Service Manual En: LWE180, LWE200, LPE200-6/8

Service Manual en
LWE180, LWE200, LPE200-6/8

Valid from serial number: 723984-
Order number: 221609-040

Issued: 2006-11-17 ITS
© BT Europe AB
Document revisions:
Issue date Order Changes

number
2004-12-16 221609 Completely new issue (Prel.)
2005-09-01 221609 Updated: P4, 0380 (new) and 5000
2006-03-13 221609 Updated: P2, P3, 0380,5000, 6000, 8340
2006-11-17 221609 Updated: Maintenance (replaces P1, P2 and P3), 2550, 5000
One section removed: 8340 (included in 5000), TruckCom
(replaced by a separate manual).
This manual covers following truck models:
T-code Model Serial number

660 LWE180 723984-
661 LWE200 723984-
662 LPE200 723984-
© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8

Table of contents
Order number Date Valid from serial number T-code
221609-040 2006-11-17 723984- 660,661,662
1- Table of contents
2- Technical data ..................................................................................... 2-1
2.1 General tightening torques............................................................. 2-4
2.1.1 Galvanised, non-oiled bolts ............................................. 2-4
2.1.2 Untreated, oiled bolts ....................................................... 2-4
3- Introduction, maintenance ................................................................. 3-1

3.1 Safety regulations during maintenance work ................................. 3-1
3.2 Cleaning and washing.................................................................... 3-3
3.2.1 Cleaning the exterior ....................................................... 3-3
3.2.2 Cleaning the motor compartment .................................... 3-3
3.2.3 Electrical components ..................................................... 3-3
3.3 Safe lifting ...................................................................................... 3-4
3.4 Maintenance schedule ................................................................... 3-5
3.5 Lubrication schedule .................................................................... 3-10
3.6 Oil and grease specification ......................................................... 3-11
4- Tools ..................................................................................................... 4-1

4.1 Super Seal connectors................................................................... 4-1
4.2 AMP connectors............................................................................. 4-2
4.2.1 AMP Connectors, 040 series ........................................... 4-3
4.3 Molex connectors........................................................................... 4-3
4.4 Grease guns .................................................................................. 4-4
4.5 Other tools ..................................................................................... 4-5
5- Fork carriage- 0380 ............................................................................. 5-1

5.1 Maintenance .................................................................................. 5-1
5.1.1 Adjusting the play between the fork carriage and body ... 5-3
6- Engine suspension– 0450 .................................................................. 6-1

6.1 Component parts ........................................................................... 6-1
6.1.1 Component List ............................................................... 6-2
7- Electric drive motor – 1760 ................................................................. 7-1

7.1 Component parts ........................................................................... 7-1
7.1.1 Dismantling/assembling of motor from truck ................... 7-2
7.1.2 Assembling ...................................................................... 7-2
7.2 Service/Repairs.............................................................................. 7-3
7.2.1 Dismantling of motor ........................................................ 7-3
7.2.2 Assembling of motor ........................................................ 7-4
7.2.3 Cleaning .......................................................................... 7-4
7.3 Technical data................................................................................ 7-5
© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- 1

Table of contents
T-code Valid from serial number Date Order number
660,661,662 723984- 2006-11-17 221609-040
8- Drive unit/gear – 2550 ......................................................................... 8-1

8.1 General .......................................................................................... 8-1
8.2 Included components..................................................................... 8-2
8.3 Disassembly of the drive unit from the truck................................... 8-4
8.4 Assembly of the drive unit in the truck............................................ 8-4
8.5 Oil inspection or changing oil ......................................................... 8-5
8.5.1 Oil inspection/replenishment ........................................... 8-5
8.5.2 Changing oil ..................................................................... 8-5
8.6 Replacing the gasket ring............................................................... 8-5
8.6.1 Disassembly .................................................................... 8-5
8.6.2 Assembly ......................................................................... 8-6
8.7 Leakage from top cover ................................................................. 8-6
9- Electro magnetic brake – 3370 ........................................................... 9-1

9.1 Brake LWE180, LWE200, LPE200-6 ............................................. 9-1
9.1.1 Main components ............................................................ 9-1
9.1.2 Maintenance .................................................................... 9-2
Exchange of brake disc ................................................... 9-2
9.2 Brake LPE200-8............................................................................. 9-3
9.2.1 Main components ............................................................ 9-3
9.2.2 Maintenance .................................................................... 9-4
Exchange of brake disc ................................................... 9-4
Adjustment of gap ............................................................ 9-4
10- Steering system – 4000 ................................................................... 10-1

10.1 Component parts, tiller arm.......................................................... 10-1
10.2 Adjustments ................................................................................. 10-2
10.2.1 Adjusting of brake microswitch ...................................... 10-2
10.3 Tiller arm handle .......................................................................... 10-3
10.3.1 Dismantling/Assembling ................................................ 10-4
Change from ignition key to keyboard (2) ...................... 10-5
Change from keyboard to ignition key (2) ...................... 10-5
Changing of signal button/switch (9, 10) ....................... 10-5
Changing of lift/lowering button (13) .............................. 10-6
Changing of pushbutton (16) ......................................... 10-6
1- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

Table of contents
221609-040 2006-11-17 723984- 660,661,662
11- Electrical System – 5000 ................................................................. 11-1

11.1 General ........................................................................................ 11-1
11.1.1 Software/hardware order numbers ............................... 11-1
11.1.2 Nomenclature ................................................................ 11-2
11.2 Electrical equipment overview...................................................... 11-3
11.2.1 Electric component overview ......................................... 11-5
11.3 Electrical wiring diagram .............................................................. 11-7
11.3.1 Symbol list ..................................................................... 11-7
11.3.2 Overview ........................................................................ 11-8
11.3.3 Wiring diagram LWE180, LWE 200, LPE200-6 ............. 11-9
11.3.4 Wiring Diagram LPE200-8 ........................................... 11-15
11.4 Functional description ................................................................ 11-26
11.4.1 Theory of operation ..................................................... 11-26
11.4.2 Spider expansion unit (SEU) ....................................... 11-31
11.4.3 Hour meter and battery condition ................................ 11-32
11.4.4 TLS - Truck log system (optional) ................................ 11-33
General ........................................................................ 11-33
Registration ................................................................. 11-33
Logging in/out SD16 .................................................... 11-33
Logging in/out S16 ....................................................... 11-33
Collision sensor ........................................................... 11-34
Settings ........................................................................ 11-34
11.4.5 ID unit (optional) .......................................................... 11-34
11.4.6 Built-in battery charger (optional) ................................ 11-35
Technical data ............................................................. 11-35
Charging ...................................................................... 11-36
Troubleshooting and service ....................................... 11-37
Adjusting the charger ................................................... 11-37
11.5 Parameters & adjustments......................................................... 11-39
11.5.1 General ........................................................................ 11-39
11.5.2 Displaying parameters - without the CAN service key . 11-39
11.5.3 Adjusting operator parameters -
without the CAN service key ........................................ 11-40
11.5.4 Displaying & changing parameters -
CAN service key connected ........................................ 11-40
Changing a parameter ................................................. 11-41
11.5.5 List of operator parameters ......................................... 11-42
11.5.6 Description of operator parameters ............................. 11-44
# 1 - Travel speed, Turtle button (LWE180, LWE200) 11-44
# 1 - Creep speed (LPE200-8) .................................... 11-44
# 2 - Maximum travel speed ........................................ 11-44
# 3 - Acceleration ......................................................... 11-44
# 4 - Neutral speed reduction ...................................... 11-44
# 5 - Logout ................................................................. 11-44
11.5.7 List of Service parameters ........................................... 11-45
11.5.8 Description of Service parameter ................................ 11-47
# 10 - PIN code ............................................................ 11-47
To enter a new PIN-code: ............................................ 11-47
To remove an existing PIN-code: ................................ 11-48
# 14 - Creep speed ...................................................... 11-48
#15 - Non-configurable options ................................... 11-48
Setting Non-configurable options ................................ 11-48
#16 - Configurable option #1 ....................................... 11-49
Table of contents
660,661,662 723984- 2006-11-17 221609-040
# 20 - Hour meter selection ......................................... 11-50

# 21 - Battery size ........................................................ 11-51
Instructions for verifying parameter setting .................. 11-52
Instructions for verifying parameter setting .................. 11-53
# 22 - Brake switch ...................................................... 11-53
# 25 - Service interval .................................................. 11-53
# 28 - Button selection ................................................. 11-53
# 39 - Login method and driver parameter access ...... 11-54
Expanded keypad - General ........................................ 11-54
Expanded keypad - Programming ............................... 11-55
11.5.9 Configurable “Option” parameters ............................... 11-57
General ........................................................................ 11-57
Parameter #16 to #19 configurable options ................. 11-58
Setting Configurable options ....................................... 11-58
11.6 Diagnostic and troubleshooting.................................................. 11-69
11.6.1 General ........................................................................ 11-69
11.6.2 Fault code history ........................................................ 11-70
11.6.3 List of fault codes ......................................................... 11-70
11.6.4 Transistor regulator troubleshooting and error codes .. 11-83
General ........................................................................ 11-83
Transistor regulator errors ........................................... 11-84
Resetting errors ........................................................... 11-85
Safety .......................................................................... 11-85
11.6.5 Built-in Test Function ................................................... 11-86
Digital inputs/outputs test mode .................................. 11-87
Transistor regulator inputs ........................................... 11-87
Transistor regulator outputs ......................................... 11-87
Digital input of logic card [A2] ...................................... 11-88
Extra functions ............................................................. 11-88
11.6.6 Display test mode ........................................................ 11-89
11.7 Technical specifications – Curtis 1243 ....................................... 11-90
12- Hydraulic/Pneumatik – 6000 ........................................................... 12-1

12.1 General ........................................................................................ 12-1
12.2 Hydraulic chart and list of symbols............................................... 12-1
12.2.1 List of Symbols .............................................................. 12-1
12.3 Adjustments LWE180 .................................................................. 12-2
12.3.1 Adjusting the pressure limit valve .................................. 12-2
12.3.2 Tools .............................................................................. 12-3
12.4 Adjustments LWE200 .................................................................. 12-4
12.4.1 Adjusting the pressure limit valve .................................. 12-4
12.5 Hydraulic chart and list of symbols............................................... 12-5
12.5.1 List of Symbols .............................................................. 12-5
12.6 Adjusting the pressure limit valve................................................. 12-6
13- PowerTrak cylinder – 6680 ............................................................. 13-1

13.1 Included components................................................................... 13-1
13.2 Disassembling the PowerTrak cylinder and spring guides ........... 13-2

Technical data
221609-040 2006-11-17 723984- 660,661,662
2- Technical data
Model LWE180 LWE200, LPE200-8

LPE200-6
Drive motor
Type TSL140S-DS20 TSL140S-DS30 TSL140S-DS40
Output, kW 1.0 1.2 1,7
Duty cycle S2, 60 min S2,60 min S2,60 min
Minimum carbon brush length, mm 13 13 13
Nominal commutator diameter, mm 47 47 60
Minimum commutator diameter, mm 47 47 60
Resistance, shunt field winding, Ω at 25 C° 0,55 0,55 0,4498
Resistance armature winding, Ω at 24 °C 0.0156 0,0156 0,0161
Insulation resistance between the wind- >=1 Mohm >= 1Mohm >= 1Mohm
ings and motor casing
Weight, kg 14 14 17
Broms
Type BFK457-08 BFK457-08 BFK458-12
Braking force, Nm 16 16 32
Output, W 25 25 40
Resistance coil, Ω 23 23 14.4
Nominal play in actuated position, mm 0.2-0.4 0.2-0.4 0.3-0.5
Minimum thickness brake disc, mm 5.5 5.5 8.8
Thickness of a new brake disc, mm 7.0 7.0 10.0
Transmission/drive gear
Type 2-stage angle 2-stage angle 2-stage angle
transmission transmission transmission
Gear ratio 19,14:1 19,14:1 16,29:1
Oil volume, litre 1.0 1.0 1.0
Oil type Hypoid oil Hypoid oil Hypoid oil
at normal temperature SAE 80W/90 SAE 80W/90 SAE 80W/90
at temperature < -15oC SAE 75W SAE 75W SAE 75W

Technical data
660,661,662 723984- 2006-11-17 221609-040

LPE200-6
Wheels
Drive wheel, mm Dia 215x70 Dia 215x70 Dia 215x70
Axle pressure without load, kg 200 374 374
Axle pressure at rated load, kg 650 565 565
Tightening torque for wheel bolts, Nm 65 Nm 65 Nm 65 Nm
Fork wheel, mm Dia 85x75 Dia 85x75 Dia 85x75
Axle pressure without load, kg 2x40 (240) 2x65 (240) 2x65 (240)
Axle pressure at rated load, kg 2x710 (240) 2x790 (240) 2x790 (240)
Support castors, mm Dia 125x40 Dia 125x40 Dia 125x40
Axle pressure without load 2X70 (240) 2X75 (240) 2x75 (240)
Axle pressure at rated load, kg 2x80 (240) 2x210 (240) 2x210 (240)
Hydraulic system
Output, kW 1.2 2.2 2.2
Duty cycle,% 10 10 10
Minimum carbon brush length, mm 7.5 12 12
Minimum commutator thickness/diame- 4.75 4.7 4.7
ter, mm
Pressure at rated load, bar 110 150 150
Overflow pressure, bar 130 170 170
Pump flow, litre/minute 4.7 4.6 4,6
Tank volume, litre 0,5 1,0 1,0
Oil type: Hydraulic oil Hydraulic oil Hydraulic oil
at normal temperature ISO-L-HM32 ISO-L-HM32 ISO-L-HM32
at temperature < -15oC ISO-L-HV32 ISO-L-HV32 ISO-L-HV32
Fuses
Drive motor circuits, A 125 125 125
Pump motor circuits, A 125 125 125
Control circuits, A 7,5 7,5 7,5

Technical data
221609-040 2006-11-17 723984- 660,661,662

LPE200-6
Battery compartment, Batteries
Dimensions LxWxH, mm 193x642x450 193x642x450-510 193x642x450-510
Capacity, Ah 160-320 240-320 240-320
Weigh, kg 165-250 210-250 210-250
Driving speed
Without load, km/t 6,0 6,0 8,0
Without load, m/s 1.7 1.7 2.22
With rated load, km/t 6,0 6,0 7.2
With rated load, m/s 1,7 1,7 2.0
Lift/lowering speed
Lift without load, s 2.2 1.7 1.7
Lift with rated load, s 3.4 2.3 2.3
Lowering without load, s 2.6 1.4 1.4
Lowering with rated load, s 3.1 1.5 1.75
Power consumption
Driving without load, A 38 28 46
Driving with rated load, A 45 46 65
Lift without load, A 39 49 49
Lift with rated load, A 80 52 52
Incline climbing ability
With rated load 8% 9% 9%
Measurement, L2
Short 519 519(LWE200)
Medium 565 660 660
Lång 613 1008 1008
Turning radius WA 1466 1960 1960
Lift height 205 205 205
Weight
Truck without battery, Medium 295 420 440

Technical data
General tightening torques
660,661,662 723984- 2006-11-17 221609-040
2.1 General tightening torques

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

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

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

Introduction, maintenance
Safety regulations during maintenance work
221609-040 2006-11-17 723984- 660,661,662
3- Introduction, maintenance
All points in the service program shall be included to attain the highest
safety and a least possible truck downtime. The service intervals are
only a guide and do not need to be followed strictly. The truck driver
must adapt these to local conditions, but it is important that the intervals
meet BT's minimum demands.
The service intervals are based on operating times and can be adapted
to most normal 8 hour shifts. The following operating hours have be
used when calculating the interval.
Day time: 08.00-17.00 (20 hours/week)
2-shifts: 06.00-14.00, 14.00-22.00 (40 hours/week)
3-shifts: 06.00-14.00, 14.00-22.00, 22.00-06.00 (60 hours/week)
Ensure the truck is given regular maintenance services according to
the maintenance schedule. The truck's safety, efficiency and service
life is dependent on the service and maintenance it is given.
Only use BT approved spare parts during service and repairs
3.1 Safety regulations during

maintenance work
Only persons trained in servicing and the repair of this type of truck are
qualified to carry out service and repair work.
• Do not carry out any maintenance work on the truck if you do not
have the right qualifications and know how to carry out the work.
• Keep the area where service work is done clean. Oil or water will
make the floor slippery.
• Never wear loose objects or jewellery when working on the truck.
WARNING!
short-circuit/Burns
short-circuiting and burn injuries can occur if metal objects come into
contact with live electrical connections, when working on the truck's
electrical system.
Remove watches, rings and other metal jewellery.
• Always remove the battery plug when carrying out maintenance on
the truck, if the instructions in this service manual do not say other-
wise.
• Always switch off the truck's power supply before the hoods to the
drive assembly and the electrical system are opened.
• Offload the system pressure slowly before work on the truck's hy-
draulic system is started.
• Use paper or rigid cardboard when checking a possible oil leakage.
Never use your hands.

