BT Pallet Truck LWE140 LWE160 LWE180 LWE200 LWE250 Repair Manual 258944-040 - PDF DOWNLOAD

Repair Manual

en

LWE140, LWE160, LWE180, LWE200, LWE250 Valid from serial number: 6053221-

Order number: 258944-040 Issued: 2009-10-05 TP

© BT

Document revisions:

Issue date

Order number

Changes

2008-08-25

258944-040

Completely new issue.

2009-04-17

258944-040

Update

2009-10-05

258944-040

Chapter 4.4 New table and amendments to text in the chapter Chapter 5.3 Measures added Chapter 6 amendments to text and values Chapter 7 amendments to text and values Chapter "10.4 Tightening torque drive motor" added Chapter 16 New descriptions related to the repair of the tiller arm Chapter "17.3 Lift height limit sensor" added Chapter 18 New text related to hygiene when working on hydraulics Chapter "18.8 Tightening torque hydraulic unit" added Various minor corrections throughout entire document

This manual covers following truck models:

T-code

Model

Serial number

838

LWE140

6053221-

838

LWE160

6053221-

838

LWE180

6053221-

839

LWE200

6053221-

840

LWE250

6053221-

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

Table of contents Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

1 – Table of contents 2 – General introduction .........................................................................

2.1 How to use the manual...................................................................

2.2 Warning symbols ...........................................................................

2.3 Pictogram.......................................................................................

2.3.1 Screws/nuts .....................................................................

2-1 2-1 2-2 2-2 2-2

3 – General safety rules ..........................................................................

3.1 Safety while working ......................................................................

3.2 Electrical system ............................................................................

3.3 Safe lifting ......................................................................................

3-1 3-1 3-2 3-3

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

© BT

5 – Maintenance .......................................................................................

5.1 General ..........................................................................................

5.2 Service intervals.............................................................................

5.3 Maintenance chart .........................................................................

5-1 5-1 5-1 5-2

6 – Functions and parameters ................................................................

6.1 General ..........................................................................................

6.2 Function description.......................................................................

Symbols on key pads and display ...................................

6.3 Principle functions..........................................................................

6.4 Timer..............................................................................................

6-1 6-1 6-1 6-2 6-3 6-8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

1– 1

Table of contents T-code 838, 839, 840

Valid from serial number 60532216.5

Date 2009-10-05

Order number 258944-040

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

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

8.1 General ..........................................................................................

8.2 Disassemble the drive unit from the fork frame ..............................

8.3 Removing the platform ...................................................................

8.4 Change of damper for castor cradle...............................................

8.5 Changing the springs and cylinder for the castor cradle ................

8-1 8-1 8-2 8-3 8-5 8-5

9 – Fork frame 0380 ................................................................................. 9-1 9.1 Components .................................................................................. 9-1 10 – Electrical drive motor 1700 ...........................................................

10.1 Components ................................................................................

10.2 Remove motor from truck.............................................................

10.3 Fitting the tempreature sensor .....................................................

10.4 Tightening torque Drive motor......................................................

10.5 Cleaning.......................................................................................

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10-1 10-1 10-2 10-3 10-4 10-5

© BT

Table of contents Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

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

11.1 General ........................................................................................

11.2 Components ................................................................................

11.3 Remove the gear from the truck...................................................

11-1 11-1 11-1 11-2

12 – Brake 3180 ...................................................................................... 12-1 12.1 Components ................................................................................ 12-1 12.2 Release of brakes ........................................................................ 12-2 13 – Drive wheel 3530 ............................................................................ 13-1 13.1 Changing drive wheel................................................................... 13-1 14 – Castor wheel 3540 .........................................................................

14.1 Components ................................................................................

14.2 Castor wheel mounting ................................................................

14.3 Changing castor wheel.................................................................

14.4 Changing castor wheel cradle......................................................

14.5 Changing springs .........................................................................

14.5.1 Removing springs ..........................................................

14.5.2 Fitting the spring ............................................................

14-1 14-1 14-2 14-3 14-3 14-3 14-3 14-3

15 – Fork Wheel 3550 ............................................................................ 15-1 15.1 Changing climber wheel............................................................... 15-1 15.2 Support arm wheel 3550 .............................................................. 15-2

© BT

16 – Tiller arm 4000 ...............................................................................

16.1 Components in tiller arm ..............................................................

16.2 Removing tiller arm ......................................................................

16.3 Changing gas suspension............................................................

16.4 Changing the safety sensor .........................................................

16.4.1 Dismantling ....................................................................

16.4.2 Assembly .......................................................................

16.5 Components in tiller arm handle...................................................

16.5.1 Removing the tiller arm handle ......................................

16.5.2 Replacing the logic card ................................................

16.5.3 Changing signal button/switch .......................................

16.5.4 Changing raising/lowering button. .................................

16.5.5 Changing push button ...................................................

16.5.6 Changing the lifting control lever – from front to back ...

16.5.7 Changing a switch for safety reversing ..........................

16-1 16-1 16-2 16-2 16-3 16-3 16-3 16-4 16-5 16-5 16-6 16-7 16-7 16-8 16-9

17 – Electrical components ..................................................................

17.1 Changing wiring harness..............................................................

17.1.1 Changing the wiring harness to the transistor regulator 17.2 Replacing the transistor regulator ................................................

17.3 Lift height limit sensor [B61] .........................................................

17.3.1 Replacing sensor [B61] .................................................

17.3.2 Adjusting sensor [B61] ...................................................

17-1 17-1 17-2 17-3 17-4 17-4 17-5

18 – Hydraulic system 6000 ..................................................................

18.1 General ........................................................................................

18.2 Hygiene when working on hydraulics ...........................................

18.2.1 Washing .........................................................................

18-1 18-1 18-2 18-2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

1– 3

Table of contents T-code 838, 839, 840

Valid from serial number 6053221-

18.3 18.4 18.5 18.6

18.7 18.8 18.9

Date 2009-10-05

Order number 258944-040

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

19 – Accessories ...................................................................................

19.1 Spider expansion unit ..................................................................

19.2 TLS - Truck log system ................................................................

19.3 ID unit...........................................................................................

19.4 Toyota Wireless Information System T.W.I.S. .............................

19.5 Intergrated battery charger ..........................................................

19.5.1 Technical data ...............................................................

19.5.2 Battery charging ............................................................

Main charge ...................................................................

Uneven charging ...........................................................

Charging complete ........................................................

19-1 19-1 19-2 19-2 19-2 19-3 19-3 19-4 19-4 19-4 19-4

20 – Appendix ........................................................................................ 20-1 20.1 General ........................................................................................ 20-1 21 – Technical data ............................................................................... 21-1 21.1 LWE140, LWE160, LWE180, LWE200, LWE250 ........................ 21-1 22 – General tightening torques ........................................................... 22-1 22.1 Galvanised, non-oiled bolts.......................................................... 22-1 22.2 Untreated, oiled bolts ................................................................... 22-1 23- Tools ................................................................................................

23.1 MQS connectors ..........................................................................

23.2 AMP connectors...........................................................................

23.2.1 AMP Connectors, 040 series .........................................

23.3 Molex connectors.........................................................................

23.4 Grease guns ................................................................................

23.5 Other tools ...................................................................................

23-1 23-1 23-3 23-4 23-4 23-5 23-6

24 – Oil and grease specification ......................................................... 24-1 24.1 Lubrication schedule .................................................................... 24-2 25 – Electrical components and electrical diagram ........................... 25-1 25.1 Electrical components.................................................................. 25-1

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Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Table of contents Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

25.2

T-code 838, 839, 840

Electrical diagram ........................................................................

25.2.1 Index of symbols ............................................................

25.2.2 Overview diagram ..........................................................

25.2.3 Electrical diagram ..........................................................

25-5 25-5 25-6 25-7

26 – Hydraulic diagram ......................................................................... 26-1 27 – Destruction instructions ...............................................................

27.1 General ........................................................................................

27.2 Marking of plastics .......................................................................

27.2.1 General marking of products and packaging material ...

27.2.2 Marking according to BT Standard ................................

Abbreviations .................................................................

Marking examples .........................................................

27.3 Pressure vessels..........................................................................

27.3.1 Gas dampers .................................................................

27.4 Sorting categories ........................................................................

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

27-1 27-1 27-1 27-1 27-2 27-2 27-2 27-3 27-3 27-4

1– 5

Table of contents T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

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Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

General introduction How to use the manual Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

2 – General introduction 2.1 How to use the manual The service manual is divided into chapters containing the following information: • Functions and parameters – This chapter contains a basic description of the main functions of the truck and the control system parameters.

• Installation and initial operation – This chapter describes the work that needs to be done before the truck is used for the first time.

• Maintenance – This chapter contains a general periodic maintenance schedule and a detailed description of the maintenance to be carried out.

• Troubleshooting – This chapter describes the error codes that appear in the display when the truck completely or partly stops working. The chapter also describes the reason why the errors occur and suggested remedies.

• Step by step – This chapter describes the various parts of the truck, for example the hydraulic system, including what the parts look like and the service activities that need to be carried out. The various descriptions are organised according to BT's C-code system.

• Appendixes – The appendixes contain: - instructions for disposal - information about electrical components and wiring diagrams - hydraulics diagrams - list of required tools - information about general tightening torques - oil and grease specifications - Technical data.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

2– 1

General introduction Warning symbols T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

2.2 Warning symbols The following warning symbols are used in the service manual: DANGER! The word DANGER! means there is a risk of accident potentially leading to death or serious injury and material loss or damage. Always accompanied by the warning symbol.

WARNING! The word WARNING! means that there are components sensitive for electro-static discharges.

Follow applicable ESD-routines to protect the device.

NOTE! The word NOTE means there is a risk of material loss or damage if the instructions are not followed. Also used to draw attention to a nonstandard torque.

2.3 Pictogram 2.3.1 Screws/nuts Wherever possible, pictograms have been used to describe certain working operations.

Pictograms are primarily used for operations that require loosening or tightening of screws:

×n s mm

The pictograms contain information about the screw head type and have arrows that show if the screw should be loosened or tightened.

Text beneath the pictogram provides additional information about 's': tool dimension, 'n': number of screws and, where necessary, 'T': recommended tightening torque.

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Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

General safety rules Safety while working Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

3 – General safety rules Only personnel trained in servicing and repairing this type of truck are authorised to carry out service and repair activities.

3.1 Safety while working To ensure that you work safely and to prevent accidents while working on a truck, remember the following: • keep the area where servicing activities are performed clean. Oil or water will make the floor slippery.

• use the correct working position. Service activities often involve kneeling or bending forward. Try sitting on a toolbox, for example, to relieve the strain on your knees and back.

• loose articles and jewellery may become trapped in the moving parts of the truck. So never wear loose articles or jewellery while working on the truck.

• use the correct tools for the work you are carrying out.

• keep all tools well maintained.

• store and transport old oil according to applicable local regulations.

• do not flush solvents, etc. down the drain unless they are intended to be disposed of in this way.

Follow the local disposal regulations.

• heated paint gives off harmful gases. So use sanding or a paint stripper to remove the paint at least 100 mm around an area where any welding/grinding is to take place.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

3– 1

General safety rules Electrical system T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

3.2 Electrical system When working on the electrical system of the truck, remember the following: • a short circuit may occur if metal objects come into contact with live connections. This can result in burns. So remove watches, rings and other metal jewellery before starting work.

• always use insulated tools while working on the electrical system.

• always switch off the truck's power supply before opening the hoods to the drive assembly and the electrical system.

• disconnect the battery when using electric welding equipment. The welding current may damage the battery.

• always remove the battery plug when carrying out maintenance on the truck, unless the instructions in this service manual state otherwise.

• blow electric motors clean using compressed air.

• clean electrical panels, electronic cards, connectors, contactors, solenoid valves, etc. with a moist cloth and a cleaning agent that will not damage the part.

NOTE! Risk of short-circuiting that may damage electrical components.

Do not break the warranty seal on the electronic cards.

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LWE140, LWE160, LWE180, LWE200, LWE250

© BT

General safety rules Safe lifting Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

3.3 Safe lifting

All lifting must be carried out on a flat, nonslip and stable surface.

Asphalt floors must be avoided if possible.

• To prevent the truck moving while it is being lifted, it must not be 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 wheel must be chocked to stop the truck 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 should be used for a well-balanced lift.

• Ensure the area where you place the jack is clean and free of oil and grease.

• Ensure there is no grease or oil on your hands or the jack lever.

• Use the lever supplied with the jack. If the lever is too short, it will require more effort than is necessary. If the lever is too long there is a risk that the jack will be overloaded.

DANGER! Risk of crushing – a poorly chocked truck may fall.

•

© BT

Never work under a truck that is not blocked with supports or secured by a lifting device.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

3– 3

General safety rules Safe lifting T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

• Place supports: - as close to the raised part of the chassis as possible to reduce the falling height if the truck tips over - so that the truck cannot roll.

• Never place a support under the jack to increase the lifting height.

• Never work under a lifted truck without appropriate supports.

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LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Installation General Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

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

4.2 Battery installation 4.2.1 Battery installation safety Remember the following safety regulations before you begin working with the battery: • Always use pprotective equipment to protect the eyes, face and skin when you are inspecting, handling or filling batteries.

DANGER! Battery acid causes burns. If your skin or clothing comes into contact with battery acid, rinse the area immediately with cold water. If your face or eyes come into contact with battery acid, rinse the area with cold water and seek immediate medical attention.

• Ensure that there is a shower and an eye bath nearby in case an accident occurs.

• A battery emits explosive gases. Never use naked flames or anything else that could cause sparks close to a battery.

• Do not put tools or other metal objects on the battery. This can lead to a short circuit or explosion.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

4– 1

Installation Battery installation T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

4.2.2 Install battery The battery that is to be installed in the truck must be of the right size. A battery that is too small in terms of size and weight can seriously affect the truck's braking ability and stability when lifting. See the truck's data plate for correct information about the battery.

1. Lift the battery into place using an approved lifting device and a suitable battery yoke or lifting straps.

DANGER! The battery may fall when the lifting device is loosened if it has not been secured with an axle stand or other similar suspension gear of the right height. Check the height of your suspension gear before loosening the lifting yoke.

2. Check the electrolyte level in the battery. This should normally be 10-15 mm above the cell plates.

3. Connect the battery cables/battery sleeve.

DANGER! Always check that you have the right polarity when connecting the battery cables. Compare the markings on the cables with the markings on the battery terminals. A wrongly connected battery may cause a short circuit.

4. Close the battery lid.

5. Put the battery front partition back.

6. Check or enter the parameters for the battery and battery charger.

See the section Adjusting battery and battery charger parameters in this chapter.

7. Carry out a function test on the truck and check that the lift height limit sensor is correctly set before using the truck. See section “17.3.2 Adjusting sensor [B61]”.

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LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Installation Programming PIN codes Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

4.3 Programming PIN codes A majority of PIN codes can be made available by activating the socalled block. Block 0 (zero) is activated as standard, which means that 3 driver profiles can be used from the start. Activating the second block makes all PIN codes for that block accessible. If all 10 blocks are activated, 10 PIN codes become available for the driver profile.

The truck programme stores a standard set PIN code according to the table “Standard assignment of PIN codes”. These PIN codes may be changed to a chosen value, but PIN codes that exist for other driver profiles should be avoided.

Carry out the following to start the programming: 1. Connect the CAN service key to socket [X41].

2. State code 341671 and press the ON button.

3. Choose the programming code from the table below:

Function

Programming

Remark

Return to factory settings.

Press 1 + ON button

Block 1-9 is deactivated. The original PIN codes are reset according to the table for standard assignment of PIN codes.

PIN codes in the block can be used.

Press 2 + b + ON button

B = Block 0-9

PIN codes in the block cannot be used.

Press 3 + b + ON button

B = Block 0-9

Programming new PIN codes

Press 4 + b + P + NNNN + ON button NOTE! The block that applies must be activated first (see function 2 above in the table).

B = Block 0-9 P = Driver profile 1-10 NNNN = PIN code NOTE! You may only state one number for driver profiles. Driver profile 10 must therefore be stated as 0 (zero).

4. Turn off the truck by pressing the OFF button.

Programming the PIN codes is now finished. Verify that the programming is correct by logging in with some of the new PIN codes.

NOTE! It is important to establish that the correct driver profiles are activated when a certain PIN code is stated. This especially applies when a driver profile is set up for a specific application.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

4– 3

Installation Programming PIN codes T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

4.3.1 Standards for PIN codes The table below shows the PIN codes that are found as standard in the programme. The PIN codes can be activated or changed according to the driver's wishes. A driver profile is activated with the normal log in of all PIN codes, whose block number is activated.

The truck programme does not permit a login using the PIN code 0000.

NOTE! It is recommended that service personnel keep notes about activated blocks, changed PIN codes and specially adjusted driver profiles.

Standard assignment for PIN codes Driver profile no.

1

Block 0

0001

0002

0003

0000

0000

0000

0000

0000

0000

0000

Block 1

7901

1437

3731

1049

9439

7265

1322

2869

1574

5421

Block 2

4854

2907

9175

5799

1490

3031

7392

5622

5023

1787

Block 3

3174

1026

3815

6703

1179

5152

7514

5668

3215

4659

Block 4

7110

5477

3846

9491

5918

8222

6923

8139

7025

9197

Block 5

6276

9879

9658

1690

4042

5201

9807

4332

9715

2549

Block 6

4142

8620

3754

8432

8788

7430

1948

2595

8527

7474

Block 7

1482

7135

2395

7365

7092

4611

2831

4185

6067

1930

Block 8

4731

1022

5377

3257

7334

9009

7881

8843

7436

2876

Block 9

3162

5878

2828

1910

6907

2136

5730

2957

7691

3242

4– 4

2

3

4

5

6

7

8

9

10 NOTE! Stated as 0

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Installation Setting the parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

4.4 Setting the parameters The parameters that are handled in this chapter are only the parameters that need to be adjusted when putting the truck into operation and that require more detailed description. For information about other parameters, see the chapter Functions and parameters.

