Lwe 180

Service Guide en
LWE180, LWE200, LPE200, LPE240

Valid from serial number: 723984-
Order number: 225553-040

Issued: 2005-05-11 ITS
© BT Europe AB
Issue date Resp. Changes
2005-05-11 ITS Completely new issue
This manual covers following truck models:
T-code Model Serial number

660 LWE180 723984-
661 LWE200 723984-
662 LPE200 723984-
497 LPE240 723984-
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 Approved by: L-G Andersson
Table of contents
Order number Date Valid from serial number T-code
225553-040 2005-05-11 723984- 660, 661, 662, 497
1- Table of contents
Technical data – M4
LWE 180/200 LPE 200 2-1
Technical data – M4
LPE 240 3-1
Preventive maintenance – P2
LWE 180/200 LPE 200 4-1
Maintenance schedule .................................. 1
Lubrication schedule ..................................... 6
Preventive maintenance – P2
LPE 240 5-1
Maintenance schedule .................................. 1
Lubrication chart............................................ 6
Oil and grease specifica tion – P3

LWE 180/200 LPE 200 6-1
Oil and grease specification – P3

LPE 240 7-1
Tools – P4
LWE 180/200 LPE 200/240 8-1
Super Seal connectors .................................. 1
AMP connectors ............................................ 2

8.2.1 AMP Connectors, 040 series .............................. 3
Molex connectors .......................................... 3
Other tools..................................................... 4
© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 1

Table of contents
T-code Valid from serial number Date Order number
660, 661, 662, 497 723984- 2005-05-11 225553-040
Electrical System – 5000

LWE 180/200 LPE 200 9-1
Electrical components................................... 1
Symbol List and Wiring Diagram................... 3
9.2.1 Wiring diagram 1(5) ............................................ 5
9.2.2 Wiring diagram 2(5) ............................................ 6
9.2.3 Wiring diagram 3(5) ............................................ 7
9.2.4 Wiring diagram 4(5) ............................................ 8
9.2.5 Wiring diagram 5(5) ............................................ 9
9.2.6 Wiring diagram 1(5) .......................................... 10
9.2.7 Wiring diagram 2(5) .......................................... 11
9.2.8 Wiring diagram 3(5) .......................................... 12
9.2.9 Wiring diagram 4(5) .......................................... 13
9.2.10 Wiring diagram 5(5) .......................................... 14
Operating description................................... 15
9.3.1 Starting truck ..................................................... 15
9.3.2 Driving speed £ 6 km/h ..................................... 15
9.3.3 Braking in neutral mode .................................... 15
9.3.4 Braking in neutral mode on a slope .................. 15
9.3.5 Braking .............................................................. 16
9.3.6 Lifting the forks ................................................. 16
9.3.7 Lowering the forks ............................................ 16
9.3.8 Horn .................................................................. 16
Hour meter................................................... 16
Error codes .................................................. 17
Parameters .................................................. 30
9.6.1 Operator parameters ........................................ 30
9.6.2 Parameter description ....................................... 31
Parameter 1 ...................................................... 31
Parameter 2 ...................................................... 31
Parameter 3 ...................................................... 31
Parameter 4 ...................................................... 31
Parameter 5 ...................................................... 31
9.6.3 Service parameters ........................................... 32
9.6.4 Parameter description ....................................... 33
Parameter 10 .................................................... 33
Parameter 14 .................................................... 33
Parameter 15 - Non-configurable option ........... 33
Parameter 16 - Configurable option #1 ............. 33
Option parameters ............................................ 34
1- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

Table of contents
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General ............................................................. 34
Parameter #15 Non-configurable options ......... 34
Changing non-configurable options .................. 34
Parameter #16 to 19 configurable optional
functions ........................................................... 35
Changing configurable optional functions ........ 36
Parameter 20 .................................................... 40
Parameter 21 .................................................... 40
Recommendation on parameter setting for freely
ventilated batteries ........................................... 41
Instructions for verifying parameter setting ...... 42
Recommendation on parameter setting for
valve-controlled batteries (VRLA) ..................... 43
Parameter 22 .................................................... 44
Parameter 25 .................................................... 44
Parameter 28 .................................................... 44
Parameter 39 .................................................... 45
Login method and driver parameter access ..... 45
Expanded keypad - General ............................. 45
Expanded keypad - Programming .................... 45
Service indication ............................................. 47
Part number................................................. 50
Transistor panel........................................... 50
9.8.1 General ............................................................. 50
Troubleshooting .......................................... 51
9.9.1 Error codes and troubleshooting ...................... 51
9.9.2 Reset error ....................................................... 52
9.9.3 Safety ............................................................... 52
Technical specifications – Curtis 1243 ........ 53

Table of contents
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Electrical systems – 5000

LPE 240 10-1
Electrical parts .............................................. 1
Symbol list and electrical diagram................. 3