Safety regulations during maintenance work
660,661,662 723984- 2006-11-17 221609-040
• Bear in mind that the oil in the transmission and hydraulic system
can be hot.
WARNING!
Risk of burn injuries
Hot transmission and hydraulic oil.
Let the truck cool before changing the oil.
• Only new and clean oil may be used in the hydraulic system.
WARNING!
The hydraulic system can be damaged.
Hydraulic components can be damaged, if the oil is contaminated.
Always use new and clean oil in the hydraulic system.
• Store and transport changed oil according to applicable local direc-
tions.
• Do not flush solvents and the like used for cleaning down drains that
are not intended for this purpose. Follow local directions that apply
for destruction.
• Disconnect the battery when welding on the truck.
NOTE!
The battery can be damaged.
When using electric welding equipment, the welding current can en-
ter the battery.
The battery must be disconnected.
• Remove at least 100 mm of paint around the welding/grinding area
using sand blasting equipment or paint remover when welding or
grinding on painted surfaces.
CAUTION!
Unhealthy gases.
Heated paint gives off unhealthy gases
Remove 100 mm of paint from around the working area.

Cleaning and washing
221609-040 2006-11-17 723984- 660,661,662
3.2 Cleaning and washing

Cleaning and washing the truck is a significant measure for the reliabil-
ity of the truck.
• Carry out general cleaning and washing each week.
NOTE!
Risk of short-circuiting.
The electrical system can be damaged.
Disconnect the battery before washing by pulling out the battery plug.
3.2.1 Cleaning the exterior

• Clean rubbish from the wheels each day.
• Use a well-known degreasing agent, diluted into an appropriate con-
centration.
• Wash off loose dirt with tepid water.
NOTE!
Jamming, corrosion
Mechanical parts can be damaged.
After washing the truck it should be lubricated as set out in the chap-
ter Maintenance and lubrication chart.
3.2.2 Cleaning the motor compartment

• Cover the electrical motors, connectors and valves before washing.
NOTE!
The electrical system can be damaged.
Electrical components must not be washed with high pressure cleaner.
• Wash the motor component using a well-known degreasing agent,
diluted into an appropriate concentration.
• Wash off loose dirt with tepid water.
3.2.3 Electrical components

• Blow electrical components clean using compressed air.
• Clean electrical panels, electronic cards, connectors, contactors, so-
lenoid valves, etc. with a moist cloth and a cleaning agent.
NOTE!
The electrical components can be damaged.
Do not break the warranty seal on the electronic card.

Safe lifting
660,661,662 723984- 2006-11-17 221609-040
3.3 Safe lifting

All lifting must be carried out on a flat, anti-slip and firm surface. Avoid
newly laid asphalt or asphalt on a hot summer day.
• Always apply the parking brake to prevent the truck from moving
while lifting. If the lift concerns the brake wheel, chock the other
wheels so that the truck stands still.
• Select the lifting points so that the lift is as easy as possible (one cor-
ner at a time). If the truck has marked lifting points on the lower part
of the chassis, these should be used to give 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 belonging to the jack. A too short lever will require
more effort than is necessary. If the lever is too long there is a risk
that the jack will be overloaded.
• Block up the truck.
- as close to the lifted part of the chassis as possible to reduce the
falling height in the event of a collapse.
- so that the truck cannot roll.
- Never block up the jack to lift higher.
- Never work under a lifted truck without appropriate blocking.
WARNING!
Risk of being crushed.
Bad blocking under a truck can collapse
Never work under a truck that is not blocked with pallets and secured
in a lifting device.

Maintenance schedule
221609-040 2006-11-17 723984- 660,661,662
3.4 Maintenance schedule

I: Inspect, rectify and change if necessary. T: Tighten. C: Clean. L: Lubricate.
M: Control measurement, rectify if necessary
Pos. Work to carry out
No. Interval in hours – may vary due to appli- 5 20 500 1000 3000
cation
Interval in days/weeks/months – may 1d 1w 6m 12m 36m
vary due to application
0000 Chassis
0000.1 Check all links and locking pins l
0000.2 Check wear on cover/battery locking l
0000.3 Check of cracking and damage l
0000.4 Check the cover locks I
0000.5 Check finger guard I
0000.6 Check signs and stickers I
0000.7 Press grease into grease nipples I/L6
0380 Fork carriage
0380.1 Check for crack formation and damage l
0380.2 Check clearance in bushes and links I
0380.3 Press grease into grease nipples (Option) I/L6
0380.4 Check the lift limit switch l
0560 Platform and mountings
0560.1 Check for any cracks or damage l
0560.2 Check gas damper and cup springs l
1700. Drive motor
1700.1 Check clearance in connections I/T1 I/T
1700.2 Check the carbon brushes in the drive motor M
1700.3 Clean the drive motor C
1700.4 Re-tighten the attachment bolts T2
1700.5 Check for abnormal noise in bearing l

660,661,662 723984- 2006-11-17 221609-040

cation
2550 Drive gear
2550.1 Check for leakage I3 I
2550.2 Check the oil level I
2550.3 Check for abnormal noise I
2550.4 Check the attachment and clearance in steering I
bearing
2550.5 Change the oil in the drive gear L4 L
3100. Brake
3100.1 Clean C
3100.2 Check for wear on the brake disc M
3100.3 Check the clearance in disengaged position M
3500 Wheels
3500.1 Remove string and other rubbish I
3500.2 Check the drive wheel for wear and the tighten- I/T
ing torque on bolts
3500.3 Check that the support wheel turns and rotates I
freely
3500.4 Check for wear on the support wheel I
4110 Tiller arm
4110.1 Check the mountings I
4110.2 Check the power in the gas damper I
5000 Electrical functions
5000.1 Check the operation of the brake microswitch in I I/L
the upper and lower brake positions. Lubricate
the switch head.
5000.2 Check the function of the collision safety switch I
5000.3 Check the function of the gate switches I I
5000.4 Check the function of platform switch I I
5000.5 Check the function of the horn I I
5000.6 Check for wear on cabling I
5000.7 Check the function of the driver’s control I I
5000.8 Check the error code log and operating times I I

221609-040 2006-11-17 723984- 660,661,662

cation
5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over the M
cell plates
5110.2 Check connections to battery, truck and charger I
5110.3 Check that the cell and pole guards are undam- I
aged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery locking I I
5400 Power system
5400.1 Cleaning and checking of mounting in chassis C/T1 C/T
5400.2 Re-tighten cable connections T1
5400.3 Check the contactor points on K10 and K30 I
5400.4 Check the movement of the contactors I
5400.5 Check the cable insulation I
5700 Electronic circuit board
5700.1 Check connectors and cables T1 I
5700.2 Check all segments on the display I

660,661,662 723984- 2006-11-17 221609-040

cation
6100 Hydraulic system
6100.1 Check hoses and connections for wear I
6100.2 Check hoses for wear and damage I
6100.3 Check the oil tank for cracks, leakage and dam- I
aged mountings
6100.4 Check that the oil level is correct I
6100.5 Change the oil and clean the filter L5 L
6600. Lift cylinder
6600.1 Check for leakage I
6600.2 Check the mountings I
6680 Power Trak
6680.1 Check if there is any damage or cracks on the I
PowerTrak spring
6680.2 Grease in the contact pressure spring’s guides C/L
1= Connections are tightened for the first time after 500 hours and then
every 1000 hrs/ 12 months.
2= Mounting bolts are tightened after 500 hrs/6 month to 45 Nm.
3= Check for leakage in connection with the first oil change.
4= The oil is changed for the first time after 500 hrs/6 month and then
every 3000 hrs/36 months.
5= The oil is changed and the filter cleaned for the first time after
500 hrs/6 month and then every 1000 hrs/12 months.
6 = If the truck goes into a refrigerated environment or other harsh envi-
ronment, the point is addressed at more frequent intervals.
When points with higher time intervals are addressed, the points with
shorter time intervals should also be addressed unless otherwise stat-
ed above.

221609-040 2006-11-17 723984- 660,661,662
5000 5000
6680
4110
5110
5700
5000
6600
5400
3100
1700
6100
0380 0000 0560
2550
5000
3500

Lubrication schedule
660,661,662 723984- 2006-11-17 221609-040
3.5 Lubrication schedule

Pos. Service point Interval/Operating hours Type of
No. 80 h 500 1000 h 3000 h lubricant
0380 Lubricating nipples (Option) L E
2550 Drive gear O4 C O C
6100 Hydraulic system O5 O B
L = Lubrication, C = Check, O = Oil change

4 = The oil is changed for the first time after 80 h/1 month, and then eve-
ry 3000 h/36 months
5= The oil is changed and the filter cleaned for the first time after
80 h/1 month, and then every 1000 h/12 months.
6100
0000
2550
0380
Oil and grease specification
221609-040 2006-11-17 723984- 660,661,662
3.6 Oil and grease specification
Pos. Lubrication Specification Application

type > -15° C < -15o C
A Grease 223690 223690 Bearings and bushes
Q8 Rembrandt EP2 Q8 Rembrandt EP2
B Hydraulic oil ISO-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease Grafloscon Grafloscon Guide bearing
A-G1 (Klüber) A-G1 (Klüber)
E Grease 213366 213366 Lubricating nipples,
Q8 Rubens WB Q8 Rubens WB Contact pressure spring

Oil and grease specification
660,661,662 723984- 2006-11-17 221609-040
This page is intentionally left blank

Tools
Super Seal connectors
221609-040 2006-11-17 723984- 660,661,662
4- Tools
4.1 Super Seal connectors
3
3
Figure Number Application

159232 Tools for fitting pins/sleeves
159229 Tools for loosening locks (1)
159230 Tool for fitting secondary locks

1-2 poles (2)
159231 Tool for fitting secondary locks

3-6 poles (2)
159228 Tools for removing pins/sleeves (3)

Tools
AMP connectors
660,661,662 723984- 2006-11-17 221609-040
4.2 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)

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

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

Tools
Molex connectors
221609-040 2006-11-17 723984- 660,661,662
4.2.1 AMP Connectors, 040 series

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

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

Tools
Grease guns
660,661,662 723984- 2006-11-17 221609-040
4.4 Grease guns
Figur Nummer Användning

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

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

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

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

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

Tools
Other tools
221609-040 2006-11-17 723984- 660,661,662
4.5 Other tools

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

2=163792 gramme changes
08-13022 Driving gear puller

Tools
Other tools
660,661,662 723984- 2006-11-17 221609-040

Fork carriage- 0380
Maintenance
221609-040 2006-11-17 723984- 660,661,662
5- Fork carriage- 0380
5.1 Maintenance
The support arms should be greased regularly according to the mainte-
nance schedule.
Table 1: Lubricating the nipples

Position Placement Picture
1 Behind the support
arms
2 Above the swivel

wheels
3 Behind/above the sup-

port arm wheels

Fork carriage- 0380
Maintenance
660,661,662 723984- 2006-11-17 221609-040
Table 1: Lubricating the nipples

Position Placement Picture
4 Behind/above the sup-
port arm wheels, on the
outside
5 On the outside of the

bogie, if there is one.

Fork carriage- 0380
Maintenance
221609-040 2006-11-17 723984- 660,661,662
5.1.1 Adjusting the play between the fork

carriage and body
The play between the fork carriage and body must be adjusted by plac-
ing shims on both sides. Symmetrical deviation between the body and
fork carriage may not exceed 3 mm.

Fork carriage- 0380
Maintenance
660,661,662 723984- 2006-11-17 221609-040

Engine suspension– 0450
Component parts
221609-040 2006-11-17 723984- 660,661,662
6- Engine suspension– 0450
6.1 Component parts
6680
2
21
20
4 5
6
19
7 8
18 11
9
14 13 12 10
15
17
16

Engine suspension– 0450
Component parts
660,661,662 723984- 2006-11-17 221609-040
6.1.1 Component List
Pos. Description Notes

1 Screw 2x M6S 8x30
2 Plate
3 Circlip
4 Console
5 Washer 8x
6 Screw 2x M6S 12x45
7 Lock bracket
8 Screw MC6S 8x12
9 Axle
11 Grease nipple 2x
12 Pivot pipe
13 Grease nipple 4x
14 Bushing 4x
15 Engine bracket
17 Axle 2x
18 Washer (0.5 mm) Number
as required
18 Washer (1 mm) Number as
required
19 Bushing 4x
20 Link 2x
21 Grease nipple 2x
6680 PowerTrak system See chapter 6680
“PowerTrak cylinder”

Electric drive motor – 1760
Component parts
221609-040 2006-11-17 723984- 660,661,662
7- Electric drive motor – 1760
7.1 Component parts

16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
Pos Description Note

1 Screw M6x25
2 Bearing shield
3 Locking ring
4 Bearing
5 Carbon brush bridge
6 Screw M5x12
7 Screw M5x20
8 Carbon brush
9 Rotor
10 Key
11 Plug
12 Stator
13 Cable

Component parts
660,661,662 723984- 2006-11-17 221609-040

14 Cable
15 Bearing shield
16 Screw M6x25
17 Seal
18 Bearing
19 Washer
20 Locking ring
21 Locking ring
7.1.1 Dismantling/assembling of motor from

truck
• Switch off the truck and pull out the battery plug.
• Remove the covers for the motor compartment.
• Release the cables for the motor and tiller arm.
• Unscrew the four nuts for the attachment of the motor to the drive gear.
• Loosen the cables for the key switch and emergency switch. Pull out
all the cables from the cover’s cable duct.
• Loosen the cover over the motor compartment and the tiller arm’s
mounting from the motor. Remove the cover over the motor com-
partment together with the tiller arm.
• Carefully lift the motor straight up, without damaging the sealing sur-
faces to the drive gear and place the motor on a clean surface.
• Protect the drive gear from impurities by covering over its opening in
an appropriate manner, e.g. with a piece of plastic.
The requisite service and repair of the motor can now be carried out.
7.1.2 Assembling
Assembling is carried out in the reverse order.
• Carefully lift down the motor in the drive gear to avoid damaging the
seals and gear wheels.
• Tighten the nuts on the studs to the prescribed torque, 26.6 Nm.
• Fit and adjust the brakes as per the instructions. Screw tight the cov-
er and tiller arm, and connect the cables that were previously re-
moved. Check that the polarity is correct.
• The function of the brakes should be checked before the truck is moved.

Service/Repairs
221609-040 2006-11-17 723984- 660,661,662
7.2 Service/Repairs
7.2.1 Dismantling of motor

16
21
20
14 19
18
13 17
15 10
12
11 8
7
6
5
4
3
1
2
• Release the brake disc’s companion flange by first removing the
locking ring together with the washer in the end of the rotor shaft.
The companion flange can now be lifted off. It may be necessary to
unclamp it with an appropriate tool.
• Remove the four plugs that cover the carbon brushes, move the
springs on the carbon brushes to one side and pull out the carbon
brushes.
• Dismantle the commutator end’s bearing shield (2) together with the
carbon brush bridge (5) and carbon brushes (8) by unscrewing the
eight screws (1). Now put down the motor with a firm resting point
against the edge of the bearing shield, and carefully tap on the rotor
shaft’s end with a rubber mallet.
• Dismantle the drive end’s bearing shield (15) together with the rotor
(9). Make sure not to damage the motor windings when the rotor is
removed from the motor housing.
• After dismantling the motor’s bearing shields and removing the rotor
from the motor housing, the gear wheel in the rotor’s drive end is re-
moved. This is done by unscrewing the nuts on the gear wheel and
then pulling the gear wheel off with a puller. Note that the gear wheel
is locked with Loctite to the rotor shaft.