Check that parameters are adjusted to desire values with regards to • maximum speed, driver parameter - see chapter Functions and parameters • acceleration, driver parameter - see chapter Functions and parameters • internal braking, driver parameter - see chapter Functions and parameters • Collision sensor (option) • battery • battery charger (option) NOTE! When you check or adjust parameters, remember to write down, in a truck report for example, the truck's specific parameter values. Separate information about the truck specific parameters are good to have e.g. truck condition, since the information cannot be received in another way.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

4– 5

Installation Setting the parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

4.4.1 Adjusting the parameters for collision sensor (option) This parameters for collision sensitivity must be adjusted on truck installation.

If a collision sensor is installed on the CAN bus, this registers when the truck knocks against something. If a knock exceeds a certain level, indicated by parameters 105 and 106, this is calculated as a collision and the truck's speed is reduced to creep speed, a signal sounds and error code 8.001 is shown on the display.

Information about the collision is stored in the truck's internal memory.

The last ten registered collisions can be read directly on the display and the driver's identity can also be read via the PIN code. Other information is received via TruckCom where the collision levels and times can also be seen.

Collision sensor parameters 105 and 106 See the table below for information about the values that can be stated:

Service parameters Parameter

Name/unit

Min/ Max

Step Std

Description

105

Collision sensor X level

0/100

1

0

States the degree of sensitivity for what should be interpreted as a collision for a shock to the side.

106

Collision sensor Y level

0/100

1

0

States the degree of sensitivity for what should be interpreted as a collision for a shock to the front and back.

NOTE! If you set the parameter value for the collision sensor at 0 (zero) this means that the collision sensor and the log function are turned off.

Programming PIN for resetting the truck When the truck has stopped after a collision, the truck must be reset by entering a special PIN code. This PIN code must be programmed by service technicians at installation.

The PIN that is activated is found in driver profile 1 and special block 10. The PIN code has a standard value 0000, which must be changed to PIN code chosen by service technicians.

NOTE! The PIN code must not contain the same number combination as any of the preprogrammed PIN codes.

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Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Installation Setting the parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

4.4.2 Adjusting the parameters for the battery and battery charger The following parameters must be adjusted or checked on battery installation.

NOTE! Even if the battery comes with the truck from the factory, the parameters must be adjusted or checked.

NOTE: Ensure that service parameter 109 is set to the value of the battery fitted, and that the correct battery capacity has been set in parameter 110.

NOTE: Only 134 Ah, 174 Ah and 201 Ah battery sizes may be used when using a Hawker Evolution battery.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

4– 7

Installation Setting the parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Parameter

Name/unit Min/Max

Step

Std

Description

107 service parameter

Battery adjustment, Ah

1

8

LWE140/160/180/200: 8 = Large battery 12 = Medium battery 17 = Small battery For more information, see text according to the table. See section “4.4.3 Parameter 107 - battery size”.

10

LWE250 and LWE200 with platform: 10 = Large battery 14 = Medium battery 19 = Small battery For more information, see text according to the table. See section “4.4.3 Parameter 107 - battery size”.

1/20

109 service parameter

Intergrated battery charger, battery type

0/3

1

0

State battery type 0 = No charge. Standard type. Error code is displayed if this parameter is set at 0 when there is a battery charger and factory parameter 1101 is set at 1.

1 = Lead/acid battery 2 = Hawker Evolution battery. Sizes 134 Ah, 174 Ah, 201 Ah 3 = Exide GEL battery

110 service parameter

Intergrated battery charger, battery capacity, Ah

0/300 (100/300)

1

0 (100)

State battery capacity.

0 (100) = No charge. Standard type.

Error code is displayed if this parameter is set at 0 (100) when there is a battery charger and factory parameter 1101 is set at 1.

The values in brackets () apply if the truck has software version -006 or later.

1101 factory parameter

Intergrated battery charger

0/1

1

0

0 = No battery charger 1= Battery charger present

NOTE! If factory parameter 1101 has a value of 0 (zero), service parameters 109 and 110 must also have a value of 0 (zero). If the truck has software version -006 or later, and if the factory parameter 1101 has the value 0 (zero), service parameter 109 must have the value 0 (zero) and 110 must have the value 100 (one hundred). The value in service parameter 109 and 110 only needs to be changed if the truck is equipped with an integrated charger and the value of factory parameter 1101 is set at 1.

4– 8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Installation Setting the parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

4.4.3 Parameter 107 - battery size You must state which type of battery the truck is equipped with. To adjust the meter for battery charge level, consideration must be given to the following: • Acid concentration when the battery is fully charged, in order to check the battery's quality. The value should lie between 1.27-1.29.

NOTE that the acid concentration can vary depending on the type of battery.

• When the lifting capability is disconnected (the battery discharged to 80 %) the value should be close to 1.14 but no lower.

Table for LWE140, 160, 180, 200 See the table below for the recommended parameter settings.

Parameter 107

Lower discharge

Deeper discharge

© BT

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Battery size Lead/acid battery

Battery size Hawker Evolution

Battery size Exide

311-330 Ah 291-310 Ah 271-290 Ah 251-270 Ah 231-250 Ah 216-230 Ah 201-215 Ah 186-200 Ah 171-185 Ah 156-170 Ah 141-155 Ah 125-140 Ah

261-280 Ah 241-260 Ah 221-240 Ah 201-220 Ah 181-200 Ah 161-180 Ah 141-160 Ah 120-140 Ah

271-290 Ah 251-270 Ah 231-250 Ah 211-230 Ah 191-210 Ah 171-190 Ah 151-170 Ah 131-150 Ah 110-130 Ah

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

4– 9

Installation Setting the parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Table for LWE200 with platform and LWE250 See the table below for the recommended parameter settings:

Lower discharge

Deeper discharge

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Battery size Lead/acid battery

Battery size Hawker Evolution

Battery size Exide

311-330 Ah 291-310 Ah 271-290 Ah 251-270 Ah 231-250 Ah 216-230 Ah 201-215 Ah 186-200 Ah 171-185 Ah 156-170 Ah 141-155 Ah 125-140 Ah

261-280 Ah 241-260 Ah 221-240 Ah 201-220 Ah 181-200 Ah 161-180 Ah 141-160 Ah 120-140 Ah

271-290 Ah 251-270 Ah 231-250 Ah 211-230 Ah 191-210 Ah 171-190 Ah 151-170 Ah 131-150 Ah 110-130 Ah

DANGER! The battery's life-span will be reduced if the value of parameter 107 is adjusted to a value that is too high. The standard adjustment of parameter 107 is set for normal handling of the truck. Other applications may require a different adjustment of parameter 107. Check that the parameter adjustment is right using the instructions below.

4 – 10

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Installation Setting the parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Verifying the parameter adjustment for free ventilated batteries (Lead/acid batteries) 1. Charge the battery 2. Use the truck in its normal application unitl the battery indicator shows an empty battery (0 % on the display).

3. Disconnect the battery from the truck and let the battery rest for at least two minutes.

NOTE! Do not charge or discharge during this time.

4. Measure the acid weight of the battery at room temperature.

If the acid weight is under 1.15 g/cm3, the parameter must be reduced. A value substantially above 1.15 g/cm3 reduces the risk of damage to the battery. At the same time the operating time of the truck is reduced. If a longer operating time is desired, the parameter value can be increase by up to one unit.

NOTE! Each change must be followed by a new verification of the parameter adjustment.

Verifying the parameter adjustment for valve controlled batteries (Hawker/Exide) 1. Charge the battery 2. Use the truck in its normal application until the battery indicator shows an empty battery (0 % on the display).

3. Disconnect the battery from the truck and let the battery rest for at least two minutes.

NOTE! Do not charge or discharge during this time.

4. Measure the voltage of the battery at room temperature.

If the voltage is under Uend (see table below) the parameter value must be reduced. A value substantially above Uend reduces the risk of damage to the battery. At the same time the operating time of the truck is reduced. If a longer operating time is desired, the parameter value can be increase by up to one unit.

NOTE! Each change must be follwoed by a new verification of the parameter adjustment.

© BT

Battery type

Battery voltage at rest, Uend

Hawker Evolution/Exide

24.24 V

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

4 – 11

Installation Function and safety check T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

4.5 Function and safety check 3

2

1, 5

12

4

6

11

10

7 9

8

13 9

Before the truck is put into operation, the following points must be checked.

Pos.

Inspection point

Measure

Duration scale

1 2

Operating control Safety reversing switch Horn Steering Brake Emergency switch Hydraulic system Drive unit Wheel Chassis Battery cover and lock Battery Fork carriage

Check function Check function

2:25 minutes

3 4 5 6 7 8 9 10 11 12 13 4 – 12

Check function Check function Check function Check function Check all components Investigate possible noises and oil leaks Investigate damage, remove dirt etc.

Investigate damage, remove dirt etc.

Check function Check acid and charging level Investigate damage, remove dirt etc.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Maintenance General Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

5 – Maintenance 5.1 General This chapter includes a survey diagram for regular maintenance followed by detailed descriptions of required maintenance procedures.

5.2 Service intervals The service intervals are merely a guideline and need not be strictly followed. The service technician should adapt these to local requirements, however, it is important that the intervals coincide with the minimum BT requirements.

The service intervals are based on truck operating hours and can be adapted to most normal 8-hour shifts. The following operating hours have been used when calculating the intervals.

Day time: 08.00-17.00 (20 h/week) 2 shifts: 06.00-14.00, 14.00-22.00 (40 h/week) 3 shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 h/week) Make sure the truck is subjected to regular maintenance at intervals of 750 operating hours. The truck's safety, efficiency and service life depend on the service and maintenance it receives.

Following completed service intervention, test drive the truck and perform an operational inspection. See the Installation chapter under the heading Function and safety checks.

Only use BT approved spare parts during service and repairs

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

5– 1

Maintenance Maintenance chart T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

5.3 Maintenance chart Service maintenance should be performed in intervals of 750 operating hours or every 12 months, whichever occurs first.

The sequence shown in the maintenance chart is not the optimised working plan and is only sorted according to ‘C’ codes.

Truck area

Pos.

Action

750h/12m

Estimated time

0000 Chassis

1

Inspect cover mountings.

X

2

Inspect signs and stickers

X

3

Inspect for cracking and other damage

X

5:20 minutes including removal of covers.

4

Inspect cylinder mounting in the fork carriage.

X

5

Inspect the locking screw in the castor wheel suspension.

X

6

Inspect the motor plate for cracks and other damage.

X

7

Tighten the paper holder tensioner if necessary

X

7

2

4

1

1

2 2

2

2

3

6 2

2

5

*M-plate to be fixed to specially manufactured trucks only.

5– 2

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LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Maintenance Maintenance chart Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

500h/12m

T-code 838, 839, 840

Truck area

Pos.

Action

750h/12m Estimated time

0380 Fork frame

1

Inspect for cracking and other damage

X

2

Inspect the play in bushings and links

X

3

Inspect the push rods and welds for cracks and other damage.

X

4

Check the function and attachment of the battery holder. Check the mounting bracket on the battery tray.

(Optional)

X

5

Insert grease in the nipples (6 pcs.) of the push rods and fork wheels.

Applies to LWE140/160.

1:30 minutes.

X

1

4 2

3 5

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

5– 3

Maintenance Maintenance chart T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

2 1

5– 4

Truck area

Pos.

Action

750h/12m

Estimated time

0560 Platform and brackets (option)

1

Check crack formation and damage

X

1:30 minutes

2

Check the spring and that the platform returns to folded position from lowered position

X

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Maintenance Maintenance chart Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Truck area

Pos. Action

750h/12m

Estimated time

1700 Drive motor

1

Inspect drive motor mounting.

X

4:30 minutes

2

Clean the drive motor

X

3

Inspect the drive motor bearing for abnormal noise.

X

4

Inspect for abnormal noise

X

5

Inspect the steering bearing for correct mounting and play, 23±3 Nm.

X

6

Clean the brake.

X

7

Inspect play in the neutral position, 0,2 +0,1 mm.

X

2550 Driving gear

3180 Brakes

6, 7

1, 2, 3 5

4 © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

5– 5

Maintenance Maintenance chart T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Truck area

Pos.

Action

750h/12m

Estimated time

3500 Wheels

1 2 3 4 5

Inspect drive wheel wear.

Inspect the nuts, 81 ±19 Nm. Inspect castor wheel wear Inspect fork wheel wear.

Check whether the castor wheel swings freely

X X X X X

2 minutes

5 2

1

5– 6

4 3

Wheels

Normal dimensions, mm (H)

Minimum dimensions, mm

Drive wheel Castor wheels Fork wheels

30 20 11

15 10 5,5

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Maintenance Maintenance chart Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Truck area

Pos.

Action

750h/12m

Estimated time

4110 Tiller arm

1

Check the mounting.

X

1:45 minutes

2

Inspect the steering console for correct mounting (4 pcs.)

23 ±3 Nm.

X

3

Inspect the handle for correct mounting.

X

4

Inspect the strength of the gas suspension and the locking performance.

The tiller arm should return to the top position both from the bottom position and the lower position in which the brake is applied.

X

3

1

4

2 © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

5– 7

Maintenance Maintenance chart T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Truck area

Pos.

Action

750h/12m

Estimated time

5000 Electrical system

1

Check the contacts, wiring harness (including battery cables), cable insulation and that all cables are running freely.

X

4:30

2

Inspect the contactors for correct operation.

X

3

Inspect the error code log, truck operating hours and all display segments.

X

4

Clean and check for possible play between the controller box and the heat deflection plate.

X

5

Retighten all cable connections.

X

6

Inspect all switches and sensors.

X

3

6 5 5 2 4

5

5– 8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Maintenance Maintenance chart Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Truck area

Pos. Action

750h/12m

Estimated time

6000 Hydraulic system

1 2

X X

16 minutes

3 4 5

6

6600 Lifting cylinder

7

20 mm 30 mm

Inspect hoses and pipes for wear Inspect the oil level (Permitted range for oil level with lowered forks, see picture) Inspect the hydraulic unit for correct mounting.

Inspect the hydraulic system for possible leakage.

Clean or replace the oil and clean the oil tank.

NOTE: Initially after 750 h/12 m, then every 4500 h/36 m.

Clean the oil filter.

NOTE: Initially after 750 h/12 m, then every 4500 h/36 m.

Check the lifting cylinder and “Powerlink-cylindern”(option) for leakage.

X X X

X

X

2 1, 3, 4, 5, 6

LWE140, LWE160, LWE180

2 10 mm

LWE200, LWE250

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

5– 9

Maintenance Maintenance chart T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

5 – 10

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters General Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

6 – Functions and parameters 6.1 General The chapter “Functions and parameters” provides a basic description of the truck's main functions and the control system's parameters.

6.2 Function description The section Function description gives a basic description of the truck's main functions.

• Event – the use of any of the truck's main functions are called events. All events are indicated using a figure.

• Preceding event – Indicates an event that must have happened immediately before the current event in order for this to be carried out correctly.

• Action(s) – An action that the driver must perform in order for an event to happen.

• Influencing factors – Conditions that must be fulfilled in order for an event to happen. Certain parameter settings also influence the event's outcome.

• Resulting conditions - Describe the key events that can be checked in order to confirm a function.

NOTE that the resulting conditions are showing what is assumed to happen when there are no errors.

Text within square brackets [ ] refer to the electrical component names in the truck's electrical diagram. {High} means ≈ 24 V and {low} ≈ 0 V unless otherwise stated.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6– 1

Functions and parameters Function description T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Symbols on key pads and display Symbol

Description ON button This button is used to both start the truck and to confirm settings OFF button

Error code

Battery charge as a percentage

Parameter

Timer

6– 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Principle functions Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

6.3 Principle functions Event:

1. The battery is connected

Action(s)

Connect the truck battery [G1]

Influencing factors

Main fuse OK [F1] Working fuses OK [F50, F51]

Resulting conditions

The status LED for the transistor regulator is lit permanently [T1].

Event:

2. Start truck

Preceding event(s)

The battery is connected.

Action(s)

Enter a valid PIN code and press the ON button on the keypad [S223].

Influencing factors

Emergency stop [S21] is not active [T1:INP. SUPPLY+24V DC] {high}.

Sensor for tiller arm in drive position is not activated [B60] [T1:INP.TILLER ARM IN DRIVE POS] {low}.

Resulting conditions

The current lamp shines. The main display show the hour meter for 4 seconds and then shows the battery's charge condition as a percentage of its full charge.

The mechanical brakes remain connected [Q1] [T1:OUT.BRAKE RELEASE] {high}.

Event:

3. Fold down tiller arm to drive position

Preceding event(s)

Start truck.

Action(s)

Lower the tiller arm.

Influencing factors

Sensor for tiller arm in drive position [B60].

Resulting conditions

Sensor for tiller arm in drive position is activated [B60] [T1:INP. TILLER ARM IN DRIVE POS] {low}.

The main contactor output voltage becomes {low} [T1:OUT. MAIN CONTACTOR] The main contactor is closed [Q10].

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6– 3

Functions and parameters Principle functions T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Event:

4. Running in fork direction

Preceding event(s)

Fold down tiller arm to drive position.

Action(s)

Turn the speed control in the fork direction

Influencing factors

Speed control with Hall-sensor [A5:S10-18].

Settings in the driver parameters 4, 5 and 6 affect the drive performance

Resulting conditions

[T1:OUT.BRAKE RELEASE] becomes {low}.

The brake [Q1] is activated, the mechanical brake is released.

The current feed to the propulstion motor's field winding (S2 +ve and S1 -ve).

The pulse current feed to the drive motor's rotor is proportional to the speed control's torsion.

Event:

5. Running in the castor wheel's direction

Preceding event(s)

Fold down tiller arm to drive position.

Action(s)

Turn the speed control in the castor wheel's direction

Influencing factors

Speed control with Hall-sensor [A5:S1-9].

Settings in the driver parameters 4, 5 and 6 affect the drive performance

Resulting conditions

[T1:OUT. BRAKE RELEASE] becomes {low}.

The brake [Q1] is activated, the mechanical brake is released.

The current feed to the propulstion motor's field winding (S2 -ve and S1 +ve).

The pulse current feed to the drive motor's rotor is proportional to the speed control's torsion.

