839, 840

Symbols on keypad and display

Battery charge as a percentage

© TMHE 4– 2 T Code(s): 838, 839, 840

4.1 Battery is connected

Event Connection of battery

Action(s) Connect the truck battery [G1]

Influencing Main power fuses OK [F1]

Resulting The status LED for the transistor regulator lights

4.2 Login via keypad

© TMHE 4– 3 T Code(s): 838, 839, 840

4.3 Tiller arm lowered for driving

Event Tiller arm lowered for driving

Action(s) Lower tiller arm

Influencing elements Tiller arm sensor in drive position [B60].

4.4 Driving in fork direction

Event Driving in fork direction

Action(s) Turn the speed control in the fork direction.

© TMHE 4– 4 T Code(s): 838, 839, 840

4.5 Driving in the drive wheel direction

Event Driving in the drive wheel direction