Service/Repairs
660,661,662 723984- 2006-11-17 221609-040
• Now release the inner locking ring together with the underlying
washer. Pull out the rotor shaft from the bearing (18).
• Release the outer locking ring together with its washer, and remove
the bearing from the bearing shield.
• Remove the bearing shield’s seal (17) and carefully clean the bear-
ing shield.
• Fit a new seal in the bearing shield.
7.2.2 Assembling of motor

Assemble the motor in the reverse order.
• Carefully check that the rotor can move freely in the direction of rota-
tion and that the carbon brushes are flush with the commutator.
• Check the motor’s insulation resistance (between respective wind-
ing and the motor housing). For a new motor this should lie between
2 - 3 Mohm. When a used motor has been exposed to impurities an
insulation resistance down to approx. 1 Mohm is acceptable.
• Fit a new O-ring in the drive shaft end’s bearing shield and a new
seal on the collar of the bearing shield.
7.2.3 Cleaning
An extremely critical factor to ensure correct functioning of the motor is
that it is kept as clean as possible. The motor and the motor compart-
ment must be regularly checked for dust, oil, and other impurities.
A vacuum cleaner with an appropriate nozzle can be used to clean the
motor if the motor windings and inner compartment are dry Com-
pressed air can be used in combination with a vacuum cleaner. In which
case the compressed air must be clean and dry.
A cloth of non-fluffing material should be used if the windings have a
coating. The cloth can also be moistened with a grease-dissolving,
organic and volatile detergent that does not damage the windings. Use
detergent sparingly to avoid it penetrating into the parts of the motor.
Residual detergent should be removed with an appropriate solvent, if it
leaves a greasy surface.
If the parts of the motor are heavily fouled it may be necessary to use a
solvent that is sprayed onto the parts. It is important that the detergent
is applied in a way to prevent dirt from penetrating into the parts of the
motor, especially for the rotor.
One method of cleaning the rotor is to dip it in solvent. If this is done
then the rotor must always be dried with the application of heat. There
must be adequate ventilation during the drying process, and the drying
should continue until a number of measurements of the insulation
resistance provide equivalent and approved results.

Technical data
221609-040 2006-11-17 723984- 660,661,662
7.3 Technical data
Type of machine LWE180 LWE200, LPE200-6 LPE200-8

Type TSL140S-DS20 TSL140S-DS30 TSL140B-DS40
Output (kW) 1.0 1.2 1,7
Intermittence S2 60 min S2 60 min S2 60 min
Minimum length of car- 13 13 13
bon brush (mm)
Minimum commutator 47 47 60
diameter (mm)
Resistance, shunt field 0,55 0,55 0,498
winding Ω at 25 C°
Resistance, armature 0,0156 0,0156 0,0161
winding,Ω at 24 C°
Insulation resistance >= 1Mohm >= 1Mohm >= 1Mohm
between windings and
motor housing
Weight (kg) 14 14 17

Technical data
660,661,662 723984- 2006-11-17 221609-040

Drive unit/gear – 2550
General
221609-040 2006-11-17 723984- 660,661,662
8- Drive unit/gear – 2550
8.1 General
These service instructions cover descriptions of service performed at
the customer site. Complete reconditioning of the driving gear must be
performed in the workshop by trained technicians.

Included components
660,661,662 723984- 2006-11-17 221609-040
8.2 Included components
2
3
5
16
15
14
13
9
8
7
6
12
11
10

Included components
221609-040 2006-11-17 723984- 660,661,662
Pos. Designation Note

1 Bleeder valve
2 Cover
3 Dip stick
4 Seal
5 Screw Upper cover and gear housing
Tightening torque 26.6 Nm
Secure with Loctite 242.
6 Nut Tightening torque 300 Nm
Lock with centre punch
7 Washer
8 Conical roller
bearing
9 Shims
10 Bolt Lower cover and gear housing
Tightening torque 25 Nm
Secure with Loctite 242.
11 Cover
12 Seal
13 Conical roller
bearing
14 Shims
15 Sealing
16 Drive shaft
Nuts (assembly of Tightening torque 26.6 Nm
motor - gear hous-
ing)
Wheel nuts Tightening torque 65 Nm

Disassembly of the drive unit from the truck
660,661,662 723984- 2006-11-17 221609-040
8.3 Disassembly of the drive unit from

the truck
1. Jack up the truck until the wheel clears the floor. Support the truck
with trestles in a safe manner.
2. Disassemble the drive wheel.
3. Drain all oil from the driving gear.
4. Disconnect the motor cables.
5. Disconnect the cables to the brake.
6. Loosen and remove the drive motor bolts and lift away the drive
motor.
7. Secure the drive unit from below.
8. Loosen and remove the nuts securing the drive unit to the chassis.
9. Lower the drive unit enabling removal from under the truck.
10. Place the drive unit on a workbench or similar.
8.4 Assembly of the drive unit in the

truck
1. Lift the gear unit into place in the chassis.
2. Fit a new O-ring on the drive motor bearing cage.
3. Assemble the drive motor and gear case.
Proceed with caution to prevent damage to the O-ring.
4. Tighten the nuts to the torque indicated in the table.
Prior to assembly, apply grease on the nuts.
5. Connect the motor cables.
6. Connect the cable to the brake unit.
7. Fill the driving gear with oil.
8. Assemble the drive wheel.
Tighten the wheel nuts diagonally to the torque indicated in the ta-
ble.
9. Lower the truck to the ground and assemble the motor cover.

Oil inspection or changing oil
221609-040 2006-11-17 723984- 660,661,662
8.5 Oil inspection or changing oil
8.5.1 Oil inspection/replenishment

Inspect the oil level in the gear case according to the maintenance
chart.
1. Check the oil level in the gear case by removing the oil filling plug
on the upper part of the gear housing.
2. Fill up with oil according to the indication on the dip stick.
8.5.2 Changing oil

Change the gear case oil in accordance with the maintenance chart.
1. Drain the old oil by removing the lower cover.
Use a new seal and apply Loctite when refitting the cover.
2. Fill with oil according to the oil filling instructions.
8.6 Replacing the gasket ring

It is easiest to replace the drive shaft gasket ring when the drive unit
has been disassembled from the truck.
If oil leaks from the drive shaft, follow the instructions below.
8.6.1 Disassembly
1. Disassemble the drive unit from the truck.
2. Remove the lower cover.
3. Loosen the nut. Remove the nut and washer.
4. Press out the drive shaft.
5. Pull of the bearing from the drive shaft is a bearing remover.
6. Verify that the bearing plates are free from damage. If the plates
have been damaged by the bearing remover, then measure the to-
tal thickness of the spacing washers and replace them prior to as-
sembly.
7. Remove the gasket ring from the drive shaft.

Leakage from top cover
660,661,662 723984- 2006-11-17 221609-040
8.6.2 Assembly
Following replacement of the gasket ring, follow the instructions below.
1. Position the outer bearing of the drive shaft in the gear housing.
2. Press the new gasket ring into the gear housing.
When pressing the gasket ring into place, exercise care to make
sure it is correctly positioned.
3. Press the drive shaft into the gear.
Check to make sure the drive shaft splines interconnect with the
drive wheel splines.
4. Screw on the nut and tighten to the torque indicated in the table.
Be sure to always to use a new nut. Prior to assembly, apply
grease on the nut.
5. Before fitting the lower cover, assemble a new seal and apply Loc-
tite.
6. Replace the cover and tighten the bolts to the torque indicated in
the table.
Make sure the seal is not damaged. Prior to assembly, apply
grease on the bolts.
7. Fill with oil.
8. Assemble the drive wheel and tighten the wheel nuts diagonally to
the torque indicated in the table.
Prior to assembly, apply grease on threads.
9. Install the drive unit in the truck.
8.7 Leakage from top cover

Follow the instructions below in case of leakage from the gear case top
cover.
1. Disassemble the gear case from the truck.
2. Loosen all bolts securing the top cover to the gear housing and re-
move the cover.
3. Carefully clean the sealing surfaces of the cover and gear housing.
4. Apply Loctite on the sealing surfaces.
5. Insert the bolts in the cover and tighten the bolts to the torque indi-
cated in the table.
Prior to assembly, apply grease on the bolts.
6. Fill with oil.
7. Assemble the gear case and drive motor. Install the drive unit in the
truck.

Electro magnetic brake – 3370
Brake LWE180, LWE200, LPE200-6
221609-040 2006-11-17 723984- 660,661,662
9- Electro magnetic brake – 3370
9.1 Brake LWE180, LWE200, LPE200-6
9.1.1 Main components

1 9
2
8
3
4
7
5 6
Pos No Description
1 Magnetic coil
2 Cap screws
3 Electrical wire
4 Pressure plate
5 Pressure springs
6 Flange
7 Mounting bolts
8 Brake disc
9 Hub

Brake LWE180, LWE200, LPE200-6
660,661,662 723984- 2006-11-17 221609-040
9.1.2 Maintenance
Basically the brake is maintenance free in normal work environments.
However it is recommended according to the preventive maintenance
schedule to check the brake disc for wear.
Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been
reduced to 5,5 mm.
• Disconnect the electrical wires of the brake.
• Undo and remove the three fastening bolts.
• Loosen the brake disc from the hub and check for wear and tear. Re-
place the brake disc if the surface is unevenly worn.
• Reassemble the brake.
• Reconnect the electrical wiring.

Brake LPE200-8
221609-040 2006-11-17 723984- 660,661,662
9.2 Brake LPE200-8
9.2.1 Main components

9 1
8
2
6
4
Pos No Description
1 Magnetic coil
2 Electrical wire
3 Pressure plate
4 Pressure springs
5 Friction plate
6 Adjustment locking nut
7 Brake disc
8 Mounting bolts
9 Hub

Brake LPE200-8
660,661,662 723984- 2006-11-17 221609-040
9.2.2 Maintenance
Basically the brake is maintenance free in normal work environments.
However it is recommended according to the preventive maintenance
schedule to check the brake disc for wear and the gap between the
magnetic coil housing and the pressure plate on a regular basis.
Exchange of brake disc

The brake disc shall be exchanged when its total thickness has been
reduced to 6 mm.
• Disconnect the electrical wires of the brake.
• Loosen and remove the three mounting bolts and remove the brake coil.
• Replace the brake disc on the hub and make a visual inspection of
the wear of the friction plate. Replace the friction plate if the surface
is worn uneven.
• Unwind the lock nuts on the coil at least 6 mm to make sure there is a
gap between the coil and the pressure plate when the coil is refitted.
• Mount the coil on the motor end and carry out adjustment of the gap.
• Reconnect the electrical wiring.
Adjustment of gap
9,5 Nm
0,3
The nominal gap between the coil housing and the pressure plate, in
applied position, shall be 0.3 mm. The maximum gap before readjust-
ment is necessary is 0.8 mm.
Adjustment:
• Loosen the tension of the three mounting bolts .
• Turn the lock nuts anti-clockwise and tighten the bolts slightly while
checking the gap on three points with a 0.3 mm feeler gauge.
• Tighten the mounting bolts 9,5 Nm and recheck the gap with the
feeler gauge.

Steering system – 4000
Component parts, tiller arm
221609-040 2006-11-17 723984- 660,661,662
10- Steering system – 4000
10.1 Component parts, tiller arm

1
9 10
11
13 12
15
14
17 16
18
19
20
21
22

1 Screw 4
2 Washer
3 Handle
4 Screw 4

Adjustments
660,661,662 723984- 2006-11-17 221609-040

5 Washer 2
6 Cable holder
7 Gas damper
8 Bracket
9 Stop screw
10 Screw 4
11 Ball joint
12 Screw
13 Distance
14 Bush 2
15 Damper 2
16 Axle
17 Cam
18 Distance
19 Screw
20 Distance
21 Distance
22 Switch S 10
10.2 Adjustments
10.2.1 Adjusting of brake microswitch

Switch (22) is always adjusted to its lowest position.
• Unscrew the screws (12, 19) that hold the switch and the distance.
• Press down the switch and tighten the screws.
• Check that the switch is actuated by the cam (17) in the arm’s top
and bottom position.

Tiller arm handle
221609-040 2006-11-17 723984- 660,661,662
10.3 Tiller arm handle

28
29
27 26
24 14
25 14
23 22
17
21 18
20 16
19 15
14
30 14
31 13
12
10 11
32 9
8
35 33
34
5 6 7
4
1 2
3

1 Screw
2 Cover Keyboard option
3 Handle
4 Electronic card
5 Screw
6 Display card
7 Top cover
8 Pushbutton Option
9 Signal switch
10 Signal button
11 Display glass
12 Arm
13 Pushbutton Lift/Lower
14 Plate
15 Spring
16 Pushbutton Not used
17 Arm
18 Holder

Tiller arm handle
660,661,662 723984- 2006-11-17 221609-040

19 Spring
20 Control switch
21 Axle
22 Sliding bearing
23 Control stop
24 Arm
25 Spring holder
26 Spring
27 Spring holder
28 Sliding bearing
29 Control switch
30 Button for safe reversing
31 Arm
32 Spring
33 Lower cover
34 Screw M4x40
35 Screw 2xM5x45 - 2xM5x60
10.3.1 Dismantling/Assembling
• Dismantle cover (2), (keyboard option).
• Remove the screws (35), hold top cover firm (7).
• Disconnect the cable connected to the electronic card (4).
• Remove the screws (34).
• Carefully lift off the lower cover (33), and place a finger between the
lower cover (33) and button (30) to hold the button (30) in place.
Assemble in reverse order.
NOTE!
Static electricity!
Risk of static discharge that can damage the electronics.
Make sure to take the necessary precautions before working with the
electronics.

Tiller arm handle
221609-040 2006-11-17 723984- 660,661,662
Change from ignition key to keyboard (2)

• Connect the CAN-key to the truck.
• Enter parameter mode (P).
• Change parameter 39 to value = 3 or 4.
• Set the required PIN-code by using parameter 10.
• Switch off the truck.
• Dismantle the cover(2) on the tiller arm.
• Fit the keyboard.
• Remove the ignition key, fit the strap.
• Fit the cover in the key hole.
• Start the truck using the chosen PIN-code.
Change from keyboard to ignition key (2)

• Connect the CAN-key to the truck.
• Enter parameter mode (P).
• Change parameter 39 to value = 1 or 2.
• Switch off the truck.
• Remove the keyboard (2) on the tiller arm.
• Fit the cover.
• Remove the strap.
• Remove the cover.
• Fit the ignition key.
• Start the truck.
Changing of signal button/switch (9, 10)

• Dismantle the button as per the diagram.
• Disconnect the connection for the switch on the electronic card (4).
• Press out the switch from its mounting.

Tiller arm handle
660,661,662 723984- 2006-11-17 221609-040
Changing of lift/lowering button (13)

• Remove the button by placing a screwdriver in the hole (A) as per
the diagram below.
A A
• Unscrew the holder (18) so that the arm (12) comes loose.
Assemble in everse order.
Changing of pushbutton (16)

• Press the button by hand sideways.
• Place a screwdriver as per the diagram and carefully pry the button
loose.
• Unscrew the button’s holder and arm.


Electrical System – 5000
General
221609-040 2006-11-17 723984- 660,661,662
11- Electrical System – 5000
11.1 General
The electrical system of the truck is based on the PowerDrive platform.
• The main power source is a 24 V DC traction battery.
• The travel drive motor is a separate excitation type (SEM) . The trav-
el drive motor is operated by an enclosed transistor regulator relying
on pulse width modulation (PWM) technology. The transistor regula-
tor also controls the input and output signals for truck travel and lift-
ing operations.
• The lift unit motor is a conventional DC motor without any external
field winding connections. Switch-on of the hydraulic unit's electric
motor is achieved using a contactor.
• All electric units communicate via a CAN bus with an IC card in the
steering unit handle. This card contains a processor and software
that controls and monitors truck functions. A set of parameters used
to adjust truck functions and characteristics is stored in the card. The
card also monitors error conditions that may occur.
11.1.1 Software/hardware order numbers

• Press and hold the horn button [S18], enter a valid PIN-code and
then press on the keypad [A17].
• Keep [S18] depressed until = the part number is

displayed.
By scrolling with [L1] you can get the following information:
• Software part number
• Hardware part number
• Hardware serial number

General
660,661,662 723984- 2006-11-17 221609-040
11.1.2 Nomenclature
Items shown in square brackets [ ] refer to electric component designa-
tions as stated in the electrical wiring diagrams. See “11.2.1 Electric
component overview” on page 5.
{high} refers to a voltage level that is approximately the same as the
supply voltage level.
{low} refers to a voltage level of approximately 0 Volt.