Event:

6. Neutral braking

Preceding event(s)

Running in the fork or castor wheel direction

Action(s)

Let the speed control go back to the free position.

Influencing factors

Adjust driver parameter 5.

Resulting conditions

The drive motor [M1] works as a generator and via the transistor regulator [T1] converts the truck's kinetic energy into electricity, which causes the truck to brake. The excess energy is fed back to the battery [G1] in the form of electricity which is then charged. The mechanical brake [Q1] is activated when the truck stops. [T1:OUT.BRAKE RELEASE] becomes {high}.

6– 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Principle functions Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Event:

7. Reverse braking

Preceding event(s)

Running in the fork or castor wheel direction

Action(s)

The speed control is turned to the other driving direction.

Influencing factors

Parameter 201.

Resulting conditions

The drive motor [M1] works as a generator and via the transistor regulator [T1] converts the truck's kinetic energy into electricity, which causes the truck to brake. The excess energy, in the form of electricity, is fed back to the battery [G1] which is then charged. The braking effect increases the more the speed control is turned.

The mechanical brake [Q1] [T1:OUT. BRAKE RELEASE] is activated when the truck stops.

Event:

8. Mechanical internal braking

Preceding event(s)

Running in the fork or castor wheel direction

Action(s)

The tiller arm is folded completely up or down.

Influencing factors

Sensor for tiller arm in drive position [B60].

Resulting conditions

Sensor for tiller arm in drive position [B60] deactivated [T1:. INP. TILLER ARM IN DRIVE POS] {low}.

When the tiller arm is folded completely up or down, this applies the highest permitted braking reduction at 200 ms or until the drive speed is lower than 0.8 m/s. Then the mechanical brakes are activated [Q1].

[T1:OUT.BRAKE RELEASE] {high}.

Event:

9. Anti-collision safety switch

Preceding event(s)

Running in the castor wheel's direction.

Action(s)

When running in the castor wheel's direction, press in the anti-collision safety switch [A5:S17].

Influencing factors

Safety switch [A5:S17].

Resulting conditions

The hall sensor [A5:S17] is activated directly. The logic card [A5] interprets this signal as a command to the transistor regulator [T1] to run the drive motor at reduced speed in the fork direction as long as the anti-collision safety switch [A5:S17] is depressed. The command signal for normal running of the drive motor from the speed control is blocked until the speed regulator is released and returnes to the neutral position.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6– 5

Functions and parameters Principle functions T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Event:

10. Fork lift

Preceding event(s)

Start truck.

Action(s)

Press in the fork lift button [A5:S19].

Influencing factors

Main contactor [Q10].

Fuse [F1].

Fork lift button [A5:S19].

Battery status OK (battery's discharge indicator > 0 or battery charge > 20 %).

Resulting conditions

[T1:OUT. PUMP CONTACTOR] become {low}.

The pump contactor [Q25] are activated, the pump motor [M3] starts.

Event:

11. Fork lower

Preceding event(s)

Start the truck or fork lift.

Action(s)

Press the button for fork lowering [A5:S20].

Influencing factors

Main contactor [Q10].

Button for fork lowering [A5:S20].

Resulting conditions

[T1:OUT. LOWER VALVE] becomes {low}, hydraulic lowering valve [Q4] is activated.

Event:

12. Click-2-Creep

Preceding event(s)

Start truck.

Action(s)

Quick double operation of speed control in order to activate the function.

Put the tiller arm in the upright position and drive the truck at low speed (2.5 km/h).

Influencing factors

Main contactor [Q10].

Adjsuting factory parameter 1002.

Resulting conditions

[T1:OUT.BRAKE RELEASE] becomes {low}.

The brake [Q1] is activated, the mechanical brake is released.

The current feed to the propulsion motor's field winding (S2 +ve and S1 -ve).

The pulse current feed to the drive motor's rotor is proportional to the speed control's torsion. “SLO” is shown on the display (blinking).

6– 6

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LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Principle functions Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Event:

13. Turtle function (option)

Preceding event(s)

Fold down tiller arm to drive position.

Action(s)

Press [S206] to activate the function.

Turn the speed control in one direction.

Influencing factors

Option button 1 [S206].

Adjusting driver parameter 7 and service parameter 202.

Resulting conditions

[T1: OUT. BRAKE RELEASE] becomes {low}.

The brake [Q1] is activated, the mechanical brake is released.

The current feed to the propulsion motor's field winding (S2 +ve and S1 -ve).

The pulse current feed to the drive motor's rotor is proportional to the speed control's torsion. The maximum speed is limited by driver parameter 7. “SLO” is shown on the display (shines constantly).

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6– 7

Functions and parameters Timer T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

6.4 Timer When the truck is started, the timer on the display and the time measurement symbol shines for 4 seconds.

The truck's control system stores five different time values. The time values are controlled by parameter 103. To choose which value should be shown, follow the instructions below.

1. Ensure that the battery is connected.

2. Ensure that the truck is turned off. Press the OFF button.

3. Punch in the chosen PIN code. NOTE! Without pressing the ON button.

4. Keep the horn button pressed down until “H” appears, and then release the button. The time measurement symbol shines.

The different time measurement symbols are shown when you press repeatedly on the speed control. The current time values are shown for a short time after the setting has been chosen.

Time measurement value

Display

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

Value 2 = Operating time The combined time whether the pump or drive motor has been in operation.

Standard display.

Value 3 = Drive motor time The total time that the drive motor has been in use.

Value 4 = Pump motor time The total time that the pump motor has been in use.

Value 5 = Time remaining until service.

Parameter 101 controls the output value.

6– 8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

6.5 Parameters 6.5.1 General The truck's control system stores a number of parameters. These parameters are used to configure the truck for the right function with regards to environment and application. The parameters are divided up into three groups.

• Driver parameters – Adjusts the driving properties in the truck to a certain driver or application. Driver parameters can be changed directly without a CAN service key.

• Service parameters – Used to adjust the truck's function properties. Service parameteters can only be adjusted using a suitable CAN service key that is connected to the truck. NOTE that the service parameters can be checked without a CAN service key having to be connected, but the values cannot be changed.

• Factory parameters – Parameters that are entered during production in the factory and may, if specific needs arise, be changed by service technicians. The parameters state e.g. the truck model and which controls to use for the hydraulic function. The factory parameters cannot be changed via the CAN service key.

All parameters can be changed via PC/PDA and TruckCom.

6.5.2 Show parameters If you only want to see the truck's different settings, use the following instructions: 1. Connect the CAN key or press in the PIN code and then press on the horn button and keep it pressed in.

The display shows: - Operating times and remaining time to the next service (H) - Error codes (E) - Parameters (P) - The hardware and software numbers (Pn) - Display test function (d) - Collision sensor log (c) - Emergency (limp home) mode (ed) 2. Release the horn button to selected what you wish to view.

3. Turn the speed control to move between the different positions in the function above.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6– 9

Functions and parameters Parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

6.5.3 Enter the parameters To enter the parameters, use the following instructions: 1. Connect the CAN key or press in the PIN code and then press on the horn button and keep it pressed in.

Release the horn button when the display shows “P”.

The parameter symbol remains lit.

2. Turn the speed control to move between parameters. Release the control when the display shows the correct parameter number.

3. Press once on the horn button to change the value.

The parameter symbol starts blinking.

4. Change the value by turning the speed control.

5. Confirm the setting by pressing once more on the horn button.

The parameter symbol lights again, and stays on.

6. Complete the programming by pressing the OFF button.

6 – 10

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

6.5.4 Driver parameters NOTE! Changing specific truck parameters changes the trucks driving properties. Do not change any parameter values without the relevant prior knowledge.

© BT

Parameter

Name/unit

Min/Max

Step

Std

Description

4

Acceleration, %

10/100

5

80

States the truck's acceleration capacity. NOTE that the lower the parameter value, the less time it takes for the truck to reach its maximum speed.

5

Internal braking, %

10/100

5

90

States the motor's internal braking force when the speed control is in neutral.

The lower the parameter value, the lower the internal braking time.

6

Maximum speed, %

30/100

5

100

States the trucks maximum speed.

7

Maximum speed turtle function, %

30/100

5

50

States the truck's maximum speed when the turtle function is activated.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6 – 11

Functions and parameters Parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Factory installed driver parameters Different driver profiles have different values input from the factory for driver parameters 4, 5 and 6. See the table below.

The values for driver profiles 1 and 4-10 apply as standard values.

Driver profile Driver profile 1

Driver profile 2

Driver profile 3

Parameter

Factory setting

4

80

5

90

6

100

4

60

5

90

6

90

4

100

5

100

6

100

PIN code 1

2

3

NOTE! When changing software, the factory settings for driver profiles 2 and 3 disappear. All driver profiles are then given the same standard values, i.e. the standard values for driver profiles 1 and 4-10. If you want to restore the factory settings, the values must be stated again, either manually or via PC/PDA.

6 – 12

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Parameters Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

6.5.5 Service parameters NOTE! Changing specific truck parameters changes the trucks driving properties. Do not change any parameter values without the relevant prior knowledge.

NOTE! Parameter 201 must be set at a value that is as great or greater than the value in parameter 5. If the value in any of the parameters is changed so that the value in parameter 201 becomes less than the value in parameter 5, the value in parameter 201 is automatically set at 100. When the parameter value changes automatically, the error code 2.002 is generated.

NOTE! Ensure that service parameter 109 is set to the value of the battery fitted, and that the correct battery capacity has been set in parameter 110.

NOTE! Only 134 Ah, 174 Ah and 201 Ah Hawker Evolution battery sizes may be used.

The CAN service key must be connected to the contact [X41] before adjustment of the service parameters can be carried out.

© BT

Parameter

Name/unit

Min/ Max

Step Std

Description

101

Service interval, hours

0/ 2000

50

0

States a limit when the next service should take place. When it is time for service, the error code 2.003 is shown in the display.

0 = Service indicator off.

102

Driver access

1/10

1

3

States which login method should be used and if the driver will have the possibility to change the driver parameter settings.

Values 1 and 2 = Key Values 3 and 4 = Keypad using 100 PIN codes Values 5 and 6 = Keypad using DHU[K110] Values 7 and 8 = ID unit Values 9 and 10 = ID unit using DHU[K110] Odd values = Open driver parameters Even values = Driver parameters must be changed using the CAN key.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6 – 13

Functions and parameters Parameters T-code 838, 839, 840

Date 2009-10-05

Order number 258944-040

Parameter

Name/unit

Min/ Max

Step Std

Description

103

Timer option

1/5

1

2

States a time value for the timer.

For more information, see the section about the Timer in this chapter.

104

Automatic log out, minutes

0/20

1

20

States the time it takes before the truck is turned off when the keypad is used. The time is calculated from when the last power consuming unit is used. Value 0 gives 4 hours.

105

Collision sensor X level

0/255

1

0

Option. States the degree of sensitivity for what should be interpreted as a collision for a shock to the side.

This parameter should be set on truck installation. For more information see the chapter Installation.

106

Collision sensor Y level

0/255

1

0

Option. States the degree of sensitivity for what should be interpreted as a collision for a shock to the front/ back. This parameter should be set on truck installation. For more information see the chapter Installation.

107

Battery adjustment, Ah

1/20

1

8

LWE140/160/180/200: 8 = Large battery 12 = Medium battery 17 = Small battery For more information, see the chapter Installation.

10

LWE250 and LWE200 with platform: 10 = Large battery 14 = Medium battery 19 = Small battery For more information, see the chapter Installation.

0

States what type of battery is to be charged.

0 = No charge. Standard type. Error code is displayed if this parameter is set at 0 when there is a battery charger and factory parameter 1101 is set at 1.

1 = Lead/acid battery 2 = Hawker Evolution battery. Sizes 134 Ah, 174 Ah, 201 Ah 3 = Exide GEL battery For more information, see the chapter Installation.

109

6 – 14

Valid from serial number 6053221-

Intergrated battery charger, battery type

0/3

Repair Manual

1

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Parameters Order number 258944-040

© BT

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Parameter

Name/unit

Min/ Max

Step Std

Description

110

Intergrated battery charger, battery capacity, Ah

0/300 (100/ 300)

1

0 (100)

States battery capacity 0 (100) = No charge. Standard type.

Error code is displayed if this parameter is set at 0 (100) when there is a battery charger and factory parameter 1101 is set at 1.

The values in brackets () apply if the truck has software version -006 or later For more information, see the chapter Installation.

111

Resetting following a collision

0/1

1

0

0 = Special pincode required for resetting after a collision.

1 = The truck can be reset using all activated pincodes.

2 = The horn sounds once every five seconds.

3 = Alternatively, 1 and 2 combined.

201

Reverse braking

70/ 100

5

100

States how powerful the truck brakes when the speed control is turned in completely the opposite direction NOTE: This value must not be set less than the value of parameter 5. If it is lower error code 2.002 will be displayed when start-up and the value will not be changed.

202

Creep speed

-200/ 200

5

0

States the speed that the truck has when it reaches the first speed sensor.

-200 = low speed at the first speed sensor.

200 = high speed at the first speed sensor.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

6 – 15

Functions and parameters Parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

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

The user identity and the time of parameter change is logged in the handle's circuit board.

6 – 16

Parameter

Name/unit

Min/ Max

Step Std

Description

1001

Truck type

0/6

1

0

0 = Unknown truck type 1 = LWE140 2 = LWE160 3 = LWE180 4 = LWE200 5 = LWE250

1002

Non-configurable option

0/3

1

1

You have access to 3 functions via parameter 1002.

These functions are either activated or deactivated.

The functions require no further adjustment and are therefor called non-configurable options.

0 = No option function 1= Click-2-Creep 2= Turtle function 3 =Both Click-2-Creep and turtle function.

1003

ConfOption Func1

0/6

1

0

Requires SEU

1004

ConfOption Func1Arg1

0/255

1

0

Requires SEU

1005

ConfOption Func1Arg2

0/255

1

0

Requires SEU

1006

ConfOption Func1Arg3

0/255

1

0

Requires SEU

1007

ConfOption Func1Arg4

0/255

1

0

Requires SEU

1008

ConfOption Func2

0/6

1

0

Requires SEU

1009

ConfOption Func2Arg1

0/255

1

0

Requires SEU

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Functions and parameters Parameters Order number 258944-040

© BT

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Parameter

Name/unit

Min/ Max

Step Std

Description

1010

ConfOption Func2Arg2

0/255

1

0

Requires SEU

1011

ConfOption Func2Arg3

0/255

1

0

Requires SEU

1012

ConfOption Func2Arg4

0/255

1

0

Requires SEU

1013

ConfOption Func3

0/6

1

0

Requires SEU

1014

ConfOption Func3Arg1

0/255

1

0

Requires SEU

1015

ConfOption Func3Arg2

0/255

1

0

Requires SEU

1016

ConfOption Func3Arg3

0/255

1

0

Requires SEU

1017

ConfOption Func3Arg4

0/255

1

0

Requires SEU

1018

ConfOption Func4

0/6

1

0

Requires SEU

1019

ConfOption Func4Arg1

0/255

1

0

Requires SEU

1020

ConfOption Func4Arg2

0/255

1

0

Requires SEU

1021

ConfOption Func4Arg3

0/255

1

0

Requires SEU

1022

ConfOption Func4Arg4

0/255

1

0

Requires SEU

1023

Control for hydraulic function

1/3

1

1

1 = Rear lift and lowering control connected to the first hydraulic function and forward control connected to second hydraulic function.

2 = Rear lift and lowering control connected to the second hydraulic function and forward control connected to first hydraulic function.

3 = Both lift and lowering control connected to the first hydraulic function. There is no second hydraulic function.

1101

Intergrated battery charger

0/1

1

0

0= Battery charger missing 1= Battery charger present

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LWE140, LWE160, LWE180, LWE200, LWE250

6 – 17

Functions and parameters Parameters T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

6 – 18

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting General Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7 – Troubleshooting 7.1 General The chapter Troubleshooting describes the error codes that are shown on the display when the truck is completely or partly not working. The causes of faults and actions for rectifying them are also described here.

The truck's electronic control system has an integrated error code display and log. When a fault occurs, the error code is shown on the display and the error code lamp blinks.

The first time that an error code is shown on the display, it can be good to check if the error persists by restarting the truck.

NOTE! The request to Restart the truck always means that the battery sleeve should be pulled out before the truck is started again.

Software compatibility Ensure that the logic card ICH [A5] and transistor regulator ACT [T1], and battery charger BCU [A30], has software from the same softwarepackage.

In order to guarantee all truckfunctions make sure to have last software package downloaded.

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

1. Enter your PIN code.

2. Press the horn button and keep it depressed.

“Ed” is displayed.

3. Relase the horn button.

All lamps blink and “SLO” is displayed.

It is now possible to drive the truck, but exercise extreme caution. It is not possible to brake by raising the tiller arm.

If the truck is on an incline, be even more careful when using the emergency travel mode. If too much acceleration is used, there is a risk the truck can roll away. To stop the truck, change the travel direction to the opposite direction.

With some errors, the emergency travel mode will not operate. In this case, it is not possible to receive information about the error. © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7– 1

Troubleshooting Troubleshooting methods T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.2 Troubleshooting methods 7.2.1 Troubleshooting general introduction Begin troubleshooting

Has an error code been displayed?

Yes

Follow the instructions in the chapter “Troubleshooting”

Yes

Follow the instructions in the troubleshooting diagram

Choose and prioritise the most likely causes

Where in the workplace did the problem occur?

When you have identified the error, see the instructions in the chapter “Actions”

Eliminate unlikely causes

No Are the symptoms in the troubleshooting diagram?

No Collect as much information about the problem as possible

When did the problem occur?

What functions are affected?

What circumstances triggered the problem?

Identify all parts which may cause the problem.

Use the wiring diagram when needed.

7– 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Troubleshooting methods Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.2.2 Completed troubleshooting Conclude troubleshooting

Ensure that all cables and hoses are placed back in the correct way.

Ensure that all parts that have been emptied of liquids have been refilled to the correct level

Drive the truck in the same way it was being driven when the problem first occurred. Verify that the problem does not occur again

Let the driver drive the truck.