10.2.1 Electrical wiring diagram 1(5) ............................. 5
10.2.6 Electrical wiring diagram Servo (Option) .......... 10
Functional description.................................. 11
10.3.1 Starting the truck .............................................. 11
10.3.2 Driving without using platform and gates,
speed £ 6 km/h ................................................. 11
10.3.3 Driving from platform without using gates,
speed £ 6 km/h ................................................. 11
10.3.4 Driving from platform and using gates,
speed Š 8 km/h ................................................. 11
10.3.5 Neutral speed reduction ................................... 11
10.3.6 Neutral speed reduction on slopes ................... 12
10.3.7 Braking ............................................................. 12
10.3.8 Lifting the forks ................................................. 12
10.3.9 Lowering the forks ............................................ 12
10.3.10 Horn ................................................................ 12
Hour meter................................................... 13
Error codes .................................................. 13
Parameters .................................................. 25
10.6.1 Driver parameters ............................................. 25
10.6.2 Parameter description ...................................... 26
Parameter 1 ...................................................... 26
Parameter 2 ...................................................... 26
Parameter 3 ...................................................... 26
Parameter 4 ...................................................... 26
Parameter 5 ...................................................... 26
10.6.3 Service parameters .......................................... 27
10.6.4 Parameter description ...................................... 28
Parameter 10 .................................................... 28
Parameter 14 .................................................... 28
Parameter 15 - Non-configurable option ........... 28
Option parameters ............................................ 29
Table of contents
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General ............................................................. 29
Parameter #15 Non-configurable options ......... 29
Changing non-configurable options .................. 30
Parameter #16 to 19 configurable optional
functions ........................................................... 31
Changing configurable optional functions ........ 32
Parameter 20 .................................................... 36
Parameter 21 .................................................... 36
ventilated batteries ........................................... 37
valve-controlled batteries (VRLA) ..................... 39
Parameter 22 .................................................... 40
Parameter 25 .................................................... 40
Parameter 28 .................................................... 40
Parameter 39 .................................................... 41
Login method and driver parameter access ..... 41
Expanded keypad - General ............................. 41
Expanded keypad - Programming .................... 41
Service indication ............................................. 43
Part numbers............................................... 46
Transistor panel........................................... 46
10.8.1 General ............................................................ 46
Diagnostic and troubleshooting ................... 47
10.9.1 Error codes and troubleshooting ...................... 47
10.9.2 Resetting errors ............................................... 48
10.9.3 Safety ............................................................... 48
Technical specifications – Curtis 1243 ........ 49

Table of contents
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Hydraulic/Pneumatik – 6000
LWE 180/200 LPE 200 11-1
General ......................................................... 1
Hydraulic chart and list of symbols................ 1
11.2.1 List of Symbols ................................................... 1
Adjustments LWE180 ................................... 2
11.3.1 Adjusting the pressure limit valve ....................... 2
11.3.2 Tools ................................................................... 3
Adjustments LWE200 ................................... 4
11.4.1 Adjusting the pressure limit valve ....................... 4
Hydraulic chart and list of symbols................ 5
11.5.1 List of Symbols ................................................... 5
Adjusting the pressure limit valve.................. 6
Hydraulic, pneumatic – 6000

LPE 240 12-1
General ......................................................... 1
12.1.1 Hydraulic diagram .............................................. 1
12.1.2 Symbol list .......................................................... 2
Adjustments .................................................. 3
12.2.1 Adjustment of the pressure limit valve ................ 3
Cleaning the filter.......................................... 4

Technical data – M4 LWE 180/200 LPE 200
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2- Technical data – M4
LWE 180/200 LPE 200
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 windings >=1 Mohm >= 1Mohm >= 1Mohm
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

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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/diameter, mm 4.75 4.7 4.7
Pressure at rated load, bar 110 150 150
Overflow pressure, bar 130 170 170
Pump flow, litre/minute 4.7 4.6 4,6
Tank volume, litre 0,5 1,0 1,0
Oil type: 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

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LPE200-6
Battery compartment, Batteries
Dimensions LxWxH, mm 193x642x450 193x642x450- 193x642x450-
510 510
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

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Technical data – M4 LPE 240
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3- Technical data – M4
LPE 240
Model LPE240
Drive motor
Type TSL160 A DS60
Output, kW 2.5
Duty cycle S2, 60 min
Minimum carbon brush length, mm 11
Nominal commutator diameter, mm 71
Minimum commutator diameter, mm 68
Resistance, shunt field winding, Ω at 24 C° 0.346
Resistance armature winding, Ω at 24 °C 0.0098
Insulation resistance between the windings >= 1 Mohm
and motor casing
Weight, kg 23
Brakes
Type 1EB46-11
Braking force, Nm 48
Output, W 44
Resistance coil, Ω 12
Nominal play in actuated position, mm 0.25-0.38
Minimum thickness brake disc, mm 7.7
Thickness of a new brake disc, mm 9.7
Transmission/drive gear
Type 2-stage angle
transmission
Gear ratio 14.20:1
Oil volume, litre 1.75
Oil type Hypoid oil
at normal temperature SAE 80W/90
at temperature < -15oC SAE 75W

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Model LPE240
Wheels
Drive wheel, mm 250x75
Drive wheel for servo, mm 250x105
Axle pressure without load, kg 460
Axle pressure at rated load, kg 770
Wheel pressure at rated load, kg/cm2 30
Tightening torque wheel bolts, Nm 130

Fork wheel, Bogie, mm 80x74
Axle pressure without load, kg 175-320
Axle pressure at rated load, kg 1800-2300
Wheel pressure at rated load, kg/cm2 47-55
Swivel wheel, mm 150x50

Axle pressure without load 175-605
Axle pressure at rated load, kg 120-790
Wheel pressure at rated load, kg/cm2 12-37
Hydraulic system
Output, kW 2.0
Duty cycle 10%
Minimum carbon brush length, mm 8
Pressure at rated load, bar 130
Overflow pressure, bar 145
Pump flow, cc/r 2.5
Tank volume, litre 1.2
Oil type:
at normal temperature ISO-L-HM32
at temperature < -15oC ISO-L-HV32