Electrical equipment overview
221609-040 2006-11-17 723984- 660,661,662
11.2 Electrical equipment overview

A2:S22 A2:S21 A2:S1-9 A2:S10-18 A2
1
10
18
A2:S17 A2:S20 A2:S19

A6
S113 S116
S112 S115
S111 S114
S18:1 S18:2
A2:S20
A2:S19
A2:S22
A2:S21
L1 A2:S17 L1
A17

660,661,662 723984- 2006-11-17 221609-040
S31 S17
X41
F50
F51
A30 R1
F1
K10
F3 Y1
K30 M1
A1
H1
X1
G1
S10
S53
S17
M3
P1
S19 Y41
S59

221609-040 2006-11-17 723984- 660,661,662
11.2.1 Electric component overview

The following table shows a summary of the major electric components
of this truck.
Symbol Description Function Comments

A1 Transistor regulator
A2 Electronic card
A6 Display Display of truck functions
A17 Keypad Login with PIN code Option
A30 Charger Battery charging Option
F1 Fuse Drive motor circuits 130 A
F3 Fuse Pump motor circuits 130 A
F50 Fuse Working circuit A5 7.5 A
F51 Fuse Working circuit A1 7.5 A
F52 Fuse Optional equipment Option
G1 Battery 24 V
H1 Horn
K10 Contactor Main contactor
K30 Contactor Pump motor
L1 Hall sensor Speed control and travel
direction selector (butterfly)
M1 Motor Drive motor
M3 Motor Pump motor
P1 Pressure sensor Load monitoring Digital (Applies to
LPE200-8)
R1 PTC resistance Power supply 15 Ohm
A2:S1-18 Hall sensor Speed control
S10 Inductive switch Mechanical activation of the Brake handle
brake
S17 Switch Key
A2:S17 Hall sensor Emergency reversing
S18 Switch Button for horn
S19 Switch Man on the platform (Applies to LPE200-8)
A2:S19 Hall sensor Fork lift (Standard)
A2:S20 Hall sensor Fork lowering (Standard)
S21 Switch Emergency switch
A2:S21 Hall sensor Support arm lift control
A2:S22 Hall sensor Support arm lower control
S31 Inductive switch Lift height limiter

660,661,662 723984- 2006-11-17 221609-040
Symbol Description Function Comments

S53 Switch Gates (Applies to LPE200-8)
S59 Switch Platform in folded position (Applies to LPE200-8)
S111 Switch Optional button Option
Y1 Electromechanical Mechanical brake
brake
Y41 Solenoid valve Fork lowering
X1 Coupling Battery
X9 Connection point CAN communication (Extra I/
O)
X41 Connection point CAN communication (Exter-
nal)

Electrical wiring diagram
221609-040 2006-11-17 723984- 660,661,662
11.3 Electrical wiring diagram
11.3.1 Symbol list
Table 2: Symbol list

Symbol Description Symbol Description
Truck battery Horn
Fuse Emergency stop switch NC
Resistor (PTC)a Switch, weight pressure oper-

ated
DC motor b(SEM type)c Sensor, inductive NO

A1 A2
M
E1 S E2
DC motor Sensor, inductive NC
Contactor Variable resistor (potentiometer)
Brake coil (normally applied) Pressure switch NO
Coil for hydraulic magnetic valve Multi-pin connector
Analogue pressure sensor NO = Normally Open

P NC = Normally closed
a. PTC = Positive Temperature Coefficient (resistance increases as temperature increases)

b. DC = Direct Current
c. SEM = Separately Excited Motor

660,661,662 723984- 2006-11-17 221609-040
11.3.2 Overview
2 1
3 F1 R1
(+) POWER 24VDC M1
24 6 A2 A1 X1
(16) SUPPLY 24VDC ARMATURE (M) M
40
(-) POWER 0VDC
4 S
G1
+
E2 E1
FIELD (S2)
-
ONLY 8 KM/H
5 X1
FIELD (S1)
63
(10) PRESSURE SWITCH
P1 K10 40
p 64
MAIN CONTACTOR (4)
49
(15) LIFT LIMIT CHARGER
S31 F51
A1 21
S21
24 57
(12) TILLER ARM IN DRIVE POS. F3
S10 M3
A1 A2
M
OPTIONS
ONLY 8 KM/H
45 24
PUMP CONTACTOR (6)
65 K30
(11) MAN ON PLATFORM H1
S19
39
SIGNAL HORN (7) Y1
66 31
(13) PLATFORM NOT BRAKE A (5)
FOLDED UP Y41
38
S59 LOWER VALVE (2)
58
(14) GATES UP
CAN HIGH/LOW
S53 (1/8)
24 F52
X41 F50
20
40 120 EXT. EQUIP.
119
OPTION ONBOARD CHARGER
X9 S17 (X3:3/7) CAN HIGH/LOW

22 RED
ONLY 40 (X3:2) +24VDC A2:S17 (1) +24VDC
BLACK
KEYBOARD (X3:6) 0VDC Hall SAFETY (2) 0VDC
REVERSE A30
A2:S19 MAINS, VAC
Hall FORK MAINS, VAC
(X1:1) HORN 2 LIFT
(X4:1) HORN 1 MAINS, EARTH
A2:S20
S18:2 A2 Hall FORK
LOWER
S18:1
(X4:2) A2:S1-S9 A2:S10-S18
Hall Hall SPEED
(X1:2) REF.
VALUE
10 6
KEYBOARD DISPLAY
(X11) (X12) (X1)
A17 A6

221609-040 2006-11-17 723984- 660,661,662
11.3.3 Wiring diagram LWE180, LWE 200, LPE200-6
1/6 Prod C
224726

660,661,662 723984- 2006-11-17 221609-040
2/6, Prod C
224726
INP. SUPPLY +24VDC
TRANSISTOR REGULATOR
INP. LIFT LIMIT
CAN HIGH
CAN LOW
16
15
A1
8
120
119
24
49
Bl
S31
Sv
Br
EMERCENCY SWITCH OFF
2
S21
120
119
21
24
40
Sh. 1
Sh. 3
Sh. 3
Sh. 1 3
Sh. 1 6

221609-040
ONLY KEY BOARD ELECTRONIC CARD, TILLER ARM

Order number
© BT Europe AB
A2
KEY
S17 X5
20 22
Sh. 1 X3 2 INP. +24VDC
X5
119 119
Date
Sh. 2 X3 3 CAN, HIGH
X5
120 120
2006-11-17
Sh. 2 X3 7 CAN, LOW
X5
40 40
Sh. 2 6 X3 6 INP. 0VDC
X9 S17
20 1 BELLY BUTTOM
723984-
Service Manual
40 2
S1-S9 S10-S18
SPEED REF. VALUE
X41 119 3
1 20
120 4 S19
2 40 FORK LIFT
CAN CONNECTION
Valid from serial number
3 119
S20
FORK LOWER
4 120
CAN, SERVICE CONNECTOR

S18:1
X4 1 INP. HORN 1
1 2
LWE180, LWE200, LPE200-6/8

X4 2 OUT. 0 VDC HORN 1
T-code
S18:2
660,661,662
X1 1 INP. HORN 2
1 2
224726
3/6, Prod C
11- 11
660,661,662 723984- 2006-11-17 221609-040
4/6, Prod C
224726
ELECTRONIC CARD
ENABLE
+5V DC
0V DC
LCLK
SCK
SI
X12 1
X12 2
X12 3
X12 4
X12 5
X12 6
A2
X1 1
X1 2
X1 3
X1 4
X1 5
X1 6
8 8 8 8
ELECTRONIC CARD
A6

221609-040 2006-11-17 723984- 660,661,662
5/6, Prod C
ELECTRONIC CARD
LED_GREEN
224726
LED_RED
2580
369#
0V DC
147-
123
456
789
-0#
X11 10
X11 1
X11 2
X11 3
X11 4
X11 5
X11 6
X11 7
X11 8
X11 9
A2
3
6
9
I
2
5
8
0
1
4
7
KEY BOARD
A17

11- 14
T-code
OPTION
ONBOARD CHARGER
660,661,662
START INTERLOCK ELECTRONIC CARD

ONBOARD CHARGER A5
S170 K10
24 23 A1 A2 64
Sh. 2 4 OUT. MAIN CONTACTOR
723984-
ONBOARD CHARGER, PLUG. A/B
Service Manual
ONBOARD CHARGER
A30
1 (RED) (RED)
Sh. 1 + OUT. POSITIVE CHARGER VOLTAGE
40 (BLACK) (BLACK)
Sh. 3 - OUT. NEGATIVE CHARGER VOLTAGE
PLUG. A
MAINS, VAC
Date
PLUG. B
MAINS, VAC
2006-11-17
LWE180, LWE200, LPE200-6/8

MAINS, EARTH
221609-040
Order number
224726
6/6, Prod C
© BT Europe AB
221609-040
Order number
© BT Europe AB
A1
X1 G1 24V X1
1 + - 40
Sh. 11 - INP. POWER SUPPLY 0VDC
R1 F1
2 3
Date
INP. POWER SUPPLY +24VDC

130A DRIVE MOTOR +
PTC 15~E PUMP MOTOR
F50 F3 M3 M1
20 2 1 9 1 2 10 A2/E2 D1/E1 A1 A2 6
Sh. 3 M M M OUT. ARMATURE
2006-11-17
7,5A 130A
F51 S
21 E1 E2 4
Sh. 2 S2 OUT. FIELD
7,5A
FEXTERNAL EQUIPMENT
5
S1 OUT. FIELD
723984-
40
Service Manual
Sh. 2
X10 Y1 X10
24 1 2 31
Sh. 2 5 OUT. BRAKE A
S10
X10 X10
Bn Bl 57
12 INP. TILLER ARM IN DRIVE POS.
Bu
X10
K10
A1 A2 64
4 OUT. MAIN CONTACTOR
K30
A1 A2 45
6 OUT. PUMP CONTACTOR
LWE180, LWE200, LPE200-6/8

T-code
Y41
11.3.4 Wiring Diagram LPE200-8
1 2 38
2 OUT. LOWER VALVE
660,661,662
H1 39
7 OUT. SIGNAL HORN
- +
IN
221397
1/11, Prod C
11- 15
11- 16
T-code
660,661,662
A1
EMERGENCY SWITCH OFF
S21
21 1 2 24
Sh. 1 16 INP. SUPPLY +24VDC
24
723984-
Sh. 1 6
P1
63
10 INP. PRESSURE SWITCH
Service Manual
p
S31
1 2 49
15
INP. LIFT LIMIT
3
40
Sh. 1 3
Date
119 119
Sh. 3 1 CAN HIGH
2006-11-17
120 120
LWE180, LWE200, LPE200-6/8

Sh. 3 8 CAN LOW
221609-040
Order number
221397
2/11, Prod C
© BT Europe AB
ONLY KEY BOARD ELECTRONIC CARD, TILLER ARM
221609-040
A2
KEY
Order number
© BT Europe AB
S17 X5
20 22
Sh. 1 X3 2 INP. +24VDC
X5
119 119
Sh. 2 X3 3 CAN, HIGH
Date
X5
120 120
Sh. 2 X3 7 CAN, LOW
2006-11-17
X5
40 40
Sh. 2 6 X3 6 INP. 0VDC
S17
BELLY BUTTON
X9
20 1
723984-
Service Manual
S1-S9 S10-S18
X41 40 2 SPEED REF. VALUE
1 20
119 3
2 40 S19
120 4 FORK LIFT
3 119
CAN CONNECTION
S20
3 120 FORK LOWER
CAN, SERVICE CONNECTOR
S18:1
1 2
X4 1 INP. HORN 1
LWE180, LWE200, LPE200-6/8

S18:2
T-code
1 2
X1 1 INP. HORN 2
660,661,662
221397
3/11, Prod C
11- 17
660,661,662 723984- 2006-11-17 221609-040
4/11, Prod C
221397
ELECTRONIC CARD
ENABLE
+5V DC
0V DC
LCLK
SCK
SI
X12 1
X12 2
X12 3
X12 4
X12 5
X12 6
A2
X1 1
X1 2
X1 3
X1 4
X1 5
X1 6
8 8 8 8
DISPLAY
A6

221609-040 2006-11-17 723984- 660,661,662
5/11, Prod C
221397
ELECTRONIC CARD
LED_GREEN
LED_RED
2580
369#
0V DC
147-
123
456
789
-0#
X11 10
X11 1
X11 2
X11 3
X11 4
X11 5
X11 6
X11 7
X11 8
X11 9
A2
3
6
9
I
2
5
8
0
1
4
7
KEY BOARD
A17

660,661,662 723984- 2006-11-17 221609-040
INP. PLATFORM NOT FOLDED UP

INP. MAN ON PLATFORM
6/11, Prod C
221397
INP. GATES UP
13
14
11
A1
65
66
58
PLATFORM FOLDING UP, WITH GATES
X:S19
2
S53
3
X:S19
1
2
S59
3
1
24
40
Sh. 2 7
Sh. 3 7

221609-040 2006-11-17 723984- 660,661,662

221397
7/11
INP. GATES UP
13
14
11
A1
65
66
58
PLATFORM STAYING DOWN, WITH GATES
2
S19
S53
3 3
1
1
2
S59
3
1
24
40
Sh. 6 8
Sh. 6 8

11- 22
T-code
660,661,662
BACK PROTECTION, WITH FIXED PLATFORM

SIDE PROTECTION, WITH FIXED PLATFORM

723984-
Service Manual
A1
S19
24 1 2 65
Sh. 7 9 11 INP. MAN ON PLATFORM
3
40
Sh. 7 9
X:S59 X:S59
66
13 INP. PLATFORM NOT FOLDED UP
Date
2006-11-17
LWE180, LWE200, LPE200-6/8

X:S53 X:S53
58
14 INP. GATES UP
221609-040
Order number
221397
8/11, Prod C
© BT Europe AB
221609-040 2006-11-17 723984- 660,661,662
9/11, Prod C
221397
INP. GATES UP
13
14
11
A1
65
66
58
PLATFORM STAYING DOWN, WITHOUT GATES
2
S19
3
1
2
S59
3
1
24
40
Sh. 8 10
Sh. 8 10

660,661,662 723984- 2006-11-17 221609-040

10/11, Prod C
INP. GATES UP
221397
13
14
11
A1
65
66
58
PLATFORM FOLDING UP, WITHOUT GATES
X:S19
X:S19
2
S59
3
1
24
40
Sh. 9 11
Sh. 9 11

221609-040
Order number
© BT Europe AB
OPTION
ONBOARD CHARGER
Date
START INTERLOCK ELECTRONIC CARD

ONBOARD CHARGER A5
2006-11-17
S170 K10
24 23 A1 A2 64
Sh. 10 4 OUT. MAIN CONTACTOR
ONBOARD CHARGER, PLUG. A/B

723984-
Service Manual
ONBOARD CHARGER
A30
1 (RED) (RED)
Sh. 1 + OUT. POSITIVE CHARGER VOLTAGE
40 (BLACK) (BLACK)
Sh. 10 - OUT. NEGATIVE CHARGER VOLTAGE
PLUG. A
MAINS, VAC
PLUG. B
MAINS, VAC
LWE180, LWE200, LPE200-6/8

MAINS, EARTH
T-code
660,661,662
221397
11/11, Prod C
11- 25
Functional description
660,661,662 723984- 2006-11-17 221609-040
11.4 Functional description
means constantly on means flashing
11.4.1 Theory of operation

This section gives basic electrical descriptions of the truck’s main func-
tions in tabular form. It describes, in simple terms, what happens when
performing any of the truck’s main operations.
• Event - The main stages in performing any of the truck’s main func-
tions are referred to as “Events”. Each event is numbered.
• Prior events - Indicates the event number which must have taken
place immediately before in order for current event function correct-
ly.
• Action(s) - A required action from the operator for the event to occur.
• Influencing elements - Conditions which must be fulfilled in order for
the event to occur. Certain parameter settings may also affect the
outcome of the event.
• Resulting conditions - Describes key occurrences which can be
checked to confirm operation.
Note that “resulting conditions” show what is expected when no error
conditions are present. Items shown in square brackets [ ] refer to elec-
trical component designations as stated in the electrical wiring dia-
grams.
Unless otherwise stated, {high} ≈ 24 V and {low} ≈ 0 V.

221609-040 2006-11-17 723984- 660,661,662
Table 3: Theory of operation

Event: 1. Battery connected
Action(s) Connect the traction battery [X1, G1].
Influencing Main power fuses ok [F1, F3] .
elements Operating circuit fuses ok [F50, F51].
PTC resistor ok [R1]
Resulting Curtis status LED blinks once every 5 seconds [A1].
conditions
Event: 2. Switch on
Prior event(s) 1
Action(s) Turn on the key [S17].
Key
Action(s)
Keypad (Option) Enter valid PIN-code and press [A17].
Influencing Emergency switch-off not activated [S21] [A1:INP.SUPPLY+24VDC] {high}.
elements Tiller in drive position sensor not activated [S10] [A1:INP.TILLER ARM IN
DRIVE POS] {low}.
Resulting
conditions Power lamp lights. Main display shows hour meter reading
and for 4 seconds followed by battery condition as a
percentage of full charge and [A6].