Verify that the problem does not occur again

If you have contacted the technical support department to discuss the problem, speak to them again and tell them that you have solved the problem

By giving feedback, you can contribute to a shared knowledge database. This is important for continually improved support to service technicians in the field

Recreate the circumstances that existed when the problem first occurred

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7– 3

Troubleshooting Error code history T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.3 Error code history Up to 50 of the last error code events can be stored together with the timer values for when the error occurred. In the error code log, the error codes are shown chronologically with the most recent error code first.

To show the error code log, work according to the following instructions: 1. Ensure that the battery is connected.

2. Ensure that the truck is turned off. Press the OFF button.

3. Punch in the chosen PIN code. NOTE! Without pressing the ON button.

4. Keep the horn button pressed down until “E” appears, and then release the button. The error code symbol is lit.

The most recent error is shown The display alternates between the error code and the timer value when the error occurred. If the error code log contains more than one code, these codes can be shown by pressing repeatedly on the speed control.

7– 4

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LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Error code system Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.4 Error code system See the tables below for an explanation of the error code system.

© BT

Structure

Description

G.ANN

Example 3.510

G (3)

Group. States which system is affected by the error.

A (5)

Error category. Describes the type of fault that occurred and what happened.

NN (10)

Error code

Group

Description

1

Do not use

2

Transistor regulator and logic card

3

The drive system

4

The hydraulic system

5

Do not use

6

Do not use

7

Do not use

8

Option

Error category

Description

0

Use caution. Mainly an information code, which indicates that certain of the truck's functions are reduced or do not work.

1-2

Lifting errors. Raising and lowering of the forks is impaired or not working and the truck's speed is reduced to safety speed.

3

Do not use.

4

Critical error. The main contactor opens. The truck stops.

5

Critical error. The main contactor opens. The truck stops.

Code

Description

00-09

Diverse error codes.

10-19

CAN related error codes.

20-39

Error codes regarding specific units.

40-59

Error codes for short-ciruited outputs.

60-79

Error codes for open electrical circuits.

80-99

Faulty signals from sensors.

Repair Manual

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7– 5

Troubleshooting Error codes T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.5 Error codes NOTE that certain error codes are stored in the programme and disappear from the display while other error codes remain on the display and require that the truck is first stopped and then restarted for the error code to disappear.

Code

Event

Possible cause Measure

Transistor regulator and logic card E141

Software download interrupted

Transfer cable disconnected.

Restart the download in “Emergency download” mode

2.001

The transistor regulator stops all functions.

Emergency switch pressed.

Check: • that the emergency switch is unaffected • cable 24.

• Fuse [F51]

2.002

No event. The truck can be driven.

Certain parameter values may be outside the predefined values. Reset the parameters to standard values.

• Check the parameter settings.

• If the code is immediately followed by error code 2.004, copy configuration via TruckCom to transistor regulator[T1].

2.003

No event. The truck can be driven.

Time for service.

Check the service meter (timer S). This may not have been reset after the last service.

2.004

No event. The truck can be driven.

The values in the transistor regulator's backup file is different from the values in the handle's logic card with regards to parameters, timers and/or machine number.

Check via TruckCom where the correct data is. See table 7.6.4.

2.101

Safety speed, raising and lowering the forks not working.

The truck type has not been indicated.

State the truck type by adjusting factory parameter 1001 (Truck type) or see table 7.6.4

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© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

2.102

Safety speed, raising and lowering the forks not working.

The stated truck type does not support the analogue raising and lowering functions.

Check the factory parameter settings 1001 (Truck type) and 1023 (Hydraulic function control).

2.501

The main contactor opens.

Low battery voltage <16.8 V> for more than 2 seconds Charge the battery. Inspect all cables and connectors

2.511

The main contactor opens.

CAN communication error.

Check: • connections and wiring harness • cables 119 and 120 • logic card in the handle.

2.514

The main contactor opens.

CAN communication error.

Check: • connections and wiring harness • cables 119 and 120.

• logic card in the handle.

2.515

The truck does not start

CAN communication error.

Check: • connections and cabling between DHU [K110] and logic card ICH [A5]

2.520

The main contactor opens.

Fault in the software for the control handle or microprocessors.

Download new software.

2.521

The main contactor opens.

The safety reversing function is faulty.

Mechanical fault of fault with the hall sensor that controls the safety reversing function.

Check via TruckCom that the hall sensor works.

2.522

The main contactor opens.

Faulty power supply to the hall sensor.

Check via TruckCom that the hall sensors work.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7– 7

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

2.523

The main contactor opens.

The main contactor is not activated.

• Check that the main contactor works.

• Open the main contactor.

Drive system 3.001

Driving is prevented until the speed control is in neutral.

• The speed control is not in neutral when starting.

• Faulty hall sensor.

Check: • speed controller's function • via TruckCom that the hall sensors work.

3.002

The transistor regulator reduces the maximum current to 50 %.

The transistor regulator's temperature exceeds +85°C. The driving may be too intensive.

• Drive the truck less intensively.

• Check for dirt around the transistor regulator. Too much dirt means that the transistor regulator does not cool down properly.

3.003

The transistor regulator reduces the maximum current to 50 %.

The motor's temperature exceeds +150°C. The driving may be too intensive.

• Drive the truck less intensively.

• Check for dirt around the motor. Too much dirt means that the motor does not cool down properly.

3.040

No event. The truck can be driven.

Faulty energy saving function in the holding position.

• Internal fault in the transistor regulator.

• Restart the truck.

• If the error persists, change the transistor regulator.

3.080

The transistor regulator reduces the maximum current to 50 %.

The temperature sensor for the transistor regulator shows abnormal values.

• Internal fault in the transistor regulator.

• Restart the truck.

• If the error persists, change the transistor regulator.

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© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

3.081

The transistor regulator reduces the maximum current to 50 %.

The temperature sensor for the motor shows abnormal values. The sensor may be faulty.

Check cables (63/64) to the temperature sensor in the motor.

3.101

Safety speed, raising and lowering the forks not working.

The transistor regulator is using predefined current gain. Internal fault • Internal fault in the transistor regulator.

• Restart the truck.

• If the error persists, change the transistor regulator.

3.120

Safety speed, raising and lowering the forks not working.

Faulty control total for parameters in the transistor regulator.

• Internal fault in the transistor regulator.

• Restart the truck.

• Reprogramme the truck.

• If the error persists, change the transistor regulator.

3.121

Safety speed, raising and lowering the forks not working.

The transistor regulator cannot use the internal memory.

• Internal fault in the transistor regulator.

• Restart the truck.

• Reprogramme the truck.

• If the error persists, change the transistor regulator.

3.140

The horn does not work. The safety speed.

The horn output has short-circuited.

Check: • connections and wiring harness • cable 50 • the horn.

3.501

The main contactor opens.

Faulty transistor regulator.

Check: • the transistor regulator • factory parameter 1001 (Truck type).

If the error persists, change the transistor regulator.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7– 9

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

3.502

The main contactor opens.

The control handle's logic card cannot download parameters to the transistor regulator.

• Restart the truck.

• Change logic card in the handle.

• If the error persists, change the transistor regulator.

3.510

The main contactor opens.

CAN communication problem with the transistor regulator when starting.

Check: • connections and wiring harness • cables 119 and 120 • make sure that the ICH [A5] and ACT [T1] have compatible software.

See Section "7.1 General".

• logic card in the handle and possibly change the card.

If the error persists, change the transistor regulator.

3.511

The main contactor opens.

The handle's logic card does not see CAN data from the transistor regulator.

Check: • connections and wiring harness • cables 119 and 120 • logic card in the handle and possibly change the card.

If the error persists, change the transistor regulator.

3.512

The transistor regulator stops all functions.

The transistor regulator does not see CAN data from the control handle's logic card.

Check: • connections and wiring harness • cables 119 and 120 • logic card in the handle and possibly change the card.

If the error persists, change the transistor regulator.

7 – 10

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© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

3.514

The main contactor opens.

The logic card in the control handle cannot send CAN data to the transistor regulator.

Check: • connections and wiring harness • cables 119 and 120 • logic card in the handle and possibly change the card.

If the error persists, change the transistor regulator.

3.515

The transistor regulator stops all functions.

The transistor regulator discovers CAN communication error.

Check: • connections and wiring harness • cables 119 and 120 • logic card in the handle and possibly change the card.

If the error persists, change the transistor regulator.

3.520

The transistor regulator stops all functions.

The transistor regulator discovers short-circuit in the output step.

Check: • motor cables • motor • the transistor regulator.

3.521

The transistor regulator stops all functions.

The transistor regulator discovers low motor voltage.

Check: • motor cables • motor • the transistor regulator.

3.522

The transistor regulator stops all functions.

The transistor regulator discovers high motor voltage.

Check: • motor cables • motor • the transistor regulator.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 11

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

3.523

The transistor regulator stops all functions.

The transistor regulator discovers internal problems with its own software or hardware.

Internal fault in the transistor regulator.

Reprogramme the truck both in the handle and the transistor regulator.

3.524

The transistor regulator stops all functions.

The transistor regulator discovers internal problems with its own software or hardware.

Internal fault in the transistor regulator.

Reprogramme the truck both in the handle and the transistor regulator.

3.525

The transistor regulator stops all functions.

The transistor regulator discovers that the motor phase is always 0 (zero).

Check: • motor cables • motor • the transistor regulator.

3.526

The transistor regulator stops all functions.

The transistor regulator's voltage feed is wrong.

Internal fault in the transistor regulator.

Change transistor regulator.

3.527

The transistor regulator stops all functions.

Faulty transistor regulator software.

Internal fault in the transistor regulator.

Check that the last software for the transistor regulator exists.

3.528

The transistor regulator stops all functions.

Internal problem for the transistor regulator's microprocessor.

• Internal fault in the transistor regulator.

Check that the last software for the transistor regulator exists.

• If the error persists, change the transistor regulator.

3.529

The transistor regulator stops all functions.

The transistor regulator discovers an internal problem.

• Internal fault in the transistor regulator. Check the software.

• If the error persists, change the transistor regulator.

7 – 12

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

3.530

The transistor regulator stops all functions.

The transistor regulator discovers an internal problem.

• Internal fault in the transistor regulator. Check the software.

• If the error persists, change the transistor regulator.

3.531

The transistor regulator stops all functions.

The transistor regulator discovers an internal problem.

• Internal fault in the transistor regulator. Check the software.

• If the error persists, change the transistor regulator.

3.532

The transistor regulator stops all functions.

The transistor regulator has an internal problem in the AD transformer.

• Internal fault in the transistor regulator.

• Change transistor regulator.

3.533

The transistor regulator stops all functions.

The charging voltage for the transistor regulator's capacitor shows abnormal values.

Check: • connections and wiring harness • cable 20 • the transistor regulator.

• pump contactor If the error persists, change the transistor regulator.

3.534

The transistor regulator stops all functions.

The transistor regulator discovers a problem with the speed sensor. The jump in frequency is too great.

Check: • connections and wiring harness • the speed sensor and possibly change it.

3.535

The transistor regulator stops all functions.

Faulty control total for parameters in the transistor regulator.

Download new programme in the handle and transistor regulator.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 13

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

3.536

The transistor regulator stops all functions.

The transistor regulator's current sensor is outside valid intervals.

Internal fault in the transistor regulator.

Change transistor regulator.

3.537

The transistor regulator stops all functions.

Multiple direction commands from the handle.

Internal fault in the handle.

3.538

The main contactor opens.

Unknown fault in the transistor regulator.

• Internal fault in the transistor regulator. Reprogramme the transistor regulator.

• If the error persists, change the transistor regulator.

3.539

The transistor regulator stops all functions.

The transistor regulator discovers that the battery voltage value is not between 18 V - 28.8 V. Check: • the cables between the battery and transistor regulator.

• the battery.

3.540

The transistor regulator stops all functions.

The transistor regulator's output to the main contactor has short-circuited.

Check: • connections and wiring harness • the main contactor.

3.541

The transistor regulator stops all functions.

The transistor regulator's output to the parking brake has short-circuited.

Check: • connections and wiring harness • the parking brake.

7 – 14

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

3.542

The transistor regulator stops all functions.

One of the transistor regulator's circuits to the main contactor, parking brake or lowering valve has shortcircuited at+24 V when starting.

Check • connections and wiring harness • main contactor • parking brake • lowering valve.

3.560

The transistor regulator stops all functions.

The transistor regulator's output to the main contactor is short-circuited.

Check: • connections and wiring harness • the main contactor.

3.561

The transistor regulator stops all functions.

The circuit between the transistor regulator and the coil in the main contactor is open.

Check: • connections and wiring harness • the main contactor.

3.562

The transistor regulator stops all functions

The transistor regulator's output to the parking brake is open.

Check: • connections and wiring harness • parking brake.

3.563

The transistor regulator stops all functions.

The transistor regulator's coil circuit to the parking brake is open.

Check: • connections and wiring harness • parking brake.

3.580

The transistor regulator stops all functions.

Main contactor closed.

Check: • connections and wiring harness • the main contactor.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 15

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

3.581

The transistor regulator stops all functions.

Main contactor closed.

Check: • connections and wiring harness • the main contactor.

• main fuse [F1]

3.582

The transistor regulator stops all functions.

The transistor regulator's output for power supply has the wrong voltage level.

Check: • connections and wiring harness • the main contactor • lowering valve • brake • pump contactor.

Internal fault in the transistor regulator.

Change transistor regulator.

3.583

The transistor regulator stops all functions.

The transistor regulator's internal power supply does not increase.

Internal fault in the transistor regulator.

Change transistor regulator.

Hydraulic system 4.001

Lifting is prevented until the analogue control of lifting and lowering is back in the neutral setting.

The analogue control for lifting and lowering is not in the neutral setting when starting. (Applies to SWE trucks).

Speed control not affected when starting the truck.

Check: • cable in the handle • potentiometer. For fault, change potentiometer.

4.101

Safety speed, raising and lowering the forks not working.

Analogue control signals for lifting and lowering shows abnormal values.

Speed control not affected when starting the truck.

Check: • cable in the handle • potentiometer. If broken, change potentiometer.

7 – 16

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

4.102

Safety speed, raising and lowering the forks not working.

The handle type does not correspond with the adjustment for factory parameter 1023 “Control for hydraulic function”.

Check the adjustment for factory parameter 1023 and compare with the truck's handle.

4.125

Safety speed, raising and lowering the forks not working.

The pump motor's current feedback is always zero when the pump motor is in operation.

The current sensor in the transistor regulator is faulty. Change transistor regulator.

4.126

Safety speed, raising and lowering the forks not working.

The pump motor's current feedback is too high when starting and in holding position.

The current sensor in the transistor regulator is faulty. Change transistor regulator.

4.521

The main contactor opens.

The pump motor's voltage is too low.

Check: • the cable between the transistor regulator and pump motor.

• the pump motor.

4.522

The main contactor opens.

The pump motor's voltage is too low.

Check: • the cable between the transistor regulator and pump motor.

• the pump motor.

4.540

The transistor regulator stops all functions.

• The transistor regulator's output to the lowering valve has shortcircuited.

• Internal short-circuit in the transistor regulator.

• Check connections and wiring harness • Loosen the connection to the lowering valve and try to restart.

• If the error persists, change the lowering valve or change the transistor regulator.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 17

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

4.541

The transistor regulator stops all functions.

The transistor regulator's output to the lowering valve has short-circuited to B-.

Check connections and wiring harness

4.560

The transistor regulator stops all functions.

The transistor regulator's output to the lowering valve is open.

Check: • connections and wiring harness • the lowering valve's coil.

Option 8.001

Safety speed, raising and lowering the forks not working.

The collision sensor has registered collision levels that are above the stated limits.

• Drive carefully.

• Check the limits for registering collisions (service parameters 105 and 106).

8.002

Safety speed, raising and lowering the forks not working.

The truck has deliberately been put in an unusable state by TLS. Reset the truck to normal operation.

8.003

No event. The truck can be driven.

Argument warning from the Spider expansion unit.

Check the settings for selected parameters.

8.010

No event. The truck can be driven.

CAN communication problem with the battery charger when starting.

• Check connections and wiring harness • Make sure that the ICH [A5] and BCU [A30] have compatible software. See Section "7.1 General".

8.011

No event. The truck can be driven.

The handle's logic card does not see CAN data from the battery charger.

Check connections and wiring harness

8.014

No event. The truck can be driven.

The logic card in the control handle cannot send CAN data to the battery charger.

Check connections and wiring harness

8.020

No event. The truck can be driven.

The battery charger is not connected to the battery.

Check connections and wiring harness

7 – 18

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Error codes Order number 258944-040

Code

Date 2009-10-05

Valid from serial number 6053221-

Event

T-code 838, 839, 840

Possible cause Measure

8.021

No event. The truck can be driven.

The battery charger has discovered low battery voltage.

Check the battery's status

8.022

No event. The truck can be driven.

The battery charger has discovered high battery voltage.

Check the battery's status

8.023

No event. The truck can be driven.

The battery charger has discovered low charging temperature.

Charge the battery at normal temperature.

8.024

No event. The truck can be driven.

The battery charger has discovered high charging temperature.

Check: • dirt in the battery charger. Clean if needed.

• that the fan works.

8.027

No event. The truck can be driven.

Serious fault in the battery charger.

Change battery charger.

8.028

No event. The truck can be driven.

The battery cahrger has exceeded the time limit for charging.

Check the battery.

8.029

No event. The truck can be driven.

The battery charger charges more than maximum capacity.

Check: • battery • service parameter 110.

8.030

No event. The truck can be driven.

There is a battery charger in the truck, but has not been activated via factory parameter 1101.

Check factory parameter 1101.

8.031

No event. The truck can be driven.

Faulty parameter adjustment for the battery charger.

Restart the truck. Check that the truck and battery charger have the right software.

8.032

No event. The truck can be driven.

If the error code is displayed when charging using a built-in charger, parameter 109 is set incorrectly Check service parameter 109

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 19

Troubleshooting Error codes T-code 838, 839, 840

Code

Valid from serial number 6053221-

Event

Date 2009-10-05

Order number 258944-040

Possible cause Measure

8.110

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 1 when starting.