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Model LPE240
Servo steering, Motor (Option)
Type MET 3B 24 V
Output, W 160
Torque constant 0.6 Nm/A
Max current 55 A
Speed, rpm 2550
Minimum carbon brush length, mm -
Minimum commutator diameter, mm -
Resistance,Ω,armature 0.27
Fuses
Control circuits, F50, F51 7.5 A
Drive motor 125 A
Pump motor 160 A
Servo steering (Option) 20 A
Battery compartment, Batteries
Battery compartment
Dimensions LxWxH, mm
Short 212x790x775
Long 296x790x775
Capacity, Ah 292-600
Weight, kg 240-500
Driving speed
Without load, km/h 12
Without load, m/s 3.33 + 5%
With rated load, km/h 9,5
With rated load, m/s 2.63 + 5%
Lift/lowering speed
Lift to top with load, s 2.0
Lowering without load, s 2.3

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Model LPE240
Power consumption
Driving without load, A 82
Driving with rated load, A 92
Lift without load, A 49
Lift with rated load, A 116
Incline climbing ability
Without load 15%, 8.5°
With rated load 8%, 4.5°
Measurement
L2
Short 730 mm
Long 814 mm
Wa with 1170 mm forks and lift fork -
Wa with 1170 mm forks and lift fork, -
fixed side gates
Wa with 1170 mm forks and lift fork, -
fixed back rest
Lift height 225 mm
Weight
Truck without battery, Max 600 kg
Fixed gates - kg
Fixed back rest - kg

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1451
1050
959
185
85
422 L2 800-2350
Wa
180
450-685
790

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Preventive maintenance – P2 LWE 180/200 LPE 200
Maintenance schedule
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4- Preventive maintenance – P2
LWE 180/200 LPE 200
4.1 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 5 20 80 500 1000 3000
Interval in days/weeks/months 1d 1w 1m 6m 12m 36m
0000 Chassis
0000.1 Check all links and locking pins l
0000.2 Check wear on cover/battery locking l
0000.3 Check of cracking and damage l
0000.4 Check the cover locks I
0000.5 Check finger guard I
0000.6 Check signs and stickers I
0000.7 Press grease into grease nipples 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

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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 I
steering 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 tight- I/T
ening torque on bolts
3500.3 Check that the support wheel turns and I
rotates 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 micros- I I/L
witch in 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

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5110 Battery
5110.1 Check the electrolyte level, 10-15 mm over M
the cell plates
5110.2 Check connections to battery, I
truck and charger
5110.3 Check that the cell and pole guards are I
undamaged
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
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 I
damaged 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

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6680 Power Trak
6680.1 Check if there is any damage or cracks on I
the PowerTrak spring
6680.2 Grease in the contact pressure spring’s guides C/L
1 = The connections are re-tightened for the first time after 80 h, and
then every 1000 h/12 months.
2 = The attachment bolts are re-tightened after 80 h/ 1 month to 45 Nm.
3 = Check for leakage in conjunction with the first oil change.
4 = The oil is changed for the first time after 80 h/1 month, and then 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.
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 hour intervals are carried out the points with
lower hour intervals should also be carried out unless otherwise speci-
fied above.

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5000 5000
6680
4110
5110
5700
5000
6600
5400
3100
1700
6100
0380 0000 0560
2550
5000
3500

Lubrication schedule
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4.2 Lubrication schedule
Pos. No. Service point Interval/Operating hours Type of

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

Preventive maintenance – P2 LPE 240
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5- Preventive maintenance – P2
LPE 240
5.1 Maintenance schedule
I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

M: Measure, correct if necessary

no. Interval in hours - may vary due to ap- 5 20 80 500 1000 3000
plication
Interval in days/weeks/months - may 1d 1w 1m 6m 12m 36m
vary due to application
0000. Chassis
0000.1 Check all links and spiral pins I
0000.2 Check for damage to the platform. I
0000.3 Check the cover locks I
0000.4 Check the finger guard I
0000.5 Check signs and stickers I
0000.6 Push in grease in the grease nipples I/L6
0380 Fork carriage
0380.1 Check for crack formation and damage I
0380.2 Check the play in bushings and links I
0380.3 Push in grease in the grease nipples I/L6 I/L
0380.4 Check the lift limit switch I

1700. Motors
1700.1 Check for loose 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 Tighten the mounting bolts T2
1700.5 Check for abnormal noise in the bearings I
1700.6 Check the steering motor carbon brushes M
(Option)

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plication
2550. Drive assembly
2550.1 Check for leakage I3 I
2550.2 Check oil level I

2550.3 Check for abnormal noise I
2550.4 Check mountings and play in the steering I
bearings
2550.5 Change the oil in the drive transmission L4 L
2550.6 Lubricate the gear ring (Servo, Option) L

3100 Brakes
3100.1 Clean C
3100.2 Check for wear to the brake discs M
3100.3 Check for play in released position M
3500. Wheels
3500.1 Remove string and other detritus I
3500.2 Check for wear on the drive wheel I
3500.3 Check that the swivel wheels rotate and I
swing freely
3500.4 Check for wear to the swivel wheels I
4110. Tiller arm
4110.1 Check for play on steering joints I
4110.2 Check the steering force I
4110.3 Check the gas cartridge's force I
4110.4 Check the adjustment of the steering chain, L/M
lubricate