Mechanical brake remains on [Y1, A1:OUT.BRAKE A] {high}.
Event: 3. Tiller unit lowered for driving
Prior event(s) 2
Action(s) Lower tiller unit handle.
Influencing Tiller in drive position sensor [S10].
elements
Resulting Tiller in drive position sensor activates [S10] [A1:INP.TILLER ARM IN
conditions DRIVE POS] {low}.
Main contactor output goes {low} [A1:OUT.MAIN CONTACTOR].
Main contactor closes [K10].

660,661,662 723984- 2006-11-17 221609-040

Event: 4. Traction, forks first
Prior event(s) 3
Action(s) Move butterfly [L1] in forks direction.
Influencing Butterfly Hall sensors [A2:S10-18].
elements #1, #2 & #3 settings affect traction performance.
Resulting [A1:OUT.BRAKE A] goes {low}.
conditions Brake coil [Y1] energises, mechanical brake releases.
Current fed to traction motor field winding (S2 +ve and S1 -ve).
Pulsed current fed to traction motor armature proportional to butterfly
deflection.
Event: 5. Traction, drive wheel first
Prior event(s) 3
Action(s) Move butterfly [L1] in drive wheel drive direction.
Influencing Butterfly Hall sensors [A2:S1-9].
elements #1, #2 & #3 settings affect traction performance.
Current fed to traction motor field winding (S2 -ve and S1 +ve).
deflection.
Event: 6. Neutral braking
Prior event(s) 4 or 5
Action(s) Let butterfly [L1] return to neutral position.
Influencing Fork load supervision sensor [P1].
elements #4 setting.
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] con-
conditions verts the trucks energy of motion into electrical energy, thus reducing the
truck’s speed. The excess electrical energy is fed back to the battery [G1]
helping to recharge it. The mechanical brake [Y1] activates when the truck
comes to a complete stand still. [A1:OUT.BRAKE A] goes {high}.

221609-040 2006-11-17 723984- 660,661,662

Event: 7. Reverse braking
Action(s) Move butterfly [L1] so as to reverse the direction of travel
Influencing Man-on platform switch [S19]
elements Fork load supervision sensor [P1]
Resulting Traction motor [M1] acts as generator and via transistor controller [A1] con-
conditions verts the trucks energy of motion into electrical energy thus reducing the
truck’s speed. The excess electrical energy is fed back to the battery help-
ing to recharge it [G1]. The braking effect increases the more the butterfly
is deflected
The mechanical brake [Y1, A1:OUT.BRAKE A] activates when the truck
comes to a complete stand still
Event: 8. Mechanical brake operation
Action(s) Move tiller unit handle to upper or lower position.
Influencing Tiller in drive position sensor [S10].
elements
Resulting Tiller in drive position sensor [S10] de-activates, [A1:INP.TILLER ARM IN
conditions DRIVE POS] {low}.
The mechanical brake [Y1] activates, [A1:OUT.BRAKE A] {high}.
Event: 9. Emergency reverse function
Prior event(s) 5
Action(s) Whilst travelling in drive wheel direction, the emergency reverse button
[A2:S17] becomes depressed.
Influencing Emergency reverse [A2:S17].
elements
Resulting Hall switch [A2:S17] is directly activated. The [A2] card interprets this sig-
conditions nal as a command to the transistor regulator [A1] to drive the traction motor
at a reduced speed in the forks direction as long as [A2:S17] is depressed.
The normal drive command signal received from [L1] is blocked until [L1] is
released and returns to neutral position.

660,661,662 723984- 2006-11-17 221609-040

Event: 10. Forks lifting
Prior event(s) 2
Action(s) Press the lift forks button [A2:S19].
Influencing Main contactor [K10].
elements Fuse [F3].
Fork lift button [A2:S19].
Battery status ok (battery discharge indicator > 0 or battery charge > 20 %).
Resulting [A1:OUT.PUMP CONTACTOR] goes {low}.
conditions Pump contactor [K30] activates, pump motor [M3] starts.
Event: 11. Forks lowering
Action(s) Press the lower forks button [A2:S20].
elements Forks lower button [A2:S20].
Resulting [A1:OUT.LOWER VALVE] goes {low}, lowering hydraulic valve [Y41] acti-
conditions vates.
Event: 14. Click-2-creep (option)
Prior event(s) 2
Action(s) “Double-operate” [L1] to activate function.
Operate [L1] with tiller arm in upright position to drive truck at creep speed
(2.5 km/h).
elements Setting of parameter #15:0.

deflection. “SLO” displayed (flashing).
Event: 15. Turtle (option)
Prior event(s) 3
Action(s) Press [S113] to activate function.
Move butterfly [L1] in either direction.
Influencing Option button 1 [S113].
elements Setting of parameter #1 & #15:1.

deflection. Maximum speed limited by parameter #1. “SLO” displayed (con-
stantly on).

221609-040 2006-11-17 723984- 660,661,662
11.4.2 Spider expansion unit (SEU)

The Spider expansion unit, referred to as the SEU, allows the main con-
trol card to handle a greater number of inputs and outputs. The SEU
allows up to 8 extra digital inputs and 4 digital outputs which can be
addressed and controlled via the CAN bus. The SEU contains firmware
but this is only for internal configuration. No truck control logic is
present in the SEU. This means a faulty SEU can be exchanged with-
out affecting the truck’s functions in any way.
There are 3 cases covering the usage of SEU:
a) The SEU can be fitted if the truck is modified according to a customer
special request. In this case, correct operation of the modification is
acheived by adjustment of service parameters 16 to 19.
b) The SEU is fitted as standard in certain truck models, to allow control
of standard features. Such trucks do not require that service parame-
ters 16 to 19 be activated. (Parameters 16 to 19 shall be set to “0”.)
c) Trucks fitted with an SEU as standard can also have additional mod-
ifications using “configurable options”. These additional modifications
are controlled by the setting of service parameters 16 to 19.
Refer to section Parameter #16 to #19 configurable options on page 58
for more detailed information.
.
A2
Electronic
card
TLS
A36 Extra / Customised
A5 SEU function(s)
Steer servo
CAN bus
A3
Pump
controller
X41
CAN service
connector
A1
Traction
controller
Fig. 1 Connection architecture for SEU
Fig. 1 shows how the SEU is used to allow a greater number of func-
tions to be controlled via the CAN bus. The SEU has one 42-pin mul-
tipin connector which handles all inputs, outputs, CAN and supply sig-
nals.
660,661,662 723984- 2006-11-17 221609-040
11.4.3 Hour meter and battery condition

At switch on, the hour meter is displayed and the hour meter symbol
lights for 4 seconds. Fig. 2.
The display will then change to show the battery’s remaining capacity
Fig. 2 expressed as a percentage of full charge and the battery symbol lights.
Fig. 3.
The truck’s control system stores 5 different elapsed time values in
units of hours. The time value normally shown depends on the setting
of service parameter #20. (See “ # 20 - Hour meter selection” on
page 50). However, any of these time values can be temporarily dis-
played on the hour meter. To choose which value to display carry out
the following procedure:
Fig. 3
• Ensure the battery is connected.
• Ensure the truck is switched off. Press on the keypad.

• Press and hold horn button [S18] for at least 1 second, enter a valid
PIN-code and then press on the keypad.

• Hold [S18] depressed until “H” is displayed, then release [S18]. Fig. 4
Hourmeter symbol lights.

Fig. 4
The different hourmeter modes are displayed by repeatedly operating
speed control [L1]. The actual time value will be displayed momentar-
ily after the mode is selected.
Table 4: Hour meter modes

Description Display
Key time:
Total time truck has been switched on
Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
Drive motor time:
Total time drive motor has been in operation
Pump motor time:

Total time pump motor has been in operation.
Remaining time to next service

(Parameter #25 controls the initial value) See “ # 25 - Service interval” on
page 53 for more information.

221609-040 2006-11-17 723984- 660,661,662
11.4.4 TLS - Truck log system (optional)

General
The truck log system, which is CAN based, is either an integrated sys-
tem (SD16) or a freestanding supplementary system (S16). A collision
sensor can also be connected.
The TLS communicates wirelessly with a base station (RG3) once the
truck is within range. The base station then receives information on
what the truck has done since they last communicated with one anoth-
er.
Built-in system PC
A2 RG3
Electronic card
Add-on system
CAN bus
TLS SD16
TLS S16
CAN bus
Shock sensor
Shock sensor
A1
Traction controller I/O-unit
Registration
To register the truck with the base station, follow the instructions below:
• Position the truck close to the base station.
• Press and hold the green button for approx. 5-10 seconds until
three LEDs on the base station start flashing at the same time.
The base station can now communicate with the truck whenever it is
within range.
Logging in/out SD16

Logging in and out is performed as usual via the keyboard on the han-
dle (or by using an ID unit). The difference is that communication pass-
es through the TLS, which makes all the decisions.
Logging in/out S16

Logging in and out is performed using the keyboard on the TLS.

660,661,662 723984- 2006-11-17 221609-040
Collision sensor
If there is a collision sensor installed on the CAN bus, it registers when
the truck bumps into something. If the impact exceeds a certain level, it
is classified as a collision and the truck comes to a halt. It can be reset
by entering the PIN code for “resetting the collision sensor” (see table
below).
Settings
Additional equipment (software and wiring) from Davis Derby is
required to change the TLS settings.
Table 5: Settings TLS

Function Description Default setting
PIN code PIN code for different driver pro- 00001 (profile 1)
files. 00002 (profile 2)
00003 (profile 3)
11111 (resetting the collision sensor)
Logoff time Time in minutes (1-254) that the 255 (not switched off)
truck is inactive before it is
switched off.
Impact level Determines how sensitive the 5 % (sideways)
truck is to an impact. 5 % (forwards/backwards)
Department Only applies when ID unit is 14
installed.
Type of truck Only applies when ID unit is 16
installed.
11.4.5 ID unit (optional)

See the separate manual that is included with the software.

221609-040 2006-11-17 723984- 660,661,662
11.4.6 Built-in battery charger (optional)
Technical data
Designation SMCI 300

Dimensions 250x115x67 mm
Weight 1,6 kg
Ambient temperature -25° C to +40° C
Line voltage 90-255 V AC, 45-400 Hz
NOTE: The charging current is
reduced in case of a line voltage
below 200 V
Rated voltage 24 V DC
Rated current 30 A
Max. output power 800 W
Efficiency > 86%
Battery types Freely ventilated lead batteries with
water filling, Valve-regulated (VR)
lead batteries
Protection class IP 20
Other Temperature regulated cooling fan
Protected against incorrect polari-
sation.
In order for chargers on trucks with
machine numbers from 936513- to
switch on, the battery voltage must
be between 19.8 and 34.7 V.

660,661,662 723984- 2006-11-17 221609-040
Charging
WARNING!
Please note that when charging valve-regulated batteries (Evolution
type), the SMCI300 has been designed to charge batteries that are
used in normal room temperature, i.e. +15°C to +30°C. For other tem-
peratures, the charger must be loaded with different firmware, availa-
ble from the charger dealer.
Machine number 723984-936512
The charger is designed for batteries with a capacity from approx. 100
Ah to 320 Ah.
Charging starts automatically when the charger is connected. During
charging, the status indicator lights in orange. When charging has been
completed, the status indicator switches to a green light.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
discharged freely ventilated 320 Ah battery may need up to 14 hours of
recharging, while a VR battery may require even longer time.
The charger has a built-in monitor system that monitors the tempera-
ture and charging duration. If a fault occurs, the charger can interrupt
the charging process or limit the amount of charging.
Machine number 936513-
The charger is designed for freely ventilated batteries with a capacity
from approx. 100 Ah to 350 Ah as well as for valve-regulated batteries
with capacities of 134 Ah, 174 Ah and 201 Ah.
When connecting the charger, first the battery type is indicated. For
valve-regulated batteries, the indicator lights green for three seconds,
while for freely ventilated batteries it lights orange for three seconds.
After this, the charger setting is indicated through a number of blinks
corresponding to the selected setting (see “ Adjusting the charger” on
page 37).
Once the setting has been indicated, charging starts. During charging,
the status indicator lights in orange. When charging has been complet-
ed, the status indicator switches to a green light.
The charging duration varies depending on the battery type and degree
of discharge. Normally, the charger would be started after the work shift
and the battery should then be fully charged the next morning. A deeply
discharged freely ventilated 320 Ah battery may need up to 14 hours of
recharging, while a VR battery may require even longer time.
The charger has a built-in monitor system that monitors the tempera-
ture and charging duration. If a fault occurs, the charger can interrupt
the charging process or limit the amount of charging.

221609-040 2006-11-17 723984- 660,661,662
Troubleshooting and service

First check whether the charger indicates an error. A red blinking indi-
cator means that the charger has not detected any connected battery
or that a battery has not been set with the selection switch. Check the
switch position, cables, terminals and other battery connections. Meas-
ure the battery voltage.
If the charger still does not operate, contact the supplier for service.
Adjusting the charger

The battery size and battery type can be selected with the switch locat-
ed on the ventilation panel (C). Set the switch using a flat screwdriver.
Machine number 723984-936512
Freely ventilated batteries

Switch Battery size Output I2 current Max. current, trickle
current charging
0 No charging (red LED lit) - - -
1 100-119 Ah 22 A 5,5 A 0,6 A
2 120-144 Ah 26 A 6,6 A 0,7 A
3 145-174 Ah 30 A 8,0 A 0,8 A
4 175-209 Ah 30 A 9,6 A 1,0 A
5 210-249 Ah 30 A 11,5 A 1,2 A
6 250-299 Ah 30 A 13,7 A 1,4 A
7 300-350 Ah 30 A 16,2 A 1,6 A
Valve-regulated batteries
Switch Battery size Output I2 current Max. current, trickle
current charging
8 No charging - - -
9 300-350 Ah 30 A 3,8 A 1,6 A
A 250-299 Ah 30 A 3,4 A 1,4 A
B 210-249 Ah 30 A 2,8 A 1,2 A
C 175-209 Ah 28 A 2,4 A 1,0 A
D 145-174 Ah 22 AA 1,9 A 0,8 A
E 120-144 Ah 18 A 1,5 A 0,6 A
F 100-119 Ah 15 A 1,3 A 0,6 A

660,661,662 723984- 2006-11-17 221609-040
Machine number 936513-
Freely ventilated batteries

Switch Battery voltage Battery Battery Indication Max. charging
position type size current = I1
0 No charging - - Continuous -
red
1 24 V Freely venti- 100-119 Ah 1 blink, 22 A
lated Orange
2 24 V Freely venti- 120-144 Ah 2 blinks, 26 A
lated Orange
lated Orange
lated Orange
lated Orange
lated Orange
lated Orange
8 No charging - - Continuous -
red
Valve-regulated batteries (Evolution type)

Switch Battery voltage Battery Battery Indication Max. charging
position type size current = I1
9 24 V Valve-regu- 134 Ah 1 blink, 23 A
lated green
A 24 V Valve-regu- 174 Ah 2 blinks, 30 A
lated green
B 24 V Valve-regu- 201 Ah 3 blinks, 30 A
lated green
C No charging - - Continuous -
red
D No charging - - Continuous -
red
E No charging - - Continuous -
red
F No charging - - Continuous -
red

Parameters & adjustments
221609-040 2006-11-17 723984- 660,661,662
11.5 Parameters & adjustments
11.5.1 General
The truck’s control system stores a number of parameters. These
parameters are used to configure the truck for correct operation in the
particular application for which it was designed. The parameters are
divided into two groups, Operator parameters and Service parameters.
• Operator parameters (1 to 9) - These parameters are used to tailor
the driving characteristics of a truck for a specific operator or opera-
tion. A maximum of 10 operator parameter sets, so called operator
profiles, can be stored in a truck. Operator parameters can be ad-
justed directly without the requirement for a suitable CAN service
key.1
• Service parameters (10 to 40) - These parameters are used to tai-
lor the truck’s performance / operation characteristics and include all
other parameters not designated as operator parameters. Service
parameters can ONLY be adjusted when a suitable CAN service key
is plugged into the truck.2
11.5.2 Displaying parameters - without the

CAN service key
Proceed as follows to display parameters when a CAN service key is
not connected:

PIN code and then press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig.
5
Parameters symbol lights.

Fig. 5
The different parameters are now displayed by repeatedly operating
speed control [L1]. Operator parameters can be both viewed and
changed.1
1.Operator parameters can only be set without a CAN key if parame-

ter #39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Login
method and driver parameter access on page 54.
2.Service parameters can be viewed without a CAN key being
plugged in but they cannot be adjusted.