Check connections and wiring harness

8.111

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 1.

Check connections and wiring harness

8.114

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 2 when starting.

Check connections and wiring harness

8.115

Safety speed, raising and lowering the forks not working.

CAN communication problem with Spider expansion unit 2.

Check connections and wiring harness

8.123

Safety speed, raising and lowering the forks not working.

Spider expansion unit 1 programme warning.

Check parameter selections.

8.124

Safety speed, raising and lowering the forks not working.

Spider expansion unit 2 programme warning.

Check parameter selections.

7 – 20

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Troubleshooting diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.6 Troubleshooting diagram The following section describes different types of error that may arise and what these errors can be caused by.

The troubleshooting is grouped according to different symptoms that can occur: • The truck cannot be driven • The truck can be driven but only at reduced speed • The truck can be driven but behaves abnormally • Faulty hydraulic functions.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 21

Troubleshooting Troubleshooting diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.6.1 The truck cannot be driven Symptom

Influencing factors

Possible cause

The mechanical brakes cannot be activated.

Sensor [B60]

• The sensor is in the wrong position and is affected by metal.

• The sensor is faulty.

The mechanical brakes cannot be released.

The control handle in drive position is always “Plus”

The cable is damaged and gives faulty plus/minus measurement

Transistor regulator, input [T1:95].

Broken transistor regulator

Sensor [B60]

• The sensor is in the wrong position and cannot be influenced normally • The sensor is faulty • Break in the sensor's cable

The truck cannot be driven after starting, despite the control handle being folded up.

7 – 22

Transistor regulator, input [T1:95] Transistor regulator, output [T1:90]

Broken transistor regulator

Corrosion

The brakes are locked due to corrosion

Sensor [B60]

• The sensor is in the wrong position and is affected by metal • The sensor is faulty

The control handle in drive position is always “Plus”

The cable is damaged and gives faulty plus/minus measurement

Transistor regulator, input [T1:95].

Broken transistor regulator.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Troubleshooting diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.6.2 The truck can only be driven at reduced speed Symptom

Influencing factors

Possible cause

Always reduced speed

Click-2-Creep function

Click-2-Creep function activated

Turtle function

Turtle function activated

Driver parameter 6 - speed

Driver parameter 6 not set at the maximum value

Pulse sensor [B11]

The pulse sensor [B11] is broken, dirty or not connected

Connection of motor cables

• One of the phases U, V, W is unconnected • Broken cable

Mechanical brakes

• Partly working brakes • Faulty play.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 23

Troubleshooting Troubleshooting diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.6.3 The truck can be driven but behaves abnormally Symptom

Influencing factors

Possible cause

The truck goes in the wrong direction.

Connection of motor cables

Connections U, V, W are wrongly connected

Always reduced acceleration

Driver parameter 4

Set at a low value.

Always reduced reverse braking.

Service parameter 201

Set at a low value.

Always reduced neutral braking

Driver parameter 5

Set at a low value

The truck cannot be switched off.

Parameter 102 The Red off key on the keypad does not work.

Parameter 102 has been incorrectly set for the log-in unit installed in the truck.

Always reduced speed.

Pulser [B11]

The pulser [B11] is broken, dirty or not connected

Connection of motor cables

• Some of the phases U, V, W are disconnected • Cable breakage

7.6.4 The truck can be driven but lacks certain functions.

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

7 – 24

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Troubleshooting diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Matrix for hardware compatibility Make sure the correct hardware for logic card [A5] and transistor regulator [T1] has been installed in the truck by referring to the matrix below.

Not replaced transistor regulator ACT[T1]

Replaced transistor regulator ACT[T1]

Not replaced ICH logic card [A5]

OK

Warning 2.004. Use TruckCom to download backup values. In TruckCom, select “Copy configuration to secondary unit ACT”

Replaced ICH logic card [A5]

Error code 2.101. Use TruckCom to upload backup values.

Select “Copy configuration to primary unit: ICH”

Replace a node at a time and carry out the corresponding step. See 17.2 and 16.5.2

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 25

Troubleshooting Troubleshooting diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.6.5 Faulty hydraulic functions Symptom

Influencing factors

Possible cause/Action

The forks can be lowered but not raised.

No or low hydraulic pressure

• Low oil level • Blocked intake filter • Faulty or wrongly adjusted pressure limiting valve • Faulty hydraulic pump, change hydraulic unit

Pump contactor [Q25] does not close

• Measure the current and voltage over the pump contactor [Q25].

For more information read more in the following table Pump contactor [Q25] does not close: • The pump contactor [Q25] current/voltage is normal” • No current or voltage through/ across the contactor coil [Q25] • Voltage across the contactor coil [Q25], but no current through it.

Pump motor [M3] does not work

• The hydraulic unit's fuse [F1], 125 A, has burned out: change the fuse.

For more information read more in the following table Pump motor [M3] does not work: • Measure the current and voltage respectively across the pump motor [M3].

• The pump motor's [M3] current/voltage is normal • No current or voltage through/ across the motor [M3] • Voltage across the motor [M3], but no current through it

The height switch [B61] does not work

7 – 26

Repair Manual

• Check the switch and its connections

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Troubleshooting diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

Symptom

Influencing factors

Possible cause/Action

The forks can be raised but not lowered.

The magnetic valve [Q4] for loweri ng the forks does not open

• Measure the current and voltage respectively across the valve's coil.

For more information read more in the following table The magnetic valve [Q4] for the lowering of forks does not open: • The magnetic valve's voltage/ current is normal • No current or voltage through/ across the magnetic valve's coil • Voltage across the magnetic valve's coil, but no current through it

The forks can neither be raised or lowered

Fuse [F50] 7.5 A is faulty

Change the fuse

Logic card [A5] is faulty

Replace logic card

Transistor regulator [T1] is faulty

Change transistor regulator

Factory parameter 1023

Check the setting of the parameter value

Continued. Pump contactor [Q25] does not close Symptom

Influencing factors

Possible cause/Action

The pump contactor [Q25] current/voltage is normal

Fault in connector

Change pump contactor

No current or voltage through/across the contactor coil [Q25]

Damage in the pump contactor cables or connections

Take control measurement of the cable with regards to breakage or short circuit to another cause

The control arm's Hall element for fork lifting is faulty

Replace logic card [A5]

Transistor regulator [T1], output 107 “OUT.PUMP CONTACTOR” is faulty

Change transistor regulator [T1]

Transistor regulator [T1], output 82 “OUT. +24 V HIGH SIDE DRIVER” is faulty

See troubleshooting table The truck cannot be driven

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 27

Troubleshooting Troubleshooting diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Continued. Pump contactor [Q25] does not close Symptom

Influencing factors

Possible cause/Action

Voltage across the contactor coil [Q25], but no current through it

Break in the pump contactor coil [Q25]

Change pump contactor

Continued. Pump motor [M3] does not work: Symptom

Influencing factors

Possible cause/Action

The pump motor's [M3] current/ voltage is normal

Mechanical fault in the pump

Change hydraulic unit

No current or voltage through/ across the motor [M3]”

Damage in the pump motor's [M3] cables or connections

Take control measurement of the cable with regards to breakage or short circuit to another cause

Voltage across the motor [M3], but no current through it

Break in the pump motor [M3]

Change hydraulic unit

Continued. The magnetic valve [Q4] for lowering the forks does not open: Symptom

Influencing factors

Possible cause/Action

The magnetic valve's [Q4] current/voltage is normal

Mechanical fault in the valve [Q4]

Change hydraulic unit

No current or voltage through/across the magnetic valve's coil [Q4]

Damage in the magnetic valve's [Q4] cables or connections

Take control measurement of the cable with regards to breakage or short circuit to another cause

The control arm's Hall element for fork lowering is faulty

Replace logic card [A5]

Transistor regulator [T1], output 108 “OUT.LOWER VALVE” is faulty

Change transistor regulator [T1]

Transistor regulator [T1], output 82 “OUT. +24 V HIGH SIDE DRIVER” is faulty

See troubleshooting table The truck cannot be driven

Break in the magnetic valve's coil [Q4]

Change hydraulic unit

Voltage across the magnetic valve's coil [Q4], but no current through it

7 – 28

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Troubleshooting Built-in test function Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.7 Built-in test function The control system of the truck has a number of built-in test functions that are useful in the troubleshooting process. To activate the test functions: 1. Connect the CAN service key to [X41] and log in.

2. The battery status symbol lights up.

3. Press the signal horn button [S18] repeatedly to select the mode of the built-in test function.

NOTE! All truck functions work as normal while the built-in test function is active. Be careful if driving the truck and reading the display at the same time.

Setting

Flashing symbol

Data shown in the display

Normal value

1

Battery voltage (V)

2

Current over battery (A)

-

3

The set speed value that is sent to the transistor regulator

Min: -142 Max: 142

4

Speed value from the speed sensor

5

Fork lowered to/from Fork lift to/from

Min: approx. 140 Max: approx.

140 To: 1 From: 0 To: 2 From: 0

6

N/A

-

7

N/A

-

8

N/A

-

9

Status of inputs/outputs, transistor regulator [T1]

-

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 29

Troubleshooting Status of digital inputs/outputs T-code 838, 839, 840

Setting

Valid from serial number 6053221-

Flashing symbol

Date 2009-10-05

Order number 258944-040

Data shown in the display

Normal value

10

Input/output status, logic card [A5]

-

11

Maximum value registered by the collision sensor (optional)

Min: 0 Max: 100

12

Status of inputs/outputs, expansion unit 1 (optional)

-

13

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

-

7.8 Status of digital inputs/outputs 7.8.1 Test function “9” – Transistor regulator In this mode, the digital inputs and outputs can be tested by checking specific segments on the display as set out in the following tables.

A F G B C

E

1

2

3

4

D

H

Position: 1. Transistor regulator inputs 2. Transistor regulator outputs 3. Digital input to electronic card [A2] 4. Extra functions A – H: Reference to segment One or more segments can be lit in each position. Indications can also be combined over several positions. [xxx] in the table is a component name {nn} in the table is a cable number in the wiring diagram.

7 – 30

Repair Manual

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© BT

Troubleshooting Status of digital inputs/outputs Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

Function

T-code 838, 839, 840

Pos 1

Pos 2

Pos 3

Pos 4

-

A

*

*

*

Not assigned

Main contactor [Q10]

B

*

*

*

On: Contactor closed Off: Contactor open

Parking brake [Q1]

C

*

*

*

On: Brake off Off: Brake on

Tiller arm in drive position [B60] INP. TILLER ARM IN DRIVE POS.

D

*

*

*

On: Tiller arm in drive position Off: Tiller arm in one of the end positions

-

E

*

*

*

Not assigned

-

F

*

*

*

Not assigned

-

G

*

*

*

Not assigned

-

H

*

*

*

Not assigned

-

*

A

*

*

Not assigned

-

*

B

*

*

Not assigned

-

*

C

*

*

Not assigned

-

*

D

*

*

Not assigned

Pump motor contactor [Q25]

*

E

*

*

On: Contactor open Off: Contactor closed

-

*

F

*

*

Not assigned

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned A F G B C

E D

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

H

7 – 31

Troubleshooting Status of digital inputs/outputs T-code 838, 839, 840

Function

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

Pos 1

Pos 2

Pos 3

Pos 4

-

*

*

A

*

Not assigned

Main contactor [Q10] OUT. MAIN CONTACTOR

*

*

B

*

On: Contactor closed Off: Contactor open

-

*

*

C

*

Not assigned

Parking brake [Q1] OUT. BRAKE RELEASE

*

*

D

*

On: Brake off Off: Brake on

-

*

*

E

*

Not assigned

-

*

*

F

*

Not assigned

Lowering valve

*

*

G

*

On: Lowering valve open Off: Lowering valve closed

-

*

*

H

*

Not assigned

Pump motor contactor [Q25] OUT. PUMP CONTACTOR

*

*

*

A

On: Contactor closed Off: Contactor open

-

*

*

*

B

Not assigned

-

*

*

*

C

Not assigned

-

*

*

*

D

Not assigned

-

*

*

*

E

Not assigned

-

*

*

*

F

Not assigned

-

*

*

*

G

Not assigned

-

*

*

*

H

Not assigned A F G B C

E D

7 – 32

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

H

© BT

Troubleshooting Status of digital inputs/outputs Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.8.2 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

*

*

*

On: Button pressed

Front fork lowering button [A5:S20]

E

*

*

*

On: Button pressed

Rear fork lift button [A5:S21]

F

*

*

*

On: Button pressed

Rear fork lowering button [A5:S22]

G

*

*

*

On: Button pressed

Control for horn [S18]

H

*

*

*

On: Button pressed

Outermost selection button, right side [S116]

*

A

*

*

On: Button pressed

Central selection button, right side [S115]

*

B

*

*

On: Button pressed

Innermost selection button, right side [S114]

*

C

*

*

On: Button pressed

Outermost selection button, left side [S113]

*

D

*

*

On: Button pressed

Central selection button, left side [S206]

*

E

*

*

On: Button pressed

Innermost selection button, left side [S111]

*

F

*

*

On: Button pressed

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned A F G B C

E D

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

H

7 – 33

Troubleshooting Status of digital inputs/outputs T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

7.8.3 Test function “12” – Expansion unit SEU (optional).

Function

Pos 1

Pos 2

Pos 3

Pos 4

Digital input 1, SEU1

A

*

*

*

-

Digital input 2, SEU1

B

*

*

*

-

Digital input 3, SEU1

C

*

*

*

-

Digital input 4, SEU1

D

*

*

*

-

Digital input 5, SEU1

E

*

*

*

-

Digital input 6, SEU1

F

*

*

*

-

Digital input 7, SEU1

G

*

*

*

-

Digital input 8, SEU1

H

*

*

*

-

Digital output 1, SEU2

*

A

*

*

-

Digital output 2, SEU2

*

B

*

*

-

Digital output 3, SEU2

*

C

*

*

-

Digital output 4, SEU2

*

D

*

*

-

-

*

E

*

*

Not assigned

-

*

F

*

*

Not assigned

-

‘

G

*

*

Not assigned

-

*

H

*

*

Not assigned A F G B C

E D

7 – 34

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

H

© BT

Troubleshooting Display test function Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

7.9 Display test function The digital display [A6] can be tested to verify that all segments light up correctly.

Follow these steps to test the display: 1. Make sure the battery is connected.

2. Make sure the truck is switched off. Press the OFF button.

3. Enter the selected PIN code. NOTE: Do NOT press the ON button.

4. Keep [S18] pressed until “d” is displayed, then release [S18].

All segments and symbol icons must flash in sequence.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

7 – 35

Troubleshooting Display test function T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

7 – 36

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Chassis 0000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

8 – Chassis 0000 8.1 General To gain access for certain inspection items, it may be necessary to disassemble the drive unit from the fork frame.

A

B

C

D E

© BT

Pos.

Designation

A

Cylinder locking

B

Mounting hole

C

Axle 2

D

Stop screw 2

E

Nut 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

8– 1

Actions Chassis 0000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

8.2 Disassemble the drive unit from the fork frame Proceed as follows to separate the fork frame from the drive unit: 1. Ensure that the truck is standing on a level surface.

2. Remove the inspection covers and the battery door The top cover is secured with Velcro tape. Be careful when 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. Insert a block under the rear edge of the drive unit (NB! Remember to use the same size of all blocks when raising the truck, so that the truck remains stationary).

10. Place the jack between the forks and lift the fork frame.

11. Lift up the truck approx 140 mm with blocks under the fork carriage and forks.

Align the mounting hole (B) on the fork frame side with the axle.

12. Remove the axles (C).

13. Then pull apart the drive unit and fork frame.

NOTE! Never lift the drive unit by the tiller arm when separating the drive unit from the fork frame.

Assemble in reverse order.

NOTE! Be careful when reassembling so that no cables are trapped.

8– 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Chassis 0000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

8.3 Removing the platform 1. Load the platform and loosen the upper damper stop and the spring’s cover plate.

2. Remove the platform from the truck by undoing the four bolts 3. Place the platform on the floor behind the truck with the spring facing towards you and the other edge under the truck’s kick guard.

4. Undo all 8 screws holding the fastening against which the spring bracket presses.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

8– 3

Actions Chassis 0000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

NB! Take care when working with tensioned springs.

5. Relieve the pressure on the spring using a crow-bar or a large screwdriver and carefully remove the fitting.

6. Pull out the axle and replace the part(s) that need to be changed.

7. Assemble in reverse order.

8– 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Chassis 0000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

8.4 Change of damper for castor cradle 1. Undo the nuts at the ends of the damper

2. Slip the damper off the threaded metal pins 3. Slip on the new damper and fasten both nuts again

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

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

8– 5

Actions Chassis 0000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

3. Undo the cylinder fastening using hex key 5 and 10

4. Undo the cylinder fastening from the cylinder

5. Change cylinder and/or spring

Assemble in reverse order

8– 6

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Fork frame 0380 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

9 – Fork frame 0380 9.1 Components

A

B C

D K

G

L I

F

H

J

M N O

E

P Q

R

© BT

Pos.

Component

Pos. Component

A B C D E F G H I

Cotter Bush Axle Screw Greasing nipple Bush Locking pin Axle Push rod

J K L M N O P Q R

Repair Manual

Bush Torsion tube Bush Bush Locking pin Axle Axle Stop screw Nut

LWE140, LWE160, LWE180, LWE200, LWE250

9– 1

Actions Fork frame 0380 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

9– 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Electrical drive motor 1700 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

10 – Electrical drive motor 1700 10.1 Components B A C F

D

E

Pos

Name

A B C

Speed sensor Cover Motor: LWE140/160/180 1,0 kW LWE200/250 1.5 kW Tension pin Lift cylinder Temperature sensor

D E F

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

10 – 1

Actions Electrical drive motor 1700 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

10.2 Remove motor from truck 1. Remove the inspection covers.

The upper inspection cover is fastened using velcro. Take care when you loosen the inspection cover. By all means use a tool to help you.

2. Lift the drive unit using a jack and lift up the truck using blocks under the drive unit so that the drive wheel hangs freely.