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plication
5000. Electrical functions
5000.1 Check the operation of the brake microswitch I I/L
in the upper and lower brake positions. Lubri-
cate the switch head
5000.2 Check the function of the safety switch I
against collision
5000.3 Check the operation of the gate switch I I
5000.4 Check the operation of the platform switch I I
5000.5 Check the horn I I
5000.6 Check for wear to the cables I
5000.7 Check the operation of the driver's controls I I
5000.8 Check the error code log and operatingtimes I I
5110. Battery
5110.1 Check electrolyte levels, 10-15 mm above M
the cell plates
5110.2 Check connections on the battery, I
truck and charger
5110.3 Check that the cell and pole guards are I
undamaged
5110.4 Check the fluid density and temperature M
5110.5 Remove overflow fluid from the battery trough C
5110.6 Check the battery lock I
5400 Power system
5400.1 Clean and check the mountings C/T1 C/T
5400.2 Tighten the cable connections T1

5400.3 Check the contactor points on K10 and K30 I
5400.4 Check the contactor movement I

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plication
5700 Electronic card
5700.1 Clean the electrical panel C
5700.2 Check the connectors and cables TI I
5700.3 Check all segments on the display I

6100. Hydraulic system
6100.1 Check for leakage from hoses and couplings I
6100.2 Check for wear to the hoses I
6100.3 Check the tank I
6100.4 Check that the oil level is correct I
6100.5 Change the oil and clean the filter L5 L
6600. Lift cylinders

6600.1 Check for leakage I
6680 PowerTrak
6680.1 Check for any damage, cracks on the Power- I
Trak springs
6680.2 Grease the ground pressure spring's guides C/L
1= Connections are tightened for the first time after 80 hours and then
every 1000 hrs/ 12 months.
2= Mounting bolts are tightened after 80 hrs/1 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 80 hrs/1 month and then
every 3000 hrs/36 months.
5= The oil is changed and the filter cleaned for the first time after 80 hrs/
1 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.
225553-040 2005-05-11 723984- 660, 661, 662, 497
5000
5000
5700
4110 4110
6680
5000 5000
5110
6600
0380
5400
3100
2550
1700
3500
0000
0000
6100
3500
5000

Lubrication chart
660, 661, 662, 497 723984- 2005-05-11 225553-040
5.2 Lubrication chart
Pos. Service point Interval/Operating hours Lubrication

no. 80 hrs 1000 hrs 3000 hrs
type
0380 Grease nipples (Option) L F

2550 Drive transmission O4 I O C
2550 Gear ring L E

4110 Steering chain L D
6100 Hydraulic system O5 O B
6680 PowerTrak, ground pressure spring L F

L= Lubricate I = Inspection O = Oil change
4= The oil is changed for the first time after 80 hrs/1 month and then
every 3000 hrs/36 months.
5= The oil is changed and the filter cleaned for the first time after 80 hrs/
1 month and then every 1000 hrs/12 months.
0000 6680
0380
4110
0380
2550
6100

Oil and grease specifica tion – P3 LWE 180/200 LPE 200
225553-040 2005-05-11 723984- 660, 661, 662, 497
6- Oil and grease specifica tion – P3

LWE 180/200 LPE 200
Pos. Type of lubricant Specification Application

> -15° C < -15o C
A Grease BT 26777 BT 26777 Bearings and bushes
(Spray) (Spray)
B Hydraulic oil ISO-L-HM32 ISO-L-VG 32 Hydraulic system
C Transmission oil Hypoid oil SAE Hypoid oil SAE Gears
80W/90 75W
D Grease Staburags Staburags Guide bearing
NBU 8EP NBU 8EP
E Grease BT 73942XX5 BT 73942XX5 Lubricating nipples,
TOTAL N3942 TOTAL N3942 Contact pressure spring

Oil and grease specifica tion – P3 LWE 180/200 LPE 200
660, 661, 662, 497 723984- 2005-05-11 225553-040

Oil and grease specification – P3 LPE 240
225553-040 2005-05-11 723984- 660, 661, 662, 497
7- Oil and grease specification – P3

LPE 240
Pos. Lubrication Specification Use

type >-15°C <-15°C
A Grease BT 26777 (Spray) BT 26777 (Spray) Bearings and bushings
B Hydraulic oil ISO-L-HM32 ISO-VG32 Hydraulic system
C Transmission oil Hypoid oil Hypoid oil Gears
SAE 80W/90 SAE 75W
D Grease BT 26778 BT 26778 Chains
(Spray) (Spray)
E Grease Grafloscon Grafloscon Gear ring
A-G1 (Klüber) A-G1 (Klüber)
F Grease BT 73942XX5 BT 73942XX5 Grease nipples,
TOTAL N3942 TOTAL N3942 Ground pressure spring

Oil and grease specification – P3 LPE 240
660, 661, 662, 497 723984- 2005-05-11 225553-040

Tools – P4 LWE 180/200 LPE 200/240
Super Seal connectors
225553-040 2005-05-11 723984- 660, 661, 662, 497
8- Tools – P4
LWE 180/200 LPE 200/240
8.1 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)
© BT Europe AB Service Manual LWE180, LWE200, LPE200, LPE240 8- 1

Tools – P4 LWE 180/200 LPE 200/240
AMP connectors
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8.2 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
8- 2 Service Manual LWE180, LWE200, LPE200, LPE240 © BT Europe AB