660,661,662 723984- 2006-11-17 221609-040
11.5.3 Adjusting operator parameters -

without the CAN service key
NOTE!
Operator parameters can only be set without a CAN key if parameter
#39 is set to value “1”, “3”, ”5”, “7”, “9” or “11”. See # 39 - Login meth-
od and driver parameter access on page 54.
To change the value of a particular operator parameter carry out the fol-
lowing:
• Switch on the truck and log in with the appropriate PIN-code. This is
important if the truck has more than one set of Operator parameters
active . Any changes made will only be in effect when that particular
“operator” is logged in.
• Select the required parameter.
• Press horn button [S18].
Parameter symbol flashes. .
• Set parameter value by repeatedly operating speed control [L1] up

or down
• Press horn button [S18] once to confirm the new setting.
Parameters symbol lights. (stops flashing).
• Switch off the truck by pressing on the keypad.

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
11.5.4 Displaying & changing parameters -

CAN service key connected
• Connect a suitable CAN-service key to [X41].

• Press and hold horn button [S18] for at least 1 second and then
press on the keypad.

• Hold [S18] depressed until “P” is displayed, then release [S18]. Fig.
6
Fig. 6

221609-040 2006-11-17 723984- 660,661,662
When pressing the speed control [L1] forwards repeatedly, the first
operator profile will be displayed. Continue to press [L1] in the forward
direction and the next operator profile will be displayed (operator no. 2),
etc. until the last operator (operator no. 10). See Fig. 7
Once the 10 operator profile have been displayed, the truck service
parameters will be displayed as [L1] is repeatedly pressed in the for-
ward direction.
Operator parameter no.
Profile no. Changing a parameter
Fig. 7 • Select the required parameter.
• Set the parameter value by repeatedly operating speed control [L1]

up or down
Parameters symbol lights. (stops flashing).

You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
The truck’s service parameters can be displayed first by operating
speed control [L1] in the backward direction. This will cause parameter
#40 to be displayed and then parameter #39 etc.1
For detailed descriptions and effects of these parameters see the sec-
tion List of Service parameters on page 45.
NOTE!
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necessary know how.
1.Certain parameters numbers displayed are not active in this truck

model.

660,661,662 723984- 2006-11-17 221609-040
11.5.5 List of operator parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in the sec-
tions Displaying parameters - without the CAN service key on page 39
and Changing a parameter on page 41.
Table 6: List of operator parameters LWE180, LWE200

Parameter Designa- Unit Min Max. Step Std Description
tion .
01 Travel speed, % 40 100 5 100 Travel speed, Turtle but-
Turtle button ton
40: Slow speed
100: Full speed
02 Max. travel % 40 100 5 100 Max. travel speed
speed 40: Slow speed
100: Full speed
03 Acceleration 10 100 5 50 10: Slow acceleration
100: Fastest acceleration
04 Braking in 5 100 5 50 Indicates motor braking
neutral posi- when the control lever is
tion set to the neutral position.
5: Slight motor braking
100: Maximum motor
braking
05 Log-out 1min 0 20 1 20 Time until truck is
switched off when keypad
is in use. The time is
counted from when the
last power-consuming
component was used.
Value = 0 results in 4
hours.
In increments of 1

221609-040 2006-11-17 723984- 660,661,662
Table 7: List of operator parameters LPE200-6/8

Parameter Designa- Unit Min Max. Step Std Description
tion . s
01 (LPE200- Creep speed % 10 100 5 100 Max. travel speed in low-
8) speed range (gates not
activated)
02 Max. travel % 10 100 5 100 Max. travel speed
speed 10: Slow speed
100: Full speed
03 Acceleration 10 100 5 80 10: Slow acceleration
100: Fastest acceleration
04 Braking in 5 100 5 70 Indicates motor braking
neutral posi- when the control lever is
tion set to the neutral position.
5: Slight motor braking
100: Maximum motor
braking
05 Log-out 1min 0 20 1 20 Time until truck is
switched off when keypad
is in use. The time is
counted from when the
last power-consuming
component was used.
Value = 0 results in 4
hours.
In increments of 1

660,661,662 723984- 2006-11-17 221609-040
11.5.6 Description of operator parameters

# 1 - Travel speed, Turtle button (LWE180, LWE200)
The travel speed when the Turtle button is used can be adjusted.
# 1 - Creep speed (LPE200-8)

Possibility to adjust the speed in the low speed range (when the safety
gates are not used).
# 2 - Maximum travel speed

The maximum travel speed can be adjusted.
# 3 - Acceleration
The lower value of the parameter the longer time it takes to accelerate
the truck to top speed.
# 4 - Neutral speed reduction

Defines motor brake force when lever [L1] goes to neutral position.The
lower value of parameter the longer time to reduce speed.
# 5 - Logout
The time until the truck will be switched off when a key pad is used.
Time is counted from when the latest power consumer is used.
Value = 0 gives 4 hours.

221609-040 2006-11-17 723984- 660,661,662
11.5.7 List of Service parameters

NOTE!
Before changing any parameters, ensure you have read and under-
stood the procedures for viewing and setting parameters in the sec-
tions Displaying & changing parameters - CAN service key connected
on page 40 and Changing a parameter on page 41.
The CAN service key must be connected to the external CAN connec-
tor [X41] before adjusting any Service parameters
Param- Description Unit Min. Max. Step Std. Description
eter
10 PIN-code 0 9999 1 1 PIN code assignment.
NOTE! Not applicable if Parameter
#39 has been set to the value 5, 6, 7
or 8.
14 Creep speed -10 10 1 -5 The amount of power the monitor
LWE180 should emit when you reach the first
LWE200 speed sensor can be specified here.
-10: low speed for the first speed sen-
sor.
10: high speed for the first speed sen-
sor
14 Creep speed -10 10 1 0 The amount of power the monitor
LPE200-6 should emit when you reach the first
LPE200-8 speed sensor can be specified here.
-10: low speed for the first speed sen-
sor.
10: high speed for the first speed sen-
sor
15 Non-configura- See “ #15 - Non-configurable options” on page 48,
ble option 0 to 9
16 Configurable See “11.5.9 Configurable “Option” parameters” on page 57,
option #1
17 Configurable
option #2
18 Configurable
option #3
19 Configurable
option #4
20 Hour meter 1 5 1 2 Select hour meter.
selection
21 Battery size 1 20 1 5 Selection of battery size.
LWE180
LWE200
LPE200-6
21 Battery size 1 20 1 7 Selection of battery size.
LPE200-8

660,661,662 723984- 2006-11-17 221609-040
Param- Description Unit Min. Max. Step Std. Description

eter
22 Brake switch 0 1 1 1 0: Mechanical switch
1: Inductive sensor
25 Service interval hrs 0 2000 50 0 Option for setting service timer
28 Button selection 1 3 1 1 Button selection
39 Password 1 12 1 1 States which level of authorization the
driver has for the parameters.
Odd values specify open driver
parameters, even values specify that
driver parameters must be opened
using the CAN key

221609-040 2006-11-17 723984- 660,661,662
11.5.8 Description of Service parameter

# 10 - PIN code
NOTE!
The functionality of parameter #10 is ignored if the value of parameter
#39 has been set to 5, 6, 7 or 8. PIN code input is facilitated via the ex-
tended keypad. For detailed information, see the section Expanded
keypad - General on page 54.
This parameter stores the active PIN-codes for the truck. The truck can
store a maximum of ten operator profiles. The operator profile is acti-
vated when the operator logs in with the assigned PIN code. Logging in
with a specific PIN code when the truck is started will activate the oper-
ator profile to which this PIN code has been assigned. This allows up to
ten operators to individually adjust the characteristics of the truck.
On delivery the truck has one default PIN-code stored which is “1“.
To enter a new PIN-code:

• Operate [L1] repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this op-
erator.
• Repeat the step above until parameter#10 for the next operator is
displayed, the display will either show PIN-code for that operator OR
“0”(zero).
• Repeat the step above until the PIN-code displayed is “0”(zero).
• Operate [L1] to set the desired value of the new PIN-code.1

Parameters symbol lights (stops flashing).
The new PIN-code has now been entered.
1.Operating [L1] lightly will step the value in increments of 1.

Operating [L1] fully will step the value in increments of 100
Valid values are 1 to 9999

660,661,662 723984- 2006-11-17 221609-040
To remove an existing PIN-code:

• Operate [L1] repeatedly in the forward direction to select parameter
#10. After one second, the display will show the PIN-code for this op-
erator.
• Repeat the step above until the PIN-code to be removed is dis-
played.
• Operate [L1] to set the PIN-code value to “0”(zero).

The selected PIN-code has now been removed.

To check whether a PIN-code will start the truck follow the procedure in
2. Switch on on page 27.
Parameter #10 cannot be displayed without the CAN service key.
# 14 - Creep speed
Defines the speed you will get when you reach the first speed sensor.
#15 - Non-configurable options

See Service Manual.
Up to 16 so called sub-parameters are stored and accessed via param-
eter #15. These options are either switched ON or switched OFF and
require no other adjustments. They are therefore called non-configura-
ble options. The number of available options is dependant on the truck
type. Consult table #15 - Non-configurable options on page 48 for avail-
able options.
Setting Non-configurable options

• Ensure the truck is in the parameter mode.
The parameters symbol lights.
• Select parameter #15 using [L1].

The first sub-parameter will be displayed
Continued operation of the speed control [L1] will display the next sub-
parameter. Note also that only relevant sub-parameters will be dis-
played.

221609-040 2006-11-17 723984- 660,661,662
After 1 second the value of the sub-parameter will be displayed.

Parameter symbol flashes.

• Set the sub-parameter value by repeatedly operating speed control
[L1] up or down. See Table 11: for details.
The parameters symbol lights. (stops flashing).

The non-configurable option will now be activated.
• Ensure the option operates correctly before returning the truck for
normal use.
P
Table 8: Parameter #15 Non-configurable option

Function name Value Note!
Sub-parameter no.
Function OFF
Basic setting
Function ON
1 "Turtle" function 1 0 0
2 to 9 For future use - - -
#16 - Configurable option #1

See “11.5.9 Configurable “Option” parameters” on page 57.




660,661,662 723984- 2006-11-17 221609-040
# 20 - Hour meter selection

This parameter determines which hour meter mode to display during
normal use.
Table 9: Hour meter parameter selection

Value Description Display
1 Key time:
Total time truck has been switched on
2 Activity time:
Combined time either pump or drive motor has been in operation
(Default display mode)
3 Drive motor time:
Total time drive motor has been in operation
4 Pump motor time:

Total time pump motor has been in operation
5 Remaining time to next service

(Parameter #25 controls the initial value)
See # 25 - Service interval on page 53

221609-040 2006-11-17 723984- 660,661,662
# 21 - Battery size
You must specify the type of battery the truck is equipped with.
In order to set the meter for the battery’s level of discharge, the follow-
ing should be taken into account:
• Acid concentration when the battery is fully charged, to check the
grade of the battery. Must be between 1.27-1.29.
• When the lifting capacity is disconnected (the battery is 80 % dis-
charged), the value must be close to, but not below, 1.14.
The acid concentration can vary depending on the battery make.
Recommendation on parameter setting for freely ventilated batteries
Parameter 21 Battery size Battery size

LWE180, LWE200, LPE200-8
LPE200-6
1
2
Less dis-
charge 3
4
5 260Ah - 320Ah
Standard value
6 190Ah - 250Ah
7 120Ah - 180Ah 260Ah - 320Ah
Standard value
8 190Ah - 250Ah
9 120Ah - 180Ah
10
11
12
13
Greater dis- 14
charge 15
16
17
18
19
20
WARNING !
The service life of the battery will be reduced if the value of parameter
21 is set at too high a value. The standard setting of parameter 21 is
set for normal truck handling. Other applications may require a differ-
ent setting of parameter 21. Check that the parameter setting is the
correct one using the instructions below.

660,661,662 723984- 2006-11-17 221609-040
Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Remove the battery from the truck and allow to rest for at least two
hours. NB! No charging or discharging during this period.
• Measure the acid weight of the battery at room temperature. If the
acid weight is less than 1.15 g/cm3, the parameter value must be
reduced. If the value significantly exceeds 1.15 g/cm3, the risk of
damage to the battery is reduced. At the same time, the operating
time of the truck is reduced. If a longer operating time is required, the
parameter value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.
Recommendation on parameter setting for valve-controlled bat-
teries (VRLA)
Parameter 21 Battery size Battery size
LWE180, LWE200, LPE200-8
LPE200-6
1
2 260Ah - 320Ah
Less discharge
3 190Ah - 250Ah
4 120Ah - 180Ah 260Ah - 320Ah
5 190Ah - 250Ah
6 120Ah - 180Ah
7
8
9
10
11
12
13
14
15
16
Greater dis- 17
charge 18
19
20
WARNING !
The service life of the battery will be reduced if the value of parameter
21 is set at too high a value. The standard setting of parameter 21 is
set for normal truck handling. Other applications may require a differ-
ent setting of parameter 21. Check that the parameter setting is the
correct one using the instructions below.

221609-040 2006-11-17 723984- 660,661,662
Instructions for verifying parameter setting

• Charge up the battery
• Use the truck in its normal application until the battery indicator
shows an empty battery (0% on the display).
• Disconnect the battery from the truck and allow the battery to rest for
at least two hours. NB! No charging or discharging during this peri-
od.
• Measure the battery voltage at room temperature. If the voltage is
less than Uend, see the table below, the parameter value must be re-
duced. If the value significantly exceeds Uend, the risk of damage to
the battery is reduced. At the same time, the operating time of the
truck is reduced. If a longer operating time is required, the parameter
value can be increased. Maximum one unit.
• Each change must be accompanied by a new verification of the pa-
rameter setting.
Battery type Battery voltage at rest, Uend

Hawker Evolution 24,24 V
# 22 - Brake switch
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1
# 25 - Service interval
Using this parameter you can specify a limit for when the next service is
to take place, from 0 to 2000 hours, in 50-hour steps. When it is time for
a service, warning 29 (C29) is shown in the display.
# 28 - Button selection
Using this parameter you can select which button is to be used for lift/
lower.
1 = Bottom lift/lower button activated (default)
2 = Top lift/lower button activated
3 = Both lift/lower buttons are activated

660,661,662 723984- 2006-11-17 221609-040
# 39 - Login method and driver parameter access

This parameter determines which function is to be used for login and
whether the operator can adjust the driver parameter settings.
• Value 1 – Key switch fitted – Driver parameters accessible (without
CAN service key).
• Value 2 – Key switch fitted – Driver parameters NOT accessible
(without CAN service key).
• Value 3 – Keypad (Standard 10 PIN code)- Driver parameters acces-
sible (without CAN service key) NB! this is the original setting.
• Value 4 – Keypad (Standard 10 PIN code)- Driver parameters NOT
accessible (without CAN service key).
• Value 5 – Expanded keypad (100 PIN code)- Driver parameters ac-
cessible (without CAN service key)
• Value 6 – Expanded keypad (100 PIN code)- Driver parameters
NOT accessible (without CAN service key)
• Value 7 – Expanded keypad (100 PIN code) + TLS- Driver parame-
ters accessible (without CAN service key)
• Value 8 – Expanded keypad (100 PIN code) + TLS- Driver parame-
ters NOT accessible (without CAN service key)
• Value 9 – ID unit – Driver parameters accessible without CAN serv-
ice key.
• Value 10 – ID unit – Driver parameters NOT accessible without CAN
service key.
• Value 11 – ID unit + TLS – Driver parameters accessible without
CAN service key.
• Value 12 – ID unit + TLS – Driver parameters NOT accessible with-
out CAN service key.
Expanded keypad - General

The truck can contain a maximum of 10 individual driver profiles. The
expanded keypad function thus allows you to assign a maximum of 10
PIN codes for each of the driver profiles. This allows you to manage a
maximum of 100 unique PIN codes.
If the expanded keypad function is activated, the standard manage-
ment of PIN codes normally accessible via parameter #10 is set aside.

221609-040 2006-11-17 723984- 660,661,662
Expanded keypad - Programming

A number of PIN codes can be made accessible by activating the so-
called block. Block no. 0 is activated as standard. This means that 3 dif-
ferent driver profiles are available from the start. Activation of other
blocks means that all PIN codes for the block are accessible (See Table
11:). If all 10 blocks are activated, there will be 10 PIN codes available
for the driver profile.
The truck program stores a standard list of PIN codes as per Table 11:
These PIN codes can be changed to any value, but you should avoid
the same PIN code in different driver profiles.
To start programming the expanded keypad:
• Connect an appropriate CAN service key to [X41]
• Enter code 341671 and press on the keypad.