3. Cut the cable duct tie on the transistor regulator's side and loosen the cable connections X5 and X60.

4. Loosen the operating console's mounting screws and remove the operating console and tiller arm.

5. Loosen the brake's mounting screws and the cable connection Q1.

6. Remove the brake.

7. Loosen the speed sensor and cable connection B1.

8. Loosen the motor cables and the motor's mounting screws.

9. Lift the motor out of the truck.

NOTE! Cover the drive gear so that no loose objects can fall into the drive gear when the drive motor is removed.

Install the motor in the reverse order.

See section “10.4 Tightening torque Drive motor”.

NOTE: When fitting it is very important that the motor is adjusted so that the slots in the motor and motor bracket are exactly opposite each other before tightening the mounting screws. See the picture below.

Screw the drive motor into place using the 4 screws (a). Always tighten the screws alternately in two stages. In other words, do not tighten the screw to its full torque in the first stage. See section “10.4 Tightening torque Drive motor”.

a

10 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Electrical drive motor 1700 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

10.3 Fitting the tempreature sensor 1. Unclip the cable from the broken temperature sensorand fit the new temperature sensor.

2. Place the new temperature sensor in the motor.

3. Clean thoroughly and ensure that the surface is dry.

4. Apply the plastic padding by squeezing out a strand of the hardener half the length of the filler and mix well (be careful not to mix more than can be used within 5 minutes).

5. Apply a layer of the plastic padding at least 4 mm thick, and overlap the repaired surface by at least 2 cm.

6. Fix the plastic padding with masking tape and allow to harden.

7. Remove the masking tape.

The temperature sensor should now be covered by plastic padding.

8. After hardening, it is a good idea to add a further layer of the plastic padding

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

10 – 3

Actions Electrical drive motor 1700 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

10.4 Tightening torque Drive motor The tightening torques for the drive motor are indicated in the picture:

3.5Nm T30

3 + 0,5 Nm 10 mm

8 Nm T30

10 – 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Electrical drive motor 1700 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

10.5 Cleaning It is crucial to the correct function that the motor is kept as clean as possible. The motor and motor housing must be regularly inspected for dust, oil and other contaminants.

Dirty and/or oily components must be cleaned using a clean cloth, moistened with solvent. Use a lint-free cloth. Do not apply so much solvent that it finds its way into the motor parts.

After cleaning, the components must be dried well, which is most effectively done by heating.

NOTE! Windings and insulation should not be heated above 125°C and for no more than 6 hours.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

10 – 5

Actions Electrical drive motor 1700 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

10 – 6

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Drive unit/gear 2550 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

11 – Drive unit/gear 2550 11.1 General The gear together with the motor and the brake are combinded as a complete drive unit.

A complete reconditioning of the driving gear must be performed in the workshop by trained technicians.

11.2 Components A

B

C

© BT

Pos

Component

A B C

Main lift cylinder Screw Gear

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

11 – 1

Actions Drive unit/gear 2550 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

11.3 Remove the gear from the truck 1. Raise the forks and lift the drive unit up approx. 190 mm.

2. Loosen the drive wheel.

3. Remove the inspection covers.

The upper inspection cover is fastened using velcro. Take care when you loosen the inspection cover. By all means use a tool to help you.

4. Cut the cable duct tie on the transistor regulator's side and loosen the cable connections X5 and X60.

5. Loosen the operating console's mounting screws and remove the operating console and tiller arm.

6. Loosen the speed sensor and cable connections Q1 and B1.

7. Loosen the motor cables and the motor's mounting screws.

8. Lift the motor out of the truck.

9. Put a plug in the hole in the gear to prevent any oil spills when taking the gear out of the truck.

10. Loosen the gear's mounting screws.

11. Lay down the gear and move it out under the forks.

Assemble in reverse order.

Put a block under the gear in order to simplify assembly.

11 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Brake 3180 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

12 – Brake 3180 In normal environments, the brake in principle is maintenance free.

12.1 Components A

B

C

F

D

G E

© BT

Pos no.

Description

A

Circlip

B

Complete brake

C

Screw

D

Key

E

Hub

F

Brake disc

G

Flange

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

12 – 1

Actions Brake 3180 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

12.2 Release of brakes NOTE! The brakes must only be released when the truck has to be moved for service and repair work.

A

A The truck's brakes can be released manually when needed by screwing in two (M5) screws into holes (A). The screws must be 30-35 mm long.

NOTE! Remember to remove the screws before the truck is put back into use again.

12 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Drive wheel 3530 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

13 – Drive wheel 3530 A

B

13.1 Changing drive wheel 1. Raise the forks and elevate the truck (approx 100 mm).

2. Loosen the drive wheel (A).

It is simplest to loosen the drive wheel between the forks. Angle the wheel to the side in order to work more easily under the truck.

3. Put the new wheel in position (A) and tighten the nuts (B) 81 ±19 Nm.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

13 – 1

Actions Drive wheel 3530 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

13 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Castor wheel 3540 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

14 – Castor wheel 3540 14.1 Components A B C

D

E

F

G

L

M

H

I

K

© BT

J

Pos.

Name

Pos.

Name

A B C D E F G

Circlip Washer Screw Fitting Nuts Storage Circlip

H I J K L M

Screw Distance Distance Storage Protection Nuts

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

14 – 1

Actions Castor wheel 3540 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

14.2 Castor wheel mounting A

B C

D

E

F H

G

I J K

14 – 2

Pos.

Name

Pos.

Name

A

Nuts

G

Screw

B

Nuts

H

Cradle

C

Steering

I

Bushing

D

Spring

J

Fitting

E

Steering

K

Screw

F

Washer

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Castor wheel 3540 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

14.3 Changing castor wheel 1. Elevate the truck securely.

2. Unscrew the castor wheel.

14.4 Changing castor wheel cradle 1. Raise the forks.

2. Remove the inspection cover.

3. Loosen the spring fasteners.

4. Loosen the bracket for the castor wheel mounting.

5. Lift the drive unit so that the cradle is free.

Assemble in reverse order.

14.5 Changing springs 14.5.1 Removing springs 1. Loosen the upper lock nuts.

2. Lift the drive unit so that the springs are released from the upper bracket.

3. Loosen the lower lock nut on the spring that is to be changed.

NOTE! The spring is pre-tensioned, take care when loosening the lower lock nut.

14.5.2 Fitting the spring 1. Place a block under the spring bolt so that the spring screw is held in place.

2. Fit the spring with the lower lock nut and washer.

Use a short sleeve in order to screw the lower lock nut tight whilst pressing the spring together.

3. Screw down the lower lock nut so that the distance between the edge of the washer and the top of the screw is 15 mm.

4. Ensure that the springs are sitting correctly in the upper fasteners when the drive part is lowered.

5. Screw the upper lock nuts tightly.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

14 – 3

Actions Castor wheel 3540 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

14 – 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Fork Wheel 3550 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

15 – Fork Wheel 3550 15.1 Changing climber wheel B

A

E

F

C D G

H

K

I J

© BT

Pos.

Component

Pos

Component

A

Screw, K6S 8x12

G

Wheel, complete

B

Screw, MF6S 8x35

H

Wheel bracket

C

Sleeve

I

Axle

D

Climber wheel

J

Wheel

E

Friction block

K

Locking pin

F

Nut, M8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

15 – 1

Actions Fork Wheel 3550 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

15.2 Support arm wheel 3550 c

b

a

f

e

d

15 – 2

Pos

Name

a

Screw

b

Bracket

c

Bogie wheel

d

Single wheel

e

Axle

f

Locking ring

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Tiller arm 4000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

16 – Tiller arm 4000 16.1 Components in tiller arm A

U

T

B C E

S

D

I

F G

R

J

H

K

Q L

w P

M N

V

O

O

© BT

Pos.

Name

Pos.

Name

A B C D E F G H I J K L

Steering arm Rubber fender Cylindrical bolt Gas spring Locking ring Rubber fender Bushing Wire thread inserts Tension pin Holder Safety sensor B60 Axle

M N O P Q R S T U V W

Indicator socket Plate Ok Cable clamp Screw Ok Screw Cover Cover Cable clamp Mounting screw for cable clamp

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

16 – 1

Actions Tiller arm 4000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

16.2 Removing tiller arm 1. Remove the inspection cover.

2. Remove the housing (T).

3. Loosen the yoke's (R) mounting screws.

4. Detach cable clamp (P) by pressing the clamp with your thumbs and lifting it upwards. Remove the cable clamp through the hole in the tiller arm.

NOTE: Do not try to prise off the cable clamp using a screwdriver.

5. Cut the cable duct tie on the transistor regulator's side and loosen the cable connections X5 and X60.

Assemble in reverse order.

16.3 Changing gas suspension 1. Remove the casing (T).

2. Loosen the cable clamp mounting screws (W).

3. Loosen the adjustment screw (Q).

4. Remove the catch (E) from the gas suspension's lock axle (C).

5. Loosen the gas suspension's lock axle (C).

6. Remove the gas suspension.

Assemble in reverse order.

NOTE! Be careful when assembling so that no cables are crushed.

See image for correct positioning of the cable.

16 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Tiller arm 4000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

16.4 Changing the safety sensor 16.4.1 Dismantling 1. Remove the gas spring. See section “16.3 Changing gas suspension”.

2. Knock the axle’s (L) spiral pin (I) into place. Use a drift to knock the spiral pin to a depth at which the spiral pin goes into the axle completely.

3. Knock out axle (L) approximately 5 mm to expose the hole for the spiral pin. Take care not to trap indicator sleeve (M).

4. Turn the axle (L) so that the reverse of the indicator sleeve (M) becomes accessible.

Prize the indicator sleeve away from both sides simultaneously to avoid damaging the sleeve.

5. Remove the axle (L).

6. Loosen the cable clamp's (P) mounting screws.

NOTE: Ensure that the handle does not fall down and pull apart the cables.

7. Remove the cable clamp mounting screw (W).

8. Remove the sensor mounting screw (S).

9. Loosen the contact [B60] from the sensor (K).

10. Remove the sensor.

16.4.2 Assembly 1. Fit the sensor (K) 2. Fit contact [B60] to the sensor.

3. Apply Loctite to the sensor mounting screw (S), or replace it. Screw in the screw.

4. Screw in the cable clamp mounting screw (W).

NOTE: Route the cable to the right of the sensor (K), against the spiral pin.

5. Knock the spiral pin (I) out of the axle (L) before fitting the axle.

6. Fit the indicator sleeve and then turn the axle so that the sleeve is turned in towards the sensor. Turn it exactly so far that the spiral pin can go into the axle.

m 19

7. Use a drift to knock the spiral pin into the yoke (O) and axle (L).

Knock in the spiral pin so that the drift goes approximately 19 mm into the yoke. See picture.

m

8. Fit the gas spring. See section “16.3 Changing gas suspension”.

9. Check the function of the safety sensor.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

16 – 3

Actions Tiller arm 4000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

16.5 Components in tiller arm handle H G A

I

F

C A

B

D E K

J

L

S

T M

K

X L R N

Q

P O

U

V

16 – 4

Pos

Description

Pos

Description

A

Symbol board

M

B C D

N O P

E F G

Push button Push button Push button for safety reversing Spring Logic card Seal

Speed regulator/ direction selector Display Cable holder Cable holder

H I J K L

Spring Cover Seal Signal button Signal switch

T U V X

Repair Manual

Q R S

Cover Plug Lid, transparent plastic Seal Handle Lid Wiring harness

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Tiller arm 4000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

16.5.1 Removing the tiller arm handle 1. Unscrew the keyboard.

2. Loosen the screws and hold opposite the upper cover (Q).

3. Disconnect the cable connected to the logic card (F).

4. Loosen the screws and carefully lift away the undercover (I), Place a finger between the undercover (I) and the switch for safety reversing (D) to hold the switch in place.

Assemble in reverse order.

WARNING! Static electricity!

Risk of static discharge that can damage the electronics.

Ensure that necessary measures are taken before working with electronics.

16.5.2 Replacing the logic card Note!

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

1. Loosen the housing's (I) mounting screws.

2. Disconnect the logic card connections.

3. Remove the logic card.

Assemble in reverse order.

Use TruckCom in order to load the software and reset the parameters from backup that are stored in the main unit.

1. Load new software into the logic card.

2. When downloading is complete, press the red button and wait for error code 2.002 to be shown clearly.

3. Press “Connect” again in TruckCom and choose the current software if TruckCom does not locate it.

4. Select “Copy truck configuration” in TruckCom. 5. Select “Copy configuration to primary unit: ICH” Start the truck.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

16 – 5

Actions Tiller arm 4000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

16.5.3 Changing signal button/switch 1. Remove the button according to the image.

2. Disconnect the switch connector on the logic card.

3. Push the switch out from its fastening.

Assemble in reverse order.

16 – 6

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Tiller arm 4000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

16.5.4 Changing raising/lowering button.

1. Remove the button by placing a screwdriver in holes (A) according to the picture below.

A

A

2. Unscrew the holder so that the arm is loose.

Assemble in reverse order.

16.5.5 Changing push button 1. Push the button sideways manually.

2. Place a screwdriver according to the image and carefully prise the button loose.

3. Unscrew the button's holder and arm.

Assemble in reverse order.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

16 – 7

Actions Tiller arm 4000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

16.5.6 Changing the lifting control lever – from front to back 1. Undo the buttons for the lifting control using a narrow chisel and swap with the rear unmarked buttons.

2. Ensure that the projections hook into position when fitting the new buttons.

3. Connect a PDA or PC and use TruckCom to change parameter 1023 to 2.

4. Start the truck to verify the change.

16 – 8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Tiller arm 4000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

16.5.7 Changing a switch for safety reversing 1. Remove the display by undoing the screws.

×1 2,5 mm

2. Undo the screws to the upper part of the control lever.

×4 4 mm

3. Disconnect the CAN contact.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

16 – 9

Actions Tiller arm 4000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

4. Undo the screws so that the holder for the switch comes loose.

×3 3 mm

5. Remove the button by unhooking the locks on both sides

6. Assemble in reverse order.

16 – 10

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Electrical components Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

17 – Electrical components- 5000 17.1 Changing wiring harness

A B X5 X21

C

X60

D

Pos.

Name

A

Contact locking

B

Contact, flange

C

Fitting

D

Contact, handle

When changing the wiring harness, work according to the following instructions: 1. When spacing the X contacts, press the contact locking (A) into the flange (B) and pull upwards.

2. Loosen the contact's flange (B) from the handle (D).

3. Then release the handle (D) by pulling it downwards.

The remainder is fastened (C) to the contact panel. © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

17 – 1

Actions Electrical components T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

17.1.1 Changing the wiring harness to the transistor regulator

A

B

C

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

• Then lift up the contact ring (C).

17 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Electrical components Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

17.2 Replacing the transistor regulator Note!

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

a

1. Remove the inspection cover.

2. Cut the cable duct tie on the transistor regulator's side.

3. Remove the contacts (a) from the contact holder.

4. Loosen all cables and contacts in the transistor regulator.

5. Loosen the fastening nuts on the fixing plate (b).

6. Remove the transistor regulator.

Angle the fixing plate on the upper edge and turn it in the drive wheel direction in order to remove it from the truck.

Assemble in reverse order After fitting a new transistor regulator, the truck will display error code 2.004.

1. Connect TruckCom. 2. Select “Copy truck configuration”.

Select “Copy configuration to secondary unit: ACT” © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

17 – 3

Actions Electrical components T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

17.3 Lift height limit sensor [B61] 17.3.1 Replacing sensor [B61]

Location of lift height limit sensor [B61] in the truck 1. Disconnect the truck battery.

2. Disconnect the sensor electrical connection (a).

3. Mark (using tape for example) the position of the sensor bracket (b).

d b a

c 4. Loosen the screws (c) of the sensor bracket (torx T30)(spanner 9mm).

17 – 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Electrical components Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

5. Remove the bracket together with the sensor, so that the two sensor screws (d) can be accessed.

6. Unscrew the sensor (torx T20) (spanner 7mm) and discard the lock nuts.

7. Screw the new sensor into place using new lock nuts. The screws (d) are only to be tightened enough so that the sensor is in place with no play.

8. Line up the bracket with the marking 9. Screw the sensor bracket into place (b) and remove any marking.

10. Connect the sensor electrical connection (a).

11. Connect the truck battery.

12. Test the function of the sensor.

13. If necessary adjust the sensor. See section “17.3.2 Adjusting sensor [B61]”.

17.3.2 Adjusting sensor [B61]

1. Loosen the screws holding the sensor bracket (torx T30)(spanner 9mm) so that the position of the bracket can be adjusted.

2. Adjust the sensor as high as possible without the forks coming into contact with the mechanical stop. Push the sensor bracket upwards or downwards to find the correct position.

3. Tighten the bracket (torx T30)(spanner 9mm).

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

17 – 5

Actions Electrical components T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

17 – 6

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Hydraulic system 6000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

18 – Hydraulic system 6000 18.1 General Remember to take the following safety measures before you beging working with the truck's hydraulic system: • Release the system's pressure gradually.

• Use paper or a stiff piece of cardboard when checking for possible leakage. Do not use hands.

• Be careful as the oil in the transmission and hydraulic systems may be hot.

DANGER! If you come into contact with hot transmission and hydraulic oil there is a risk of burns. Allow the truck to cool down before changing the oil.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

18 – 1

Actions Hydraulic system 6000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

18.2 Hygiene when working on hydraulics NOTE: Risk of malfunction.

If contaminants get into the hydraulic system there is a risk of malfunctions in parts of or in the entire hydraulic system. There is also a risk of serious damage to incorporated components.

Observe the following instructions at all times when working on hydraulic systems.

NOTE! Only new and clean oil should be put into the hydraulic system.

If the oil is polluted, the hydraulic components will be damaged.

18.2.1 Washing Wash hydraulic components, including hydraulic hoses and pipes, using filtered cleaning fluid, in a manner suitable for that component.

The cleaning fluid is to have a cleanliness code of 19/16/13 according to ISO4406:1999, or alternatively 16/13 according to ISO4406:1987.

Components can be blown clean using dry filtered air when this is the only practically feasible cleaning method.