Tools – P4 LWE 180/200 LPE 200/240
Molex connectors
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8.2.1 AMP Connectors, 040 series

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

16
9
8
1
156937 Tools for fitting pins/sleeves
156936 Tools for fitting sleeves/pins
© BT Europe AB Service Manual LWE180, LWE200, LPE200, LPE240 8- 3

Tools – P4 LWE 180/200 LPE 200/240
Other tools
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8.4 Other tools

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

2=163792 gramme changes
08-13022 Driving gear puller
8- 4 Service Manual LWE180, LWE200, LPE200, LPE240 © BT Europe AB

Electrical System – 5000 LWE 180/200 LPE 200
Electrical components
225553-040 2005-05-11 723984- 660, 661, 662, 497
9- Electrical System – 5000

LWE 180/200 LPE 200
9.1 Electrical components
S17 S10
S31
S21
X41
X5
Y1
X1
F50
M3
F51
F1
R1 Y41
K10
F3
M1
K30
A1
H1

Electrical components
660, 661, 662, 497 723984- 2005-05-11 225553-040
A17

Symbol List and Wiring Diagram
225553-040 2005-05-11 723984- 660, 661, 662, 497
9.2 Symbol List and Wiring Diagram
Symbol Description Function Comments

A1 Transistor regulator
A2 Electronic card
A6 Display Display of truck functions
A17 Keypad Login with PIN code Option
F1 Fuse Drive motor circuits 130 A

F3 Fuse Pump motor circuits 130 A
F 50 Fuse Working circuit A5 7.5 A
F 51 Fuse Working circuit A1 7.5 A
F 52 Fuse Optional equipment Option
G1 Battery 24 V
H1 Horn
K10 Contactor Main contactor

K30 Contactor Pump motor
A2:S1-S9 Speed controls Forward/backward

A2:S10-S18
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
S111 Switch Option

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Symbol Description Function Comments

S112 Switch Option
S113 Switch Option
S114 Switch Option
S115 Switch Option
S116 Switch Option
S10 Inductive switch Mechanical activation of the Brake handle
brake
S17 Switch Key
S18 Switch Button for horn
S19 Switch Man on the platform (Applies to LPE200-8)
A2:S17 Switch Emergency reversing
S21 Switch Emergency switch
S31 Switch Lift height limiter
A2:S19 Switch Fork lift (Standard)
A2:S20 Switch /Fork lowering (Standard)
A2:S21 Switch Fork lift (Alternative, see
parameter 28)
A2:S20 Switch /Fork lowering (Alternative,
see parameter 28)
S53 Switch Gates (Applies to LPE200-8)
S59 Switch Platform in folded position (Applies to LPE200-8)
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)

225553-040 2005-05-11 723984- 660, 661, 662, 497
9.2.1 Wiring diagram 1(5)

LWE180/200, LPE200-6

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LWE180/200, LPE200-6

225553-040 2005-05-11 723984- 660, 661, 662, 497

LWE180/200, LPE200-6

660, 661, 662, 497 723984- 2005-05-11 225553-040

LWE180/200, LPE200-6

225553-040 2005-05-11 723984- 660, 661, 662, 497

LWE180/200, LPE200-6

660, 661, 662, 497 723984- 2005-05-11 225553-040

LPE200-8

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LPE200-8

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LPE200-8

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LPE200-8

660, 661, 662, 497 723984- 2005-05-11 225553-040

LPE200-8

Operating description
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9.3 Operating description
9.3.1 Starting truck

To enable the truck to be started, the battery plug must be connected,
the emergency switch (S21) closed and the start key (S17) in the ON
position.
9.3.2 Driving speed ≤ 6 km/h

When driving at a speed of 6 km/h
A1 - the switch for driving brake (S10) must be closed, and the
B- - Speed controls must be activated in any direction.
S1
T1
Ish S2
-
A2
M- 9.3.3 Braking in neutral mode
+
Shunt
A • when the speed controls are in neutral mode, the engine functions
Ia A1
T2 as a generator. The braking energy is fed back to the battery.
K10 B+
• The brake (Y1) is engaged when the truck stops completely even if
the tiller arm is in drive position.
• Energy is fed back to the battery (see diagram below).
• The transistors (T2) for the brake circuit generated are not live.
A1
B-
S1
T1
Ish S2
- M-
A2
+
Shunt
A
Ia A1
T2
K10 B+
9.3.4 Braking in neutral mode on a slope

If the driver releases the speed control on a slope and the truck does
not stop within a certain space of time, the electrical brake is automati-
cally engaged.

Hour meter
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9.3.5 Braking
The brake is always engaged when the truck is started with the tiller
arm in the top or bottom position (S10 open). The brake is released
once all the requirements for driving have been fulfilled, and the truck
begins to move.
Requirements for the truck to be able to brake:
• S10 open.
9.3.6 Lifting the forks

• S34
• S31 closed.
• Battery status OK (if battery capacity remaining is > 20 %).
9.3.7 Lowering the forks

• S41 activated.
9.3.8 Horn
• S18 activated.
9.4 Hour meter

• Press and hold S18 while turning S17 to “ON” position.
• Press and hold S18 until H = hour meter is displayed.
• You have now selected H = hour meter. The “B” symbol lights up.
• You can now select type of hour meter by pressing the speed control.
1A = Key time
2b = Movement time
A 3c = Drive motor time
4d =Pump motor time
5s = Time remaining until service
E D C B

Error codes
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9.5 Error codes

• Press and hold S18 until E = error codes is displayed.
• When E is selected, the “E” symbol will light up as an indication of
what is shown in the display.
• The 50 most recent error codes are stored. The latest error is dis-
played first. The display shows the error code first, followed by the
time when the error occurred.
• The error codes are divided into two groups, C = caution and E = error.
• C codes are not stored. They are only cautions and remain lit in the
display as long as the fault remains.
• If there is only one error registered in the memory, the other empty
entry lines appear as follows: Error: E - - - and time: - - - - .
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
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

Error codes
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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
position.
2. Replace the electronic card.