• Select the programming command from Table 10:
Table 10: Programming command - expanded keypad

Progamming Function Notes
Reset to factory settings Block 1 - 9 is deacti-
Press “1” + vated. Original PIN
codes reset as per
Table 11:
PIN codes in the block can be B= Block no. 0 - 9
Press “2” + B + used
PIN codes in the block cannot B= Block no. 0 - 9
Press “3” + B + be used
Programming a new PIN code B= Block no. 0 - 9
Press “4” + B + F + NNNN + F= Driver profile no.
0-9
NNNN = PIN code

The expanded keypad programming is now complete
Parameter #39 must be set with the value 5, 6, 7 or 8 for the new PIN
codes to be valid.
Carry out a practical test by logging in using some of the new PIN codes. It
is important to establish that the correct driver profile has been activated
when a certain PIN code has been entered, especially if a specific driver
profile has been set for a specific application/goods handling.
Table 11: shows the PIN codes available as standard in the program.
These can be activated for use or changed according to the driver’s wish-
es.
One or more of these blocks can be activated.

660,661,662 723984- 2006-11-17 221609-040
A driver profile is activated, on normal login, by all PIN codes whose block
no. is activated.
The truck program does not approve login using the PIN code “0000”.
Service personnel should keep notes on activated blocks, changed PIN
codes and specially-set driver profiles.
NOTE!
Resetting the expanded keypad does NOT affect the driver profile set-
tings.
Table 11: Standard PIN code assignment with the expanded

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

221609-040 2006-11-17 723984- 660,661,662
11.5.9 Configurable “Option” parameters

WARNING!
The information in this section is not intended as a programming ref-
erence and is included solely to allow the reader to gain a thorough
understanding of parameter setting/checking.
Do not attempt to make any adjustments to these parameters unless
you have sufficient knowledge of the truck’s options/modified func-
tions. This manual only covers the truck’s standard equipment. Spe-
cially modified trucks may require that you have access to special
service information. Improper adjustment of the option service pa-
rameters may compromise safe operation and/or result in a malfunc-
tion.
General
Parameters #16 to #19 are reserved in the truck’s control system for
extra truck options and/or special product modifications. The parame-
ters configure and control the behavior of the Spider expansion unit
(SEU) which must be fitted in the truck. See “11.4.2 Spider expansion
unit (SEU)” on page 31. This method of implementation allows the
standard software program to be used without the need for a special-
ised software. Normally, these parameters are configured by the manu-
facturer when the truck is modified or customized. It is advisable to up-
load the parameter settings from trucks which are modified. In the event
the main control card[A2] is changed, the original parameter settings
can then be transferred to the new card thus ensuring the special option
functions correctly.
Parameter Nos. #16, #17, #18 & #19 can be adjusted to allow up to a
maximum of 4 preprogrammed “base options” to be activated and con-
figured to suit a specific special option or customisation. See table
below.
Table 12: Summary of base options

Base Function Refer to..
option
no.
1 Pressing an option button controls a digital o/p table 13 on page 60
2 Activating a digital input will reduce maximum drive speed table 14 on page 61
3 Specific truck movement(s) activates a digital o/p table 15 on page 62
4 Activating a digital input causes main contactor to close table 16 on page 65
5 Activating digital inputs will operate lift /lower table 17 on page 66
6 Lift height can be restricted by activating a digital input + abil- table 18 on page 68
ity to override by pressing an option button

660,661,662 723984- 2006-11-17 221609-040
Parameter #16 to #19 configurable options

• Each parameter can be designated to hold a particular base option.
• Each designated option has up to 4 arguments associated with it.
• Each argument holds a value which configures that option.
Parameter no. (range 16-19)

Argument: #0 holds option designator (displayed for 2 s only)
Argument value (range 0 - 63)
0= no base option is activated for this parameter
1 to 6 = Base option no. See See separate tables)
16 - 0 - 1
OPTION ASSIGNATION
Argument: #1, #2, #3 & #4 hold configurable values for the option
Argument value (range depends on argument)
Value depends on option and argument selected
See separate table
16 - 1- 1
OPTION CONFIGURATION
Fig. 8 Configurable option layout
Setting Configurable options

To activate a configurable option the base option must first be assigned
to one of the parameters #16 to #19. This is achieved by setting argu-
ment #0 to the base option number. Once it is assigned, the option’s
arguments must be configured. This is achieved by setting a value for
arguments #1, #2, #3 and #4.
• Ensure the truck is in parameter mode.
• Select parameter #16, #17, #18 or #19 using [L1].

Argument #0 will be displayed
After 1 second the argument’s value will be displayed. A value of “0”

indicates no option is assigned to this parameter, in which case contin-
ued operation of the speed control [L1] will display the next parameter.

221609-040 2006-11-17 723984- 660,661,662
• Set argument #0 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 12:
• Select argument #1 by operating speed control [L1].

After 1 second the value of argument #1 will be displayed.
Parameter symbol flashes..
• Set argument #1 value by repeatedly operating speed control [L1]

up or down. Refer to base option list Table 12:
Adjust arguments #2, #3 and #4 using the same method as above.

The special option shall now be activated.
• Ensure the special option operates correctly before returning the
truck for normal use.

660,661,662 723984- 2006-11-17 221609-040
Table 13: Base option 1 - Option button controls SEU output

Argument #0 Option designator
Initial display Values Meaning
1 Sets relevant parameter to handle base option 1
(value shown after 2s delay)

Argument #1 Selection of SEU unit 1 or 2
0 Option is handled by SEU unit 1 [A36]
1 Option is handled by SEU unit 2 (second SEU unit)
Argument #2 Selection of SEU digital output
Initial display Values Meaning Pin no.
0 Activate SEU digital o/p 1 (1,6A) 16
(value shown after 2s delay) 2 Activate SEU digital o/p 3 (1,6A) 1
Argument #3 Selection of option button
1 Activated by option button 1
(value shown after 2s delay) 3 Activated by option button 3
Argument #4 Type of switching
0 Activated when button is depressed
1 Option is toggled when button is pressed

221609-040 2006-11-17 723984- 660,661,662
Table 14: Base option 2 - Reduced drive speed by SEU i/p

2 Sets relevant option parameter to handle base option
2
0 Option is handled by SEU unit 1[A36]
Argument #2 Selection of SEU digital input
0 Activate SEU digital i/p 1 (1mA) 5
(value shown after 2s delay) 2 Activate SEU digital i/p 3 (1mA) 33
Argument #3 Speed limitation as a percentage of max. speed
0-12 Max. speed adjustable from 40-100%
formula: =40+5*Arg.3
e.g. 40+5*4=60%
Argument #4 Speed range
0 Affects only high speed range
1 Affects only low speed range
(value shown after 2s delay) 2 Affects both speed ranges

660,661,662 723984- 2006-11-17 221609-040
Table 15: Base option 3 - Truck movement activates SEU O/P

3 Sets relevant option parameter to handle base
option 3

Argument #2 Selection of SEU digital output
(value shown after 2s delay) 2 Activate SEU digital o/p 3 (1,6A) 1
...table continued on next page

221609-040 2006-11-17 723984- 660,661,662

...continued from previous page
Argument #3 Selection of activating movement
Initial display Values Drive Drive Lift Lower Any
forward back- forks forks other
ward movement
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X
16 X
17 X X
18 X X
19 X X X
20 X X
21 X X X
22 X X X
23 X X X X
24 X X
25 X X X
26 X X X
27 X X X X
28 X X X
29 X X X X
30 X X X X
31 X X X X X

660,661,662 723984- 2006-11-17 221609-040

Argument #4 Output switching mode
0 Output continuously on
1 Output switches at 1Hz
(value shown after 2s delay) 2 Output switches at 2Hz

221609-040 2006-11-17 723984- 660,661,662
Table 16: Base option 4 - Activate main contactor by SEU i/p

4 Sets relevant option parameter to handle base option 4

Argument #2 Selection of SEU digital input
0 Activated by SEU digital i/p 1 (1mA) 5
(value shown after 2s delay) 2 Activated by SEU digital i/p 3 (1mA) 33
Argument #3 Hold time in minutes
0-30 Contactor is held on from 0 to 30 minutes after digital
i/p is activated
Argument #4 Not used

660,661,662 723984- 2006-11-17 221609-040
Table 17: Base option 5 - Activate lift/lower by SEU i/p

5 Sets relevant option parameter to handle base
option 5.

Argument #2 Selection of SEU digital inputs
0 Lift - SEU digital i/p 1 5
Lower - SEU digital i/p 2 19
Lower inhibit - SEU digital i/p 3 33

221609-040 2006-11-17 723984- 660,661,662
Table 17: Base option 5 - Activate lift/lower by SEU i/p

Argument #3 Enable/disable lower inhibit
0 Lower inhibit disabled
1 Lower inhibit enabled
Argument #4 Selection of fork / support arm
0 Selects fork lift/lower
1 Selects support arm lift/lower

660,661,662 723984- 2006-11-17 221609-040
Table 18: Base option 6 - Lift height restriction by SEU i/p &
override
6 Sets relevant option parameter to handle base option 6

Argument #2 Selection of SEU digital input for restriction switch
(value shown after 2s delay) 2 Activate SEU digital i/p 3 (1mA) 33
Argument #3 Selection of option button to override
(value shown after 2s delay) 3 Activated by option button 3
Argument #4 Not used

Diagnostic and troubleshooting
221609-040 2006-11-17 723984- 660,661,662
11.6 Diagnostic and troubleshooting
11.6.1 General
means constantly on means flashing.

The trucks’s electronic control system incorporates built-in fault code
display and logging. This capability works as a powerful complement in
assessing the cause of eventual truck malfunctions. When a fault code
occurs the code number is displayed and the fault condition LED flash-
es. Fig. 9.
Fig. 9
The codes can be broadly divided into two groups:
• Caution codes - denoted by prefix “C”. These codes alert the opera-
tor to the presence of a caution condition. Caution codes in the
range C50 to C99 will limit the truck’s maximum speed to creep-
speed. The conditions which cause such codes can usually be easi-
ly remedied without further attention. Caution codes C1 to C49 are
not stored in the code history log.
• Error codes - denoted by prefix “E”. These codes alert the operator
to the presence of a fault condition in the truck. Error codes E100
and higher will stop all truck driving functions until the error code is
cleared.
The first time any fault code is displayed it is advisable to check if the
condition persists by switching the truck off completely, i.e. disconnect
the battery and then switch back on. Check to see if the fault code is
again displayed.

660,661,662 723984- 2006-11-17 221609-040
11.6.2 Fault code history

Up to 50 of the most recently occurred fault codes will be stored in a log
along with the hour meter reading when the fault occurred. When the
fault code log is displayed, it shows the fault codes in chronological
order with the newest code first.
Carry out the following to display the fault code log:


• Hold [S18] depressed until “E” is displayed, then release [S18]. Fig.
10
Fig. 10 Fault symbol lights.
The most recently occurred error will be displayed. The display will
alternate between the fault code and the hour meter reading when the
fault occurred. If the fault code log contains more than one fault code,
these can be displayed by repeatedly operating the speed control [L1].
11.6.3 List of fault codes

NOTE!
The text “Restart the truck!” in the following tables always means
switching the truck off completely by removing the battery connector
[X1], reconnecting and then switching the truck on again.
Code C3
Description TLS: Shock sensors registered values outside
the limits
Possible error A shock sensor has reported values that exceed
cause the truck’s tolerance values.
Driving may be too hard
Check that the shock sensor’s limit values are
correctly set.
Check that the shock sensor is correctly posi-
tioned./The brake engages and stops the truck.
The TLS reset command activates the truck

221609-040 2006-11-17 723984- 660,661,662
Code C4
Description TLS: Use of the truck has been blocked
Possible error Truck use can be “blocked” by a TLS command. /
cause The truck cannot be used until a new TLS com-
mand cancels the blocking of the truck
Code C19
Description Parameter caution. Displayed for 5 seconds.
Possible error The parameters have probably been changed.
cause When changing/updating the program the param-
eters have automatically been changed to default
values (only applies to old program versions).
In later program versions the parameters are only
changed if they are outside the values permitted
by the new program.
Action 1. This means that the special parameters must
be reset manually.
Code C20
Description Speed control caution.
Possible error Problem with the speed control sensors.
cause The toggle switch may have been activated when
starting or there may be a fault on one of the sen-
sors on the electronic card. (tiller arm head)
Action 1. Restart with the speed control in neutral posi-
tion.
2. Replace the electronic card.

660,661,662 723984- 2006-11-17 221609-040
Code C28
Description Emergency switch caution
Possible error The emergency switch has been activated.
cause No current to the travel regulator, input. A1/16.
Action 1. Check fuse F51.
2. Check the emergency switch.
3. Check the cables from the battery and the bat-
tery contacts.
4. If PTC resistor R1 is very hot, remove the bat-
tery contact and allow the resistor to cool.
Restart.
Code C29
Description Service warning
Possible error Time for service.
cause The service counter has not been reset since the
last service.

221609-040 2006-11-17 723984- 660,661,662
Code C31
Description Pressure switch warning.
Possible error A problem with the pressure switch. Check that
cause the voltage is approximately 24 V between cables
24 and 40 connected to the pressure sensor.
Check the voltage between cable 40 and 63 con-
nected to the pressure sensor. The output voltage
should be 0.5 Volt (unloaded machine) - 5 Volt
(max load).
Code C41
Description Warning of low battery voltage
Possible error Battery voltage < 17 volt.
cause The battery parameters are not correctly set.
Time to charge up the battery.
Action 1. Check parameter 21, battery size and type.
2. Check the battery contact and the pole con-
nections on the battery
3. Check the key switch, S17, poor contact
causes unpermitted voltage drop.
The electrical system measures the voltage inside
the travel regulator.

660,661,662 723984- 2006-11-17 221609-040
Code C42
Description Warning of high battery voltage
Possible error Battery voltage > 33 volt.
cause Energy return feed to battery during motor braking
with a fully-charged battery.
Action 1. The fault disappears after a few lifts, once the
battery has been run down slightly.
2. Check the cabling, the battery contact and the
contact points on main contactor K10.
Code C43
Description The travel regulator shuts off due to excess or
subnormal temperature.
Possible error Too intensive operation or ambient temperature
cause too cold.
Error in the travel regulator.
Temperature levels below -25oC or above +85oC
reduce running speed.
Action 1. Check that the M12 fan is functioning.
2. Check that the travel regulator is installed with
good contact with the chassis.

221609-040 2006-11-17 723984- 660,661,662
Code C90 (Option)

Description Extra I/0 (0) CAN communication error
Possible error Data from extra I/0 box /(0) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.
Code C91 (Option)

Description Extra I/0 (1) CAN communication error
Possible error Data from extra I/0 box /(1) not being received by
cause [A2]/ Check the CAN-bus cable and the
connections. [A2] Restart the truck.
Code C92 (Option)

Description Configuration error Extra I/0 (0)
Possible error Incorrect setting of options in the extra I/0 box (0)
cause Check the outputs’ allocation on the I/0 expansion
box (0)
Code C93 (Option)

Description Configuration error Extra I/0 (1)
Possible error Incorrect setting of options in the extra I/0 box (1)
cause Check the outputs’ allocation on the I/0 expansion
box (1)

660,661,662 723984- 2006-11-17 221609-040
Code E101
Description Travel regulator does not correspond with the type
of truck
Possible error Incorrect travel regulator or electronic card has
cause been installed. The truck has a built-in control
function that checks to ensure the wrong combina-
tion of travel regulator and electronic card has not
been installed.
Action Check travel regulator and electronic card.
Code E104
Description Switch-transistor to brake is short-circuited
Possible error Error in the travel regulator, output. A1/3.
cause Incorrect value on parameter 22
Action Check cabling and contacts. Measure Ohms on
the magnet coil (Y1) for the brake. Value 13-15
ohm.
Check parameter 22

221609-040 2006-11-17 723984- 660,661,662
Code E106
Description Digital outputs short-circuited or exceeding field
current limit.
Possible error Problem regulating the field current.
cause Internal monitoring error.
Action 1. Check the output for main contactor K10 (A1/
4), check cabling and contacts and measure
ohms for the coil. Value 25-30 ohm. Check the
output for the brake coil K10 (A1/3), check ca-
bling and contacts and measure ohms for the
coil. Value 13-15 ohm.
2. Check the output for horn (A1/7), check ca-
bling and contacts.
3. Check the drive motor’s shunt winding and ca-
bling and contacts. Unfortunately it is not pos-
sible to measure ohms for the field winding us-
ing a standard universal instrument, since the
winding has a value as low as 0.3 ohm.