18.2.2 Packaging After cleaning all openings must be sealed using protective plugs.

Connection faces must be protected against damage caused by handling and against the ingress of dirt.

Completely dry components can be packaged in plastic bags or boxes with lids.

Packaging (protective plugs, masking, plastic bags etc.) must not be removed until immediately before components are to be fitted, and then in a workplace that is adapted for the handling of hydraulic components.

Tape must never be used without subsequent cleaning.

Protective plugs are to be stored in plastic bags or boxes with lids until they are used.

Plugs and plastic bags are to be discarded after use.

18.2.3 Handling Hydraulic components are to be handled and transported with great care.

Transport packaging is to be used throughout the chain of operations.

This packaging is to be clean and free of swarf etc.

18 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Hydraulic system 6000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

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

18.2.5 Carrying out work When work is being carried out on hydraulic systems, observe a level of cleanliness such that contaminants do not get into the system.

Machining by chip removal must never take place at the same, or close to a workplace at which work is carried out on hydraulic systems.

The service technician is to ensure that components being used are thoroughly deburred and cleaned.

Closures for pipe ends or other openings must not be removed until the component is being connected to its mated component.

NOTE: All hydraulic components that have not been washed such as pipe unions and nipples must be blown clean prior to fitting.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

18 – 3

Actions Hydraulic system 6000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

18.3 Hydraulic system components LWE140, LWE160, LWE180

B A

D

C F E

18 – 4

Pos.

Name

A

Pump motor

B

Screw

C

Pressure limit valve

D

Magnetic valve, fork lowering

E

Tank (suitable oil volume 0.8 l)

F

Filling tube

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Hydraulic system 6000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

18.4 Hydraulic system components for LWE200 and LWE250 A

B

F

C E

D

© BT

Pos.

Name

A

Pump motor

B

Screw

C

Pressure limit valve

D

Tank (suitable oil volume 0.5 l)

E

Filling tube

F

Magnetic valve, fork lowering

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

18 – 5

Actions Hydraulic system 6000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

18.5 Fitting the tube connection 1. Removing the dust shield.

Use the dismantling tool to remove the dust shield from the flange.

NOTE! Foreign objects in the flange may cause damage.

2. Installing the assembly stop.

The assembly stop is moved into place on the handle.

3. Connect the handle and the flange by pushing them together.

Turning the handle during connection reduces the connection power.

NOTE! The handle should not be without the assembly stop as there is a risk of accidental disconnection.

4. Complete the connection until the assembly is against the flange.

NOTE! Chect that there is no play between the assembly stop and the flange.

5. Try pulling the connection apart to check that the handle is locked.

18 – 6

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Hydraulic system 6000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

18.6 Hydraulkopplingar 6230 18.6.1 Quick change connector Assembling the quick change connector

1. Place the assembly stop (1) on the male fitting and make sure that the dismantling ring (2) runs freely in the groove.

2. Push the male fitting into the female fitting until the assembly stop makes contact with the female fitting.

3. The coupling is now made and locked.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

18 – 7

Actions Hydraulic system 6000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

18.7 Adjusting the pressure-limiting valve

3 2

1

The truck must be capable of lifting the rated load on the forks.

Place the rated load on the forks and check that the truck is able to lift it.

If the truck is unable to lift the rated load: 1. Prize off the white sealing stopper (1) around the pressure-limiting valve using a screwdriver..

2. Loosen the lock nut (2) by unscrewing it anticlockwise.

3. Screw in the adjusting screw (3) clockwise until the truck is able to lift the load easily.

4. Screw in the locking washer (2) clockwise.

If the truck is able to lift the rated load, place a further 100 kg on the forks. Check that the truck is not able to lift the load.

If the truck is able to lift 100 kg more than the rated load: 1. Prize off the white sealing stopper (1) around the pressure-limiting valve using a screwdriver.

2. Loosen the lock nut (2) by unscrewing it anticlockwise.

3. Unscrew the adjusting screw (3) clockwise until the truck is no longer able to lift the load.

4. Screw down the locking washer (2) clockwise.

5. Press a new sealing stopper (1) around the pressure-limiting valve

18 – 8

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Hydraulic system 6000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

18.8 Removing the hydraulic unit Ensure that the forks are lowered before you start working on the hydraulic unit.

2

4

1 3

1. Disconnect the hydraulic hose (1); see the quick-release coupling, section 18.5.1 for further information.

2. Disconnect the motor cables (2) with a number 13 spanner.

3. Undo the connection (3) to the lowering valve.

4. Undo the bracket for the hydraulic unit (4) and lift out the unit from the truck.

5

5. Undo screw (5) to remove the tank from the motor and lift off the motor from the tank. © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

18 – 9

Actions Hydraulic system 6000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

6 7

6. Loosen the locking ring (6) on the oil filter (7).

7. Remove and clean the filter, and then fit it back into position.

8. Change the oil and clean the tank.

9. Fit everything back in reverse order.

18 – 10

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Hydraulic system 6000 Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

18.9 Tightening the torque for the hydraulic unit The tightening torque for the hydraulic unit should be as shown in the figure:

8 +- 11 Nm 10 mm

33 +- 55 Nm 33 +- 55 Nm

25 mm

24 mm

8 +- 11 Nm 22 mm 0,8 Nm 5 +- 0,8

30 +- 55 Nm 19 mm

0,5 Nm 4 +- 0,5

7 mm

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

18 – 11

Actions Hydraulic system 6000 T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

18 – 12

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Accessories Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

19 – Accessories 19.1 Spider expansion unit The spider expansion unit, called SEU, allows the main logic card to manage a large number of inputs and outputs. There is no truck control logic in SEU, which means that a faulty SEU can be changed without it affecting the truck's function.

SEU is used for modifying the truck in accordance with special requirements from the customer.

Electronic card

Truck Log System

Pump controller

Extra/Customised function(s)

CAN bus

Spider Expansion Unit

CAN service connector Motor Controller

The image above shows how SEU is used to allow a large number of functions to be controlled via the CAN bus. SEU has a 42 pin, multipin contact that manages all inputs, outputs, CAN and power supply signals.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

19 – 1

Actions Accessories T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

19.2 TLS - Truck log system See the separate manual that follows about the truck log system.

19.3 ID unit See the separate manual that follows about the software.

19.4 Toyota Wireless Information System T.W.I.S. See the separate manual that follows about the software.

19 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Actions Accessories Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

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

B

19.5.1 Technical data

© BT

Name

SMCO 24/30

Measurement, mm

240x111x77

Weight, kg

1,7

Ambient temperature, ºC

-25 - +40

Mains voltage, V AC

195-264

Rated voltage, V DC

24

Rated current, A

30

Maximum output, W

800

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

19 – 3

Actions Accessories T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

19.5.2 Battery charging Open the battery door and connect the charger's contact to wall socket to begin charging.

NOTE! Always switch off the truck before charging and disconnect other electrical connections to the truck.

When the truck is being charged, the following is shown on the display:

Main charge On the left of the sign window, lines are shown in sequence as the battery is charged. The battery symbol and OFF button blink.

Uneven charging Four lines on the left of the sign window shine constantly while four lines on the right are shown in sequence. The battery symbol and OFF button blink.

Charging complete The sign window shows the capacity value and the unit (Ah) alternately.

The battery symbol shines at a fixed brightness and the OFF button blinks.

Remove the contact from the wall socket when the battery charge is complete. The OFF button now shines permanently. The truck is ready for use.

19 – 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix General Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

20 – Appendix 20.1 General In the Appendix chapter you can quickly find the following information: • Technical data • General tightening torques • Tools • Oil and grease specification • Electrical components and wiring diagrams • Hydraulics diagram • Destruction.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

20 – 1

Appendix General T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

20 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Technical data Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

21 – Technical data 21.1 LWE140, LWE160, LWE180, LWE200, LWE250 Model

LWE140, LWE160, LWE180

LWE200, LWE250

Type

Iskra AML7108

Iskra AML7109

Output, kW

1,0

1,5

Duty cycle

S2-60 min

S2-60 min

Weight, kg

9,0

10,5

Type

Warner PK10

Warner PK10

Braking force, Nm

15

15

Output, W

51/13

51/13

Resistance coil, Ω

10,5-12,0

10,5-12,0

Nominal play in actuated position, mm

0,3-0,6

0,3-0,6

Minimum thickness brake disc, mm

7,9

7,9

Thickness of a new brake disc, mm

8,2

8,2

Oil volume, litre

0,8

0,8

Oil type at normal temperature at temperature < -15oC

Synthetic API GL-5 SAE 75W-90

Synthetic API GL-5 SAE 75W-90

Drive motor

Brake

Transmission/drive gear

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

21 – 1

Appendix Technical data T-code 838, 839, 840

Valid from serial number 6053221-

Model

Date 2009-10-05

Order number 258944-040

LWE140, LWE160, LWE180

LWE200, LWE250

Drive wheel, mm

230

230

Axle pressure without load, kg

200, 255, 260

260

Axle pressure at rated load, kg

590, 695, 760

815, 950

Tightening torque for wheel bolts, Nm

81±19

81±19

Fork wheel, mm

125

125

Axle pressure without load, kg

105, 115, 135

135

Axle pressure at rated load, kg

1115, 1275, 1435

1580, 1945

Support castors, mm

85

85

Axle pressure without load

150

150

Axle pressure at rated load, kg

150

150

Output, kW

1

1,4

Minimum carbon brush length, mm

-

12,5

Pressure at rated load, bar

85-125, 100-140, 115-155

130-170, 170-210

Overflow pressure, bar

120-145, 135160, 150-175

165-190, 205-230

Pump flow, litre/minute

4,5-6,0

6,0-10,0

Suitable oil volume, litre

0,5

0,5

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

Hydraulic oil ISO-HM32 ISO-HV32

Hydraulic oil ISO-HM32 ISO-HV32

Drive motor circuits, A

125

125

Pump motor circuits, A

125

125

Control circuits, A

7,5

7,5

Wheels

Hydraulic system

Fuses

21 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Technical data Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

Model

T-code 838, 839, 840

LWE140, LWE160, LWE180

LWE200, LWE250

120-165, 120220, 180-270

180-270

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

6,0 1.7

6,0 1.7

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

6,0 1,7

6,0 1,7

Lift without load, m/s

0,05

0,09

Lift with rated load, m/s

0,04

0,06, 0,05

Lowering without load, m/s

0,08

0,08

Lowering with rated load, m/s

0,09

0,09

8, 8, 9

9, 8

Short Medium Long

1628 1685 1735

1685 1735

Lift height

205

205

290, 300, 325

325

Battery compartment, Batteries Weight, kg

Driving speed

Lift/lowering speed

Incline climbing ability With rated load

Measurement, L2

Weight Truck without battery, Medium

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

21 – 3

Appendix Technical data T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

21 – 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix General tightening torques Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

22 – General tightening torques Millimetre thread M3 to M24. The following applies under ideal conditions, e.g. steel against steel.

22.1 Galvanised, non-oiled bolts Tightening torques (Nm) Strength class: M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24

8,8

10,9

12,9

1,1 2,8 5,5 9,5 23 45 78 123 189 370 638

1,6 3,8 7,7 13 32 62 109 174 266 519 898

2,0 4,7 9,3 16 38 76 130 208 320 623 1075

22.2 Untreated, oiled bolts Tightening torques (Nm) Strength class: M3 M4 M5 M6 M8 M10 M12 M14 M16 M20 M24

8,8

10,9

12,9

1,2 2,9 5,7 9,8 24 47 81 128 197 385 665

1,7 4,0 8,1 14 33 65 114 181 277 541 935

2,1 4,9 9,7 17 40 79 136 217 333 649 1120

NOTE: Experience has shown that if you adjust the torque wrench to the values for untreated bolts, you will achieve the correct torque value for galvanised bolts. Do not tighten more than the values set out in the table, as the bolts may otherwise be destroyed. © BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

22 – 1

Appendix General tightening torques T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

22 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Tools Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

23- Tools 23.1 MQS connectors

Tools

Number

Use

257841

MQS Basic toolbox.

The box contains: 1 set pliers with tools 25 x splice 0.5-1.5 mm2 2 x 2, 3, 4, 6, 8 and 12 pin complete contacts (male and female) with cables and splice attached.

Used for replacing damaged contacts in the truck.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

23- 1

Appendix Tools T-code 838, 839, 840

Valid from serial number 6053221-

Tools

Date 2009-10-05

Order number 258944-040

Number

Use

257842

MQS assortment box.

Used for the complete MQS 257843 toolbox.

The assortment box contains: 200 x sleeves 0.2-0.5 mm2 200 x SWS sleeves 0.2-0.5 mm2 400 x SWS sleeves 0.5-0.75 mm2 100 x Clean body sleeves 0.5-0.75 mm2 200 x SWS pins 0.2-0.5 mm2 400 x SWS pins 0.5-0.75 mm2 1200 x seals 200 x blindplugs

257843

Complete MQS toolbox.

Contains 4 pliers with tools: MQS SWS 0.25-0.5 mm2 MQS SWS 0.5-0.75 mm2 MQS Std&Clean body 0.25–0.5 mm2, MQS Std&Clean body 0.5-0.75 mm2 Extraction tool for 2, 3, 4, 6, 8 and 12 pin male and female contacts.

23- 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Tools Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

23.2 AMP connectors PT = Power Timer (4,8. 5,8. 6,3 mm) JPT = Junior Power Timer (2,8 mm) MPT = Micro Power Timer (1,5 mm)

Figure

2

Number

Application

151080 (PT)

Tools for removing pins/sleeves

213296 (JPT)

Tools for removing pins/sleeves

213298 (MPT)

Tools for removing pins/sleeves

1=163787 2=163788

Tools for fitting sleeves

1=213336 (MPT) 2=213337 (MPT)

1

1=213336 (JPT) 2=213549 (JPT)

2

© BT

Tools for fitting pins For 0,5-2,5 mm2

1

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

23- 3

Appendix Tools T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

23.2.1 AMP Connectors, 040 series

Figure

Number

Application

213130

Pin removal tool

213129

Tools for fitting pins

23.3 Molex connectors 16 9 8 1 Figure

23- 4

Repair Manual

Number

Application

156937

Tools for fitting pins/sleeves

156936

Tools for fitting sleeves/pins

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Tools Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

23.4 Grease guns Figur

fif

© BT

Nummer

Användning

24981

A tool with a pointed nozzle used to apply grease. Length 170 mm.

755132

Single-hand grease gun with straight discharge pipe and nozzle.

755142

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

755152

Two-hand grease gun with hose and nozzle.

755146

Grease hose 450 mm.

Grease hose 750 mm.

Grease hose 1500 mm.

202154PM

Pointed nozzle for grease guns used to apply grease in recessed nipples.

Fits grease guns with hose and discharge pipe.

Length 125 mm.

755140

Nozzle for neck nipples. Fits grease guns with hose and discharge pipe.

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

23- 5

Appendix Tools T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

23.5 Other tools Figure

23- 6

Repair Manual

Number

Application

156263

Service instrument (CAN)

1=163793 2=163792

Service instrument for programme changes

08-13022

Driving gear puller

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Oil and grease specification Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

24 – Oil and grease specification Table 1: Oil and grease specification Lubricant type

Specification

Use

> - 15°C

< - 15°C

A

Grease

S213366 Q8 Rubens WB

S213366 Q8 Rubens WB

Storage and bushings

B

Hydraulic oil

ISO-HM32

ISO-VG32

Hydraulic system

C

Transmission oil

Synthetic API GL-5 SAE 75W-90

Synthetic API GL-5 SAE 75W-90

Gear

D

Grease

See table below

See table below

Chains

E

Grease

Grafloscon A-G1 (Klüber)

Grafloscon A-G1 (Klüber)

Toothed rim

F

Grease

755711-040

755701-040

Castor

G

Grease

S213366 Q8 Rubens WB

S213366 Q8 Rubens WB

Mast

Pos

Ambient temperature

Viscosity class

Recommended products*

D

> - 40°C < - 30°C

VG 15

Klüberoil 4UH 1-15, Klüber Lubrication

D

> - 30°C < + 5°C

VG 68

Klüberoil 4UH 1-68N, Klüber Lubrication Anticorit LBO 160 TT, Fuchs DEA

D

> + 5°C < +45°C

VG 150

Klüberoil 4UH 1-150N, Klüber Lubrication Anticorit LBO 160, Fuchs DEA Rexoil, Rexnord Kette

D

>+ 45°C <+ 80°C

VG 220

Klüberoil 4UH 1-220N, Klüber Lubrication

* Similar products from another manufacturer may be used.

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

24 – 1

Appendix Oil and grease specification T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

24.1 Lubrication schedule Pos.

Service point

Service interval 12 m

Lubricant type (see table above)

0380

Grease nipples

Greasing1

E

6000

Hydraulic system

Oil change2

B

1 = Lubrication of nipples must happen at continuous intervals of 500 h or 12 months, depending on which comes first.

2 = The oil is changed and the filter cleaned for the first time after 750 h/ 12 months, and then after 4,500 h/36 months.

6000

0380

24 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Electrical components and electrical diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

25 – Electrical components and electrical diagram 25.1 Electrical components The table below shows a compilation of the most important electrical components on the truck.