Error codes
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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.

Error codes
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LPE200-6, LPE200-8
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.

Error codes
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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.
(Applies to P 24)
2. Check that the travel regulator is installed with
good contact with the chassis.

Error codes
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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)

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)

box (1)

Error codes
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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

Error codes
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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.

Error codes
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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.

Error codes
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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.

Error codes
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Code E141
Description Software problem.
Possible error Fault on the internal monitoring (tiller arm head),
cause incorrect software or circuit board.
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 contacts.
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

Error codes
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Code E159
Description Transgression error.
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

Error codes
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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 regulator
cause
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

Parameters
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9.6 Parameters
A • Press and hold S18 while turning S17 to “ON” position.
• Press and hold S18 until P = parameters is displayed.
• You have now selected P = parameters and the symbol “C” is lit as
an indication of what is now shown in the display.
• Press L1 up or down and scroll to the parameter you want to change
E D C B or view.
• Press S18 once to access the parameter.
• Press L1 up or down to specify the parameter value.
• Press S18 once to confirm the change.
• Turn S17 to the off position.
You have now changed the parameter and the new setting will come
into force the next time you start the machine.
NOTE:
Truck handling
When you change specific truck parameters, the truck’s driving char-
acteristics are also changed.
Do not change any parameters unless you really know what you are
doing.
9.6.1 Operator parameters

Parameter Description Unit Min. Max. Step Std. Description
01 Speed, Turtle % 40 100 5 100 Speed, Turtle button
button 10: slow speed
100: maximum speed.
02 Max. speed % 40 100 5 100 Max. speed
10: slow speed
100: maximum speed
03 Acceleration 10 100 5 50 10: slow acceleration
100: maximum accelera-
tion
04 Braking in neu- 5 100 5 50 Specifies motor braking
tral mode once the lever is put into
neutral.
5: weak braking power
100: maximum breaking
power
05 Logout 1min 0 20 1 20 The time it takes for the
truck to switch off when
the keypad is used. The
time counts down from
the moment the last
power-consuming unit is
used.
Value = 0 gives 4 hours.
In steps of 1

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
9.6.2 Parameter description

Parameter 1
The speed of use of the turtle button can be adjusted.
Parameter 2
The maximum speed can be adjusted.
Parameter 3
The lower the parameter value, the longer it takes for the truck to
achieve maximum speed.
Parameter 4
Specifies the motor braking power when the lever (L1) is put into neu-
tral. The lower the parameter value, the longer the braking time.
Parameter 5
The time it takes for the truck to switch off when the keypad is used.
The time counts down from the moment the last power-consuming unit
is used.

Parameters
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9.6.3 Service parameters

A • Connect the CAN key to X41.
• Press and hold S18 until P = parameters is displayed.
• You have now selected P = parameters and the symbol “C” is lit as
an indication of what is now shown in the display.
E D C B • Press L1 up or down and scroll to the parameter you want to change
or view.
• Press S18 once to access the parameter.
• Press L1 up or down to specify the parameter value.
• Press S18 once to confirm the change.
• Turn S17 to the off position.
You have now changed the parameter and the new setting will come
into force the next time you start the machine.
NOTE:
Truck handling
When you change specific truck parameters, the truck’s driving char-
acteristics are also changed.
Do not change any parameters unless you really know what you are
doing.

10 PIN-code 0 9999 1 1 Facility for specifying up to 10
PIN codes (10 different drivers).
14 Crawling -10 10 1 0 The amount of power the mon-
speed itor should emit when you
reach the first speed sensor
can be specified here.
-10: low speed for the first
speed sensor.
10: high speed for the first
speed sensor
15 Non-config- See “Option parameters” on page 34, Servicemanual
urable option
0 to 9
16 Configurable See “Option parameters” on page 34, Servicemanual
option #1
17 Configurable
option #2
18 Configurable
option #3
19 Configurable
option #4
20 Hour meter 1 5 1 2 Select hour meter.
option
21 Battery size 1 20 1 5 Selection of battery size.