660,661,662 723984- 2006-11-17 221609-040
Code E107
Description Contactor K10 does not close.
Possible error Problem with main contactor points or coil.
cause Contactor’s operating cabling off/not connected.
Interruption in the travel regulator’s output, A1/4.
Action 1. Check if the contactor is activated.
2. If the contactor is working, check the contact
points and accompanying cabling.
3. If the contactor is not working, check the coil
and accompanying cabling. Measure Ohms
for the coil. Value 25-30 ohm.
4. Check the travel regulator’s output, A1/4.

221609-040 2006-11-17 723984- 660,661,662
Code E108
Description Contactor K10 does not open.
Possible error Main contactor points welded.
cause Short circuit in the travel regulator’s output A1/4.
Action 1. Check that the contactor’s contact points are
not welded together.
2. Check that the R1 resistor is not short-
circuited.
3. If the contact points are OK, but the contactor
engaged, check cable 64 and the travel regu-
lator’s output A1/4.
Code E110
Description System error.
Possible error Temporary error/error in the travel regulator.
cause
Action 1. Restart the machine.
2. Replace travel regulator.
Code E140
Description Error in control total.
Possible error Fault on the internal micro-monitoring (tiller arm
cause head), incorrect software or circuit board.

660,661,662 723984- 2006-11-17 221609-040
Code E141
Description Software problem.
Possible error Fault on the internal monitoring (tiller arm head),
cause incorrect software or circuit board.
Action 1. Restart the machine.
2. Download the program again.
3. Replace the electronic card
w
Code E150
Description Fault in the data communication.
Possible error Break on the CAN cable.
cause
Action 1. Check the 119 and 120 cables and their con-
tacts.
Code E151
Description Tx error in data communication.
Possible error Travel regulator not responding.
cause
Action 1. Check 119 and 120 cables and the connec-
tions on the travel regulator.
Code E157
Description Bus shut off.
Possible error CAN bus problem.
cause

221609-040 2006-11-17 723984- 660,661,662
Code E159
Description Transgression error.
Possible error CAN bus problem.
cause
Code E160
Description Error in safety reversing function
Possible error Error in important sensor part.
cause
Action 1. Replace the electronic card
Code E200
Description Open field.
Possible error Shunt field’s circuit open.
cause
Action 1. Check the field winding connections E1 and
E2. Unfortunately it is not possible to measure
ohms for the field winding using a standard
universal instrument, since the winding has a
value as low as 0.3 ohm.
2. Check cables 4 and 5 and outputs S1 and S2
3. Replace travel regulator

660,661,662 723984- 2006-11-17 221609-040
Code E201
Description M minus error.
Possible error Problem with switch transistor in the armature cir-
cause cuit inside the travel regulator.
Action 1. Check cable and connections between A1/M
on the travel regulator and connection A2 on
drive motor.
Code E202
Description Fault on sensor in travel regulator
Possible error Fault on armature current sensor in travel regula-
cause tor
Action Replace travel regulator
Code E214
Description CAN timeout in power amplifier.
Possible error The motor monitor is reporting an unexpected
cause data loss from the electronic card in the tiller arm
head.
Action 1. Check cables 119 and 120 between electronic
card and travel regulator.
2. Replace electronic card

221609-040 2006-11-17 723984- 660,661,662
11.6.4 Transistor regulator troubleshooting

and error codes
B+ M-
STATUS
MODEL VOLTAGE
SERIAL CURRENT
A1
M A2
General
Curtis 1243 is a regulator [A1] for controlling shunt motors. Varying the
voltage applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
S1 S2
involves varying the “on” time of the MOS-FET transistors regulating
the armature current.
Switching of the rotational direction is achieved by switching the polari-
ty on the field winding (S1-S2). The regulator is fitted with a four-quad-
rant transistor bridge for the field winding and a single-quadrant transis-
tor bridge for the armature winding.

660,661,662 723984- 2006-11-17 221609-040
Transistor regulator errors

The table below depicts the error codes that may be shown by the STA-
TUS LED or read using the hand-held terminal.
STATUS
MODEL VOLTAGE
SERIAL CURRENT
Table 19: Transistor regulator error code

STATUS LED Hand-held Explanation Possible cause
terminal dis-
play
LED off - No voltage or Burnt fuse, bad contact, not con-
defective regulator nected, defective regulator.
LED on - Defective regulator Defective regulator.
1,1 ¤¤ CURRENT Built-in current Armature current sensor fault in motor
SHUNT FAULT shunt defective controller.
1,2 ¤ ¤¤ HW FAILSAFE Power amplifier Motor controller reports unexpected
CAN-timeout loss of data flow from tiller head.
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short to Problem with switch transistor in arma-
B- ture circuit inside motor controller.
3,1 ¤¤¤ ¤ CONT COIL/FLD Too high current for Attempt to drive more current than
SHORT contactor feeding specified from outputs.
or shorted field Problem to regulate field current.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shunt field open, harness broken,
motor controller defect.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage 1. Battery voltage <17 volts
VOLTAGE 2. Corroded battery terminals
3. Loose battery or regulator connec-
tions.
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Overvoltage 1. Battery voltage > 33 volts
4,3 ¤¤¤¤ ¤¤¤ THERMAL Over-/under-tem- 1. Temp. >85oC or < - 25oC
CUTBACK perature reduction 2. Truck overloaded
3. Wrong installation of transistor regu-
lator
4. Operation under extreme condi-
tions.

221609-040 2006-11-17 723984- 660,661,662
Resetting errors
To reset an error turn [S17] to off and then on again.
Error Reset when

OVERVOLTAGE Battery voltage falls below 33 V
THERMAL CUTBACK The temperature is within allowed range
THROTTLE FAULT 1, 2 Error has been fixed
LOW BATTERY VOLTAGE When battery voltage exceeds 16 V
Safety
The regulator is a high-power component. When working on a battery
operated vehicle, necessary precautions should be taken. This
includes, but is not limited to, correct training, use of eye protectors,
avoiding use of lose-fitting clothes, removal of watches and jewellery,
and use of insulated tools only.
WARNING!
Remove all watches, jewellery and always use insulated tools only.

660,661,662 723984- 2006-11-17 221609-040
11.6.5 Built-in Test Function

The truck’s control system provides a number of useful built-in test
functions
• Connect CAN-key in [X41] and press [A17].
• Battery status is shown.
• Press Horn [S18] repeatedly to choose Built-in Test mode.

NOTE!
All truck functions operate as normal in this mode. Care should be
taken when operating the truck and reading the display at the same
time!
Table 20: Built-in test modes

Mode Flashing symbol Displayed data
1 Speed reference value sent to Curtis.
2 Digital inputs/outputs can be tested. See Table

21:, Table 22: & Table 23:for more information.
3 Battery voltage (V)
4 Armature current (A)
5 Field current (A)
6 PWM Armature in %
7 Status Curtis

221609-040 2006-11-17 723984- 660,661,662
Digital inputs/outputs test mode

In the digital inputs/outputs mode, the operation of both inputs and out-
puts can be checked by checking the individual segments of the main
display as given in the following tables.
Transistor regulator inputs
Table 21: Transistor regulator inputs check

Segment Function
Lift height limit [S31], input A1:INP.LIFT LIMIT
Watchdog [Y1], A1:OUT.BRAKE RELEASE

(Senses whether Y1 is drawing current correctly
- should normally show the inverse of output sig-
nal)
Mechanical brake [S10], input A1:INP.TILLER
ARM IN DRIVE POSITION
Transistor regulator outputs
Table 22: Transistor regulator outputs

check
Segment Function
Fork lowering [Y41], output A1:OUT.LOWER
VALVE
Main contactor [K10], output A1:OUT.MAIN

CONTACTOR
Horn [H1], output A1:OUT.SIGNAL HORN
Mechanical brake [Y1], output A1:OUT.BRAKE

A
Pump contactor [K30], output A1:OUT.PUMP

CONTACTOR

660,661,662 723984- 2006-11-17 221609-040
Digital input of logic card [A2]
Table 23: Digital input of logic card [A2]

check
Segment Function
Cabin up [A2:S19]
Cabin down [A2:S20]
Initial forks [A2:S21]
Initial forks [A2:S22]
Horn [A2:S18]
Extra functions
Table 24: Extra functions check

Segment Function
Extra function 6
Extra function 5
Extra function 4
Extra function 3
Extra function 2
Extra function 1

221609-040 2006-11-17 723984- 660,661,662
11.6.6 Display test mode

The digital display itself can be tested to verify all the segments of the
display function correctly.
To select Display test mode carry out the following procedure:
Fig. 11 • Ensure the truck is switched off. Press on the keypad.


• Hold [S18] depressed until “d” is displayed, then release [S18]. Fig.
11
All number segments on the display and symbol lamps should flash
Fig. 12 sequentially. Fig. 12

Technical specifications – Curtis 1243
660,661,662 723984- 2006-11-17 221609-040
11.7 Technical specifications – Curtis

1243
Value Unit Explanation

Operating voltage 24 Volt
Top voltage limit 33 Volt
Bottom voltage limit 16 Volt Minimum operating voltage
Electrical insulation against cold 500 V AC Minimum
chassis
PWM frequency 16 kHz
Maximum current in rotor winding* 150 Ampere for 2 minutes
100 Ampere for 1 hour
Maximum current in field winding 20 Ampere for 2 minutes
20 for 1 hour
Contactor voltage 24 Volt The same as for the battery
Contactor current 2 Ampere Max (valid limit for 2.5 ampere)
KSI input voltage, min. 16,8 Volt
KSI input current 50 mA
Logical voltage value in > 7.5; High Volt
< 1; Low
Logical input current value 15 mA
Operating temperature -40 to +50 °C
Upper temperature limit, reduction 85 °C
Lower temperature limit, reduction -25 °C
* Under special test conditions.

Hydraulic/Pneumatik – 6000
General
221609-040 2006-11-17 723984- 660,661,662
12- Hydraulic/Pneumatik – 6000
12.1 General
To avoid functional problems with the lowering valve (Y41), such as
unintentional lowering of forks, the valve must be cleaned and the func-
tion checked before replacing the valve.
12.2 Hydraulic chart and list of symbols

LWE180, LWE200
n
Y41
4
M3 P 5
12.2.1 List of Symbols
Pos No Description Function Remarks

1 Lift cylinder Lifting the forks
2 Preasure relief valve
3 Flow control valve
4 Non-return valve
5 Filter
M3 Motor Pump motor
P Pump
T Tank 1,2 litre (B20 0,5 litre)
Y41 Valve Lowering valve for the forks

Adjustments LWE180
660,661,662 723984- 2006-11-17 221609-040
12.3 Adjustments LWE180
12.3.1 Adjusting the pressure limit valve

The pressure limit valve is set to the correct value at the factory, but
may need to be adjusted if the valve or the complete hydraulic unit is
replaced.
The truck should be capable of lifting a load of between 1850-1900 kg.
1. Locking nut. Use special tool, see drawing in chapter “Tools”.

2. Adjuster screw, pressure limit.
Adjusting clockwise results in increased pressure.
Adjusting anticlockwise results in decreased pressure.
3. Pressure limit valve. Use special tool, see drawing in chapter
“Tools”.
• Loosen the locking nut (1) using a special tool (see drawing 3.2).
Place a load of 1800 kg on the forks and check that the truck can lift
it.
• If the truck lifts 1800 kg, place a further 100 kg on the forks. Check
whether the truck can lift the load.
• If the truck lifts 1900 kg, adjust the pressure limit by turning the ad-
juster screw (2) anticlockwise using a 4 mm allen key until the truck
cannot lift the load.

Adjustments LWE180
221609-040 2006-11-17 723984- 660,661,662
12.3.2 Tools
• Use a 22 mm standard socket and turn it down to the values shown
below in drawing A, when you wish to loosen or tighten the pressure
limit valve.
• Use a 10 mm standard socket and turn it down to the values shown
below in drawing B, when you wish to loosen or tighten the locking
nuts.
A B
12
8
26,5 13,5

Adjustments LWE200
660,661,662 723984- 2006-11-17 221609-040
12.4 Adjustments LWE200
12.4.1 Adjusting the pressure limit valve

replaced.
1. Locking nut.
• Loosen the locking nut (1) using a 13 mm spanner.
• Place a load of 2000 kg on the forks and check that the truck can lift
it.

Hydraulic chart and list of symbols
221609-040 2006-11-17 723984- 660,661,662
12.5 Hydraulic chart and list of symbols

LPE200-6, LPE200-8
n
1 2
Y41
5
M3
P 6
12.5.1 List of Symbols
Pos No Description Function Remarks

1 Lift cylinders Lifting the forks 2 pieces
2 Powertrakcylinder Increase the pulling quality when loaded
3 Preasure relief valve
4 Flow control valve
5 Non-return valve
6 Filter
M3 Motor Pump motor
P Pump
T Tank 1.2 litre
Y41 Valve Lowering valve for the forks

Adjusting the pressure limit valve
660,661,662 723984- 2006-11-17 221609-040
12.6 Adjusting the pressure limit valve

replaced.
1. Locking nut.
• Loosen the locking nut (1) using a 13 mm spanner.
• Place a load of 2000 kg on the forks and check that the truck can lift
it.

PowerTrak cylinder – 6680
Included components
221609-040 2006-11-17 723984- 660,661,662
13- PowerTrak cylinder – 6680
13.1 Included components

3
2
4
Pos. Designation Notes

1 PowerTrak spring
2 PowerTrak cylinder
3 Spring guide 2 pcs.
4 Drive unit

Disassembling the PowerTrak cylinder and spring guides
660,661,662 723984- 2006-11-17 221609-040
13.2 Disassembling the PowerTrak

cylinder and spring guides
Make sure the truck is unloaded and the forks have been lowered to the
ground.
1
2
• Switch off the truck and disconnect the battery connector.
3
• Remove the upper covers and the top cap.
• Loosen the hydraulic hose (1).
• Carefully loosen the screws (2) of the cap (3), which secures the
4 spring guides, in order to relieve the spring force.
• Then completely unscrew the screws and remove the cap.
5 • Lift out the PowerTrak cylinder (4).
• Lift out the spring guides (5)
Reassemble in reverse.
49
The measure from washer to screw head must be 49 mm.

WARNING!
Risk of injury.
Risk of injury when working on the PowerTrak system. Because the
spring guides hold a considerable latent force, proceed with extreme
care.
Carefully follow the instructions.

Disassembling the PowerTrak cylinder and spring guides
221609-040 2006-11-17 723984- 660,661,662

© BT Europe AB
SE-595 81 Mjölby
Sweden
www.bt-industries.com

Service Manual En: LWE180, LWE200, LPE200-6/8

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual En: LWE180, LWE200, LPE200-6/8

Uploaded by

Copyright:

Available Formats

Service Manual en

LWE180, LWE200, LPE200-6/8

Order number: 221609-040

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8

3- Introduction, maintenance ................................................................. 3-1

4- Tools ..................................................................................................... 4-1

5- Fork carriage- 0380 ............................................................................. 5-1

6- Engine suspension– 0450 .................................................................. 6-1

7- Electric drive motor – 1760 ................................................................. 7-1

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 1- 1

8- Drive unit/gear – 2550 ......................................................................... 8-1

9- Electro magnetic brake – 3370 ........................................................... 9-1

10- Steering system – 4000 ................................................................... 10-1

1- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

11- Electrical System – 5000 ................................................................. 11-1

# 20 - Hour meter selection ......................................... 11-50

12- Hydraulic/Pneumatik – 6000 ........................................................... 12-1

13- PowerTrak cylinder – 6680 ............................................................. 13-1

1- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

Model LWE180 LWE200, LPE200-8

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 2- 1

Model LWE180 LWE200, LPE200-8

2- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

Model LWE180 LWE200, LPE200-8

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 2- 3

2.1 General tightening torques

2.1.1 Galvanised, non-oiled bolts

2.1.2 Untreated, oiled bolts

2- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

3.1 Safety regulations during

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 1

3- 2 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

3.2 Cleaning and washing

3.2.1 Cleaning the exterior

3.2.2 Cleaning the motor compartment

3.2.3 Electrical components

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 3

3.3 Safe lifting

3- 4 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

3.4 Maintenance schedule

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 5

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

3- 6 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

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

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 7

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

3- 8 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 9

3.5 Lubrication schedule

L = Lubrication, C = Check, O = Oil change

3.6 Oil and grease specification

Pos. Lubrication Specification Application

© BT Europe AB Service Manual LWE180, LWE200, LPE200-6/8 3- 11

This page is intentionally left blank

3- 12 Service Manual LWE180, LWE200, LPE200-6/8 © BT Europe AB

4.1 Super Seal connectors

Figure Number Application

159229 Tools for loosening locks (1)

159230 Tool for fitting secondary locks

159231 Tool for fitting secondary locks