© BT

Symbol

Description

Function

A5

Logic card

Logic card actuating lever

A5:S1-18

Hall sensor

Speed control forwards/backwards

A5:S17

Hall sensor

Safety reversing

A5:S19

Hall sensor

Fork lifting control

A5:S20

Hall sensor

Fork lowering control

A5:S21

Hall sensor

Control of support arm lift

A5:S22

Hall sensor

Control of support arm lowering

A30

Battery charger

Onboard battery charger

B1

Temperature sensor

Temperature sensor for drive motor

B11

Pulse converter

Speed sensor

B60

Inductive switch

Mechanical brake activation

B61

Inductive switch

Lifting height limiting

B90

Collision sensor

F1

Fuse

Main fuse

125 A

F50

Fuse

Working circuit A5

7.5 A

F51

Fuse

Working circuit T1

7.5 A

F52

Fuse

Optional equipment

Option

G1

Battery

K110

Data handling unit (DHU)

Unit for handling data

M1

Motor

Drive motor

M3

Motor

Pump motor Repair Manual

Remarks

Option

Option

24 V Option

LWE140, LWE160, LWE180, LWE200, LWE250

25 – 1

Appendix Electrical components and electrical diagram T-code 838, 839, 840

25 – 2

Valid from serial number 6053221-

Date 2009-10-05

Symbol

Description

P4

Horn

P6

Display

Truck function display

Q1

Electromechanical brakes

Mechanical brakes

Q4

Magnetic valve

Fork lower

Q10

Contactor

Main contactor

Q25

Contactor

Pump contactor

S18

Switch

Horn button

S21

Switch

Emergency switch

S206

Switch

Turtle button (Turtle)

Option

S111

Switch

Option button

Option

S113

Switch

Option button

Option

S114

Switch

Option button

Option

S115

Switch

Option button

Option

S116

Switch

Option button

Option

S223

Keypad/Smart card

Login with PIN code

T1

Transistor regulator

T7/T8

DC/DC transformer

T7=24V/12V T8=24V/24V

X1

Connection

Battery

X21

Connection point

DC/DC transformer

X40

Connection point

CAN communication (Extra I/O)

X41

Connection point

CAN communication (External)

Repair Manual

Function

Order number 258944-040

Remarks

Option

Option

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Electrical components and electrical diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

A5:S22 A5:S21 A5:S1-9

A5:S10-18

T-code 838, 839, 840

A5

9

1 10 18

A5:S17 A5:S20 A5:S19 P6 S113 S206 S111

S116 S115 S114

S18:1

S18:2

A5:S20 A5:S22 A5:S19

A5:S21

A5:S17

S223 B60 X41

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

25 – 3

Appendix Electrical components and electrical diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

S21 X1 G1

T7/T8

F50, F51, F52 F1

Q25

Q10

X21 X40 B90

T1 A30

25 – 4

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Electrical components and electrical diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

25.2 Electrical diagram 25.2.1 Index of symbols Table 2: Index of symbols Symbol

Description

Symbol

Description

Truck battery

Emergency switch NC

Fuse

Switch, pressure (weight) operated

Horn

Sensor, inductive NO

Motor, a.c.a

Sensor, inductive NC

Contactor

Variable resistance (potentiometer)

Brake (normally joined)

Push switch NO

Coil for hydraulic magnetic valve

Contact, multipolar

M

Pressure sensor, analogue P

NO = Normally open NC = Normally closed

a. AC = Alternating Current

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

25 – 5

Appendix Electrical components and electrical diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

25.2.2 Overview diagram F51 F1

6 (+) B+ 24 (83) +24V 40 (-) B-

Q10

MAIN CONTACTOR (106) 31

-

72 (95) TILLER ARM IN DRIVE POS.

M1

A1

T1

M3 M

BRAKE RELEASE (90) 32

73 (87) LIFT LIMIT

A2

40

Q1 Q4

LOWER VALVE (108) 33

F

+24V (82) 30

20 (84) ENABLE/PRE-CHARGE

EXT. EQUIP.

P4

B11

61 (104) CH A, SPEED SENSOR 62 (103) CH B, SPEED SENSOR SIGNAL HORN (112) 50 +5V SPEED SENSOR (85) 60 64 NEGATIVE SPEED/ (105) B1 63 (92) THERMAL THERMAL SENSOR SENSOR

F52

25 +24VDC 40 0VDC T7/T8 X23 12VDC/24VDC 26 0VDC 41 OPTION

CAN HIGH/LOW (99/100) 119/120 F50

20

20

24

24 119/120 (3/4) CAN HIGH/LOW

119/120 (X3/X3) CAN HIGH/LOW

B90

20 (1) +24V DC 40 (2) 0V DC

119/120 (3/4) CAN HIGH/LOW RED (+) POS. VOLT. BLACK (-) NEG. VOLT.

A2:S17

Hall SAFETY

REVERSE

OPTION

20 (X3) +24V DC 40 (X3) 0V DC

A2:S19

Hall FORK Hall FORK

LOWER

Hall

S18:1

(X4 2) (X1 2) (X2:1/2) TURTLE

S206

KEYBOARD / SMART CARD S223

(X2:1/3) TURTLE

(X11)

Repair Manual

MAINS, VAC MAINS, VAC MAINS, EARTH OPTION

A2:S20

A2:S1-S9 A2:S10-S18

S18:2

A30

LIFT

(X1 1) HORN 2 (X4 1) HORN 1

25 – 6

G1

Q25

PUMP CONTACTOR (107) 34 B61

+

B60

U V W

S21

Hall

SPEED REF. VALUE

A5 +24V DC (X3) 20 0V DC (X3) 40 CAN HIGH (X3) 119 CAN LOW (X3) 120

(X12)

X41 T20

119/120 (2/3) CAN HIGH/LOW 20 (1) +24V DC 40 (8) 0V DC

K110

ANTENNA

OPTION

DISPLAY P6

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

© BT

Sh. 2

Sh. 3

Sh. 2

Sh. 2

30

20

24

1

40

24/BN

1

S21

A1/1D1

M3

A2/2D2

PUMP MOTOR

X21

Repair Manual

B11 4

2

B11 3

B11 2

6

TEMP. DRIVE MOTOR

2

Q25 1

1

7,5A F51

WH

|R

21

BK

B11

X21

BU

10

21/WH

B1

F1 125A

GN RD

2

1

B1

M1

B1 1

DRIVE MOTOR

2

Q10 1

1

-

G1 7,5A F50

+

64

63

62

61

60

4

3

2

34

31

6

20

40

OUT. NEGATIVE SPEED / THERMAL SENSOR

INP. THERMAL SENSOR

INP. CH B, SPEED SENSOR

INP. CH A, SPEED SENSOR

OUT. +5V SPEED SENSOR

OUT. W

OUT. V

OUT. U

OUT. PUMP CONTACTOR

OUT. MAIN CONTACTOR

INP. B+

INP. ENABLE / PRE-CHARGE

LWE140, LWE160, LWE180, LWE200, LWE250

02318.wmf

Valid from serial number 6053221-

1/9 PROD E 236994

105

92

103

104

85

107

106

84

INP. B-

Date 2009-10-05

RD

B11 1

2

MOTOR CONTROLLER T1

Order number 258944-040

2

Sh. 2

Electrical components and electrical diagram

Appendix

T-code 838, 839, 840

25.2.3 Electrical diagram

25 – 7

25 – 8

40

EXTERNAL EQUIPMENT

Repair Manual 2

33

32

120/WH

Q1

30

50

73

72

120/WH

2

1

2

X65

100

99

108

90

82

112

87

95

83

LWE140, LWE160, LWE180, LWE200, LWE250

02319.wmf

2/9 PROD E 236994

INP. CAN LOW

INP. CAN HIGH

OUT. LOWER VALVE

OUT. BRAKE RELEASE

OUT. +24V, "HIGH SIDE DRIVER"

OUT. SIGNAL HORN

INP. LIFT LIMIT

INP. TILLER ARM IN DRIVE POS.

INP. +24V, "HIGH SIDE DRIVER"

Date 2009-10-05

Sh. 3

1

Q4

B61

2

119/RD

IN

1

1

119/RD

30

P4

X65

X65

B60

24

Valid from serial number 6053221-

Sh. 3

Sh. 1

NOTE! EXTERNAL EQUIPMENT SHALL NOT BE ELECTRICAL CONNECTED TO THE TRUCK FRAME.

Sh. 1 3

24

3

Sh. 1

T-code 838, 839, 840

3

MOTOR CONTROLLER T1

Appendix

Electrical components and electrical diagram Order number 258944-040

© BT

© BT

Repair Manual

Sh. 1 8

Sh. 2 6

20

40

X41

40

119

120

2

3

4

CAN, SERVICE CONNECTOR

20

1

20

40

119

120

A5 1 A5 8 A5 4

20

40

119

120

A5 5

A5 6

X5

A5 7

A5 3

A5 2

119

120

X5

X5

X5

X3

X3

X3

X3

X3

X3

X3

X3

CAN LOW

CAN HIGH

OUT. 0V DC

Valid from serial number 6053221-

LWE140, LWE160, LWE180, LWE200, LWE250

02320.wmf

3/9 PROD E 236994

OUT.+24V DC

INP. +24V DC

INP. 0V DC

CAN HIGH

CAN LOW

Date 2009-10-05

119/RD

120/WH

Order number 258944-040

Sh. 2 6

Sh. 2 6

ELECTRONIC CARD TILLER ARM A5

Electrical components and electrical diagram

Appendix

T-code 838, 839, 840

25 – 9

25 – 10

8 8 8 8

DISPLAY P6

DISPLAY P6

1

2

S18:1

1

Repair Manual

OPTION

1

S206 2

2

TURTLE

LWE140, LWE160, LWE180, LWE200, LWE250

02321.wmf

4/9 PROD E 236994

Date 2009-10-05

X2:1/3

TURTLE

OUT. 0V DC HORN 2 X1 2

X2:1/2

INP. HORN 2 X1 1

Valid from serial number 6053221-

S18:2

OUT. OV DC HORN 1

0V DC

X4 2

X12 6

X1 6

LCLK

INP. HORN 1

X12 5

X1 5

ENABLE

X4 1

X12 4

SCK

SI

+5V DC

T-code 838, 839, 840

X1 4

X12 3

X12 2

X1 2

X1 3

X12 1

X1 1

ELECTRONIC CARD TILLER ARM A5

Appendix

Electrical components and electrical diagram Order number 258944-040

© BT

Appendix Electrical components and electrical diagram

-0#

LED_GREEN

LED_RED

0V DC

X11 7

X11 8

X11 9

X11 10

789 X11 6

02322.wmf

T-code 838, 839, 840

SMART CARD

456 X11 5

123 X11 4

9

I

8

0

7

2580 X11 2

369#

147X11 1

X11 3

6 5 4

3 2 1

KEY BOARD / SMART CARD S223

© BT

Valid from serial number 6053221-

5/9 PROD E 236994

Date 2009-10-05

ELECTRONIC CARD TILLER ARM A5

Order number 258944-040

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

25 – 11

25 – 12

Repair Manual

Sh. 3 8

Sh. 3 8

(RED)

X40

X40

119/RD

120/WH

BLACK

RED

3

4

-

+

LWE140, LWE160, LWE180, LWE200, LWE250

02323.wmf

6/9 PROD E 236994

Date 2009-10-05

MAINS, EARTH

MAINS, VAC

MAINS, VAC

INP. CAN HIGH

INP. CAN LOW

OUT. NEGATIVE CHARGER VOLTAGE

OUT. POSITIVE CHARGER VOLTAGE

Valid from serial number 6053221-

MAINS CONNECTOR

119/RD

120/WH

40 (BLACK)

1

BCU A30

T-code 838, 839, 840

Sh. 3 7

Sh. 2 7

ONBOARD CHARGER

OPTION

Appendix

Electrical components and electrical diagram Order number 258944-040

© BT

Appendix Electrical components and electrical diagram

02324.wmf

7/9 PROD E 236994 41 41

OUT. 0VDC

26 X23

X21

X21

Repair Manual

26

INP. 0VDC

INP. +24VDC 25

DC/DC CONVERTER (T7=24V/12V, T8=24V/24V)

OPTION © BT

T-code 838, 839, 840

OUT. 12VDC / 24VDC

Valid from serial number 6053221-

40

Date 2009-10-05

DC/DC CONVERTER T7 / T8

Order number 258944-040

LWE140, LWE160, LWE180, LWE200, LWE250

25 – 13

Appendix Electrical components and electrical diagram Order number 258944-040

CAN LOW 4

120/WH

3

119/RD

40

2

CAN HIGH

INP. 0V DC

INP. +24V DC 20

1

SHOCK SENSOR B90

Repair Manual

X40

X40

X40

X40

SHOCK SENSOR

OPTION 25 – 14

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

f

Date 2009-10-05

02325

Valid from serial number 6053221-

8/9 PROD E 236994

T-code 838, 839, 840

Appendix Electrical components and electrical diagram Valid from serial number 6053221-

T-code 838, 839, 840

INP. ANTENNA

INP. 0V DC 8

40

3

120/WH

119/RD

2

CAN LOW

CAN HIGH

INP. +24V DC 20

1

DHU K110

Repair Manual

X40

X40

X40

X40

T20

DATA HANDLING UNIT (DHU)

OPTION © BT

02326.wmf

Date 2009-10-05

9/9 PROD E 236994

Order number 258944-040

LWE140, LWE160, LWE180, LWE200, LWE250

25 – 15

Appendix Electrical components and electrical diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

25 – 16

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Hydraulic diagram Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

26 – Hydraulic diagram Only for trucks with Power Link

A

M

B H Max 230 Bar

C G D M3

E F

© BT

T

Pos.

Description

A B C D E F M3 G H T

Lift cylinder Magnetic valve, lowering forks Flow control valve Air filter Filter Pump Pump motor Pressure reducing valve, max 230 Bar Non return valve Tank

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

26 – 1

Appendix Hydraulic diagram T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

This page is intentionally left blank

26 – 2

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Destruction instructions Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

27 – Destruction instructions 27.1 General These destruction instructions have been introduced to support our company's objective of protecting the environment. By recycling materials, resources can be utilised more efficiently, while emission of undesirable substances is reduced.

The instructions below indicate the proper sorting category for the materials used in the various truck components. To achieve optimum sorting, all components should be disassembled to a level corresponding to the sorting categories.

27.2 Marking of plastics 27.2.1 General marking of products and packaging material Markings on plastics consist of three arrows, a number and usually also a designation for the plastic material used. The picture shows an example with the marking for polypropylene.

• 01: PET – Polyethylene terephthalate • 02: PE-HD – Polyethylene with High Density • 03: PVC – Polyvinyl chloride • 04: PE-LD – Polyethylene with Low Density • 05: PP - Polypropylene • 06: PS – Polystyrene • 07: O – Others

© BT

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Appendix Destruction instructions T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

27.2.2 Marking according to BT Standard Standards: BT 58-02-001, BT58-02-003 and BT58-02-004.

Only a few examples of markings are presented here. Fore more information, please refer to the standards mentioned above.

The product material and trade name are indicated between arrows.

Example: >PP<.

Abbreviations -

ABS: acrylonitrile/butadiene/styrene HDPE: High Density Polyethylene LDPE: Low Density Polyethylene PA: Polyamide PA6: Amide resin 6 PA66: Amide resin 66 PBT: Polybutylene terephtalate PC: Polycarbonate PET: Polyethylene terephtalate PMMA: Plexiglas POM: Polyoxymethylene, Polyformaldehyde PP: Polypropylene PUR: Polyurethane

Marking examples Products made from a single substance ABS (acrylonitrile/butadiene/polystyrene): >ABS< Polyurethane: >PUR< Plastic compounds A compound based on acrylonitrile/butadiene/polystyrene and carbonate plastic: >ABS+PC< Filled or reinforced materials Polypropylene with 30% mineral powder: >PP-MD30<

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Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

© BT

Appendix Destruction instructions Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

T-code 838, 839, 840

27.3 Pressure vessels Pressure vessels sent for recycling/destruction must have been depressurised beforehand and, if possible, opened.

Examples of existing pressure vessels are gas dampers and accumulators used in hydraulic systems.

27.3.1 Gas dampers DANGER Gas dampers have extremely high internal pressure. To prevent injury, always heed the instructions of the manufacturer.

Use safety goggles when disassembling springs.

To allow the gas to escape, only open and disassemble gas dampers as prescribed by the manufacturer. An example of how to perform this is given for “Stabilus Lift-O-Mat/Inter-stop”:

2

1

ca 20 mm

1: Drill or cut a hole in the cylinders, approximately 20 mm from the bottom.

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

© BT

Repair Manual

LWE140, LWE160, LWE180, LWE200, LWE250

27 – 3

Appendix Destruction instructions T-code 838, 839, 840

Valid from serial number 6053221-

Date 2009-10-05

Order number 258944-040

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

COMPONENT

Category

Comment

Chassis

• Iron/steel

Covers and doors, sheet metal

• Iron/steel

Covers and doors, plastic

• Plastic

Forks and bodies

• Iron/steel

Operator platforms

• Iron/steel, also possible gas dampers

• Handles: >ABS< Sort according to the material marking Be sure to depressurise dampers

• Mats, cushions: combustible Roofs and overhead guards

• Iron/steel

Gates and operator protective devices

• Iron/steel • Plastic handles: >PA< • Crush protectors: >PMMA<

Hydraulic units

• Oil • Hydraulic hoses: Oil polluted material • Oil tank: >PP< • Motor, valves: Electronic parts

Ensure the system has been depressurised.

Carefully drain all oil.

Any accumulators should be emptied of gas and if possible opened.

• Pump: Iron/steel • Accumulator: Iron/steel

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© BT

Appendix Destruction instructions Order number 258944-040

Date 2009-10-05

Valid from serial number 6053221-

COMPONENT

Category

Travel drive motors

• Motor: Electronic parts

T-code 838, 839, 840

Comment

• Cables • Parking brake: Hazardous waste Drive gears

• Iron/steel

Carefully drain all oil.

Hazardous waste

• Oil Wheels

• Tread: Plastic according to marking • Hub: Iron/steel

Tiller arms

• Electronic parts • Cables

If the tread and hub cannot be separated, then sort the wheel as complex material Be sure to depressurise dampers

• Iron/steel, also gas dampers Electric systems

• PCBs, transistor regulators, Exansion unit SEU, contactor: Electronic parts

Hazardous waste

• Cables

Masts

• Small batteries

Hazardous waste

• Fluorescent tubes

Hazardous waste Because of the chemical content in fluorescent tubes, do not destroy them.

Obsolete fluorescent tube must be packaged and transported according to local regulations.

• Mast members, rollers, cylinders, hydraulic pipes: Iron/steel

Oil-polluted components should be handled as hazardous waste

• Hydraulic hoses: Oil-polluted () • Cables • Sensors/switches: Electronic parts • Plastic components: According to marking or as combustible waste Chargers and connectors

© BT

• Electronic parts • Cables

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