Parameters
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22 Inductive 0 1 1 1 0: Mechanical switch
sensor 1: Inductive sensor
25 Service inter- 1h 0 2000 50 100 Option for setting service timer
val
28 Lift button 1 3 1 1 Button selection
selection
39 Password 1 12 1 1 States which level of authoriza-
tion the driver has for the
parameters.
Odd values specify open driver
parameters, even values spec-
ify that driver parameters must
be opened using the CAN key

Parameter 10
NOTE!
The functionality of parameter #10 is set aside if the value of parame-
ter #39 is set to 5,6,7 or 8. The PIN codes are managed using the so-
called expanded keypad. See section Expanded keypad - General on
page 45 for more detailed information.
Ten drivers can have their own PIN code to gain access to the truck.
Each driver can set all driver parameters individually.
On delivery the PIN code is set to 1 and this only applies for driver no. 1.
Code 0 is not accepted as a solitary code.
When you wish to start the truck enter your code and press the green
button numbered 1.
When you want to switch off the truck, press the red button numbered 0.
When the CAN key is connected, you can start the truck by simply
pressing the green button numbered 1. Switch off by pressing the red
button numbered 0.
Parameter 14
Specifies the speed you will have when you reach the first speed sensor.
Parameter 15 - Non-configurable option

See “Option parameters” on page 34, Servicemanual
Parameter 16 - Configurable option #1



Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040


Option parameters
WARNING !
Do not try to change these parameter unless you have specific knowl-
edge of the truck options or truck modifications. This service manual
only covers the truck’s standard equipment. Specially modified
trucks may require you to have access to particular service informa-
tion. Incorrect adjustment of option parameters may result in incor-
rect function.
General
Parameters #15 to #19 have been reserved in the truck control system
for extra options and/or specific product modifications. These parame-
ters are normally configured by the manufacturer on modification or
customisation of the truck. It is recommended that the parameter set-
tings be loaded up from the truck when carrying out any modification. If,
for example, the main electronic card [A2] must be replaced, the origi-
nal parameter settings can then be simply transferred to the new card,
which ensures that all the special options function correctly.
Parameter #15 Non-configurable options

Up to 16 so-called sub-parameters are stored under parameter #15.
Their status is either ON or OFF and they do not require any other
adjustments. They are therefore called non-configurable options.
Changing non-configurable options

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

The first set-up of sub-parameters is displayed
The next set-up of sub-parameters is displayed if you continue to acti-
vate the speed control L1. Ensure that only the relevant sub-parame-
ters are displayed.
The value of the sub-parameters is displayed after 1 second.
• Press the horn button S18.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
The parameter symbol flashes. .
• Enter the sub-parameter value by repeatedly operating the speed

control L1 in either direction. See Table 1: for more information.
• Press the S18 horn button once to confirm the new setting.
The parameter symbol is lit (i.e. stops flashing).
• Switch off the truck by pressing on the keypad.

The non-configurable option is now activated.
• Check that the function works correctly before the truck is put back
in operation.
P
Table 1: 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 - - -
Parameter #16 to 19 configurable optional functions

Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a
maximum of 4 pre-programmed functions and configure these to suit
optional equipment or customisation of the truck. See “Table 2:List of
configurable optional functions” on page 37. These are thus called the
configurable optional functions.
• Each parameter can be programmed to cover a specific optional
function.
• Each optional function can have up to 4 independent variables asso-
ciated with it.
• Each independent variable has a value you can change to configure
the function.

Parameters
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Parameter no. (range 16-19)

Independent variable: #0 is the option designation
Independent variable value (range 0-63)
0= no option has been activated for this parameter
1 to 63 = Pre-programmed option number. See separate table.)
16 - 0 - 1
SETTING THE OPTIONAL FUNCTION
Independent variable: #1, #2, #3 & #4 contain the optional function valu
Independent variable value (the range depends on the function referred
The value depends on the option and independent variable selected.
See separate table
16 - 1- 1
CONFIGURING THE OPTIONAL FUNCTION

Fig. 1 Summary – option parameter
Changing configurable optional functions

In order to activate a configurable optional function, it must first be
assigned a parameter from #16 to #19. This is done by changing inde-
pendent variable #0 to the pre-programmed option number. Once this
has been done, the independent variable for the option must be config-
ured. This is done by changing the values for independent variables #1,
#2, #3 and #4.
• Select parameter #16, #17, #18 or #19 using [L1].

Independent variable #0 is displayed
The independent variable value is displayed after 1 second. The value
“0” means that an optional function has not been assigned to this
parameter, and the speed control L1 in this case displays the next
parameter if you continue to activate it.
The parameter symbol flashes.
• Enter the independent variable value #0 by repeatedly operating the

speed control L1 in either direction. See Table 2:

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

speed control L1 in either direction. See the list of optional functions
in Table 2:
Adjust independent variables #2, #3 and #4 in the same way as above.

The optional function is now activated.
• Check that the optional function works correctly before the truck is
put back in operation.
Table 2: List of configurable optional functions

Independent Independent vari- Independent var- Independent varia-
variable #1 able #2 iable #3 ble #4
Independent variable #0 = 1: The option button controls the spider output
0:Spider 0 0:Digital output 1 1-6:option button 1-6 Type of function:
1:Spider 1 1:Digital output 2 0:instantaneous
2: :Digital output 3 1:butterfly switch
3: :Digital output 4
Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input
0:Spider 0 0-7:Digital input 1-8 0-12:reduced speed 0:high-speed range
1:Spider 1 40-100% 1:low-speed range
(i.e. 40+5*arg3 e.g. 2: both ranges
4: 40+5*4=60%)
Independent variable #0 = 3:Activate the spider output for specific movements
0:Spider 0 0:Digital output 1 Select movements. Initial position:
1:Spider 1 1:Digital output 2 See Table 3: 0: shines constantly
2: :Digital output 3 1: flashes 1 Hz

Parameters
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Independent Independent vari- Independent var- Independent varia-
variable #1 able #2 iable #3 ble #4
Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input
0:Spider 0 0-7:Digital input 1-8 0-30:Holding time 0- Not used
1:Spider 1 30 minutes
Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs
0:Spider 0 0: Lift, digital input 1 0: Blocking of lower- 0: Fork lift/lowering
1:Spider 1 Lowering, digital ing disconnected 1: Support arm lift/lower-
input 2 1: Blocking of lowering
Blocking of lowering connected
ing, input 3
1: Lift, digital input 2
Lowering, digital
input 3
Blocking of lower-
ing, input 4
Lowering, digital
input 4
Blocking of lower-
ing, input 5
Lowering, digital
input 5
Blocking of lower-
ing, input 6
Lowering, digital
input 6
Blocking of lower-
ing, input 7
Lowering, digital
input 7
Blocking of lower-
ing, input 8
Independent variable #0 = 6:Lift height limitation with by-pass
0:Spider 0 0-7: Limit 1-6: By-pass, Not used
1:Spider 1 switch for option switch 1-6
digital input 1-8

Parameters
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Table 3: Option 3 – Choice of movement

Selected movement Independent
variable #3
- 0
Driving forward 1
Driving backward 2
Driving forward or backward 3
Fork lift 4
Fork lift or driving forward 5
Fork lift or driving backward 6
Fork lift or driving forward or driving back- 7
ward
Fork lowering 8
Fork lowering or driving forward 9
Fork lowering or driving backward 10
Fork lowering or driving forward or driving 11
backward
Fork lift or fork lowering 12
Fork lift or fork lowering or driving forward 13
Fork lift or fork lowering or driving backward 14
Fork lift or fork lowering or driving forward or 15
driving backward
All other movements (AOM) 16
Driving forward or AOM 17
Driving backward or AOM 18
Driving forward or driving backward or AOM 19
Fork lift or AOM 20
Fork lift or driving forward or AOM 21
Fork lift or driving backward or AOM 22
Fork lift or driving forward or driving back- 23
ward or AOM
Fork lowering or AOM 24
Fork lowering or driving forward or AOM 25

Parameters
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variable #3
Fork lowering or driving backward or AOM 26
backward or AOM
Fork lift or fork lowering or AOM 28
AOM
or AOM
driving backward or AOM
Parameter 20
You decide yourself what the hour meter will show.
1A = Key time
2b = Movement time
3c = Drive motor time
4d =Pump motor time
5s = Time for service
Parameter 21
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.

Parameters
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ventilated batteries
Parameter 21 Battery size Battery size

LWE180, LWE200, LPE200-8
LPE200-6
1
Less dis- 2
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
Greater dis- 12
charge 13
14
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.

Parameters
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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.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497

valve-controlled batteries (VRLA)
Parameter 21 Battery size Battery size

LWE180, LWE200, LPE200-8
LPE200-6
1
Less discharge 2 260Ah - 320Ah

3 190Ah - 250Ah
4 120Ah - 180Ah 260Ah - 320Ah
5 190Ah - 250Ah
6 120Ah - 180Ah
7
8
9
10
11
12
13
Greater dis-
charge 14
15
16
17
18
19
20
WARNING !

Parameters
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• 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.
rameter setting.
Battery type Battery voltage at rest, Uend

Hawker Evolution 24,24 V
Parameter 22
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1
Parameter 25
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.
Parameter 28
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

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
Parameter 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)
ters NOT accessible (without 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.
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
5:). 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 5:
These PIN codes can be changed to any value, but you should avoid
the same PIN code in different driver profiles.

Parameters
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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 4:
Table 4: Programming command - expanded keypad

Progamming Function Notes
Reset to factory settings Block 1 - 9 is deactivated.
Press “1” + Original PIN codes reset
as per Table 5:
PIN codes in the block can be used B= Block no. 0 - 9
Press “2” + B +
PIN codes in the block cannot be B= Block no. 0 - 9
Press “3” + B + 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 han-
dling.
Table 5: shows the PIN codes available as standard in the program.
These can be activated for use or changed according to the driver’s
wishes.
One or more of these blocks can be activated.
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.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
Table 5: Standard PIN code assignment with the expanded

keypad
Driver profile 0 1 2 3 4 5 6 7 8 9
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
_
Service indication
A • Connect CAN key to X41 and start the truck
• Battery status is shown and symbol “D” is lit
• Press S18 to go to display mode.
See the table below.
E D C B
Flashing symbol Data
B A speed reference value has been sent
to Curtis
C Digital inputs to Curtis and hall sensors.
* See explanation below
BC Battery voltage (V)
D Armature voltage (A)
BD Field current (A)
CD PWM (pulse width modulation) armature
in percentage
BCD Status of Curtis
*These are displayed by segments of three of the figures being marked (A).

Parameters
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• The figure with the highest value is active (marked with an arrow).
• Power amplifier, inputs.
A T
Segment Function
A
B
E D C B
C S31, input A1:15
D S10, input A1:12
A
E
F B
G F
G S10, input A1:5
E C
DP DP
D
• The figure with the second highest value is active (marked with an
arrow).
A • Power amplifier, inputs
Segment Function
A
E D C B B
C Y41, output A1:2
D Y1, output A1:3
A E K10, output A1:4

F H1, output A1:7
F B
G G Y1, output A1:5
E C DP K30, output A1:6

DP
D

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
• The figure with the third highest value is active

(marked with an arrow).
A • Digital input from control sensors.
Segment Function
A
E D C B
B
C
A D Forks up
E Forks down
F B
G F Support arm up
E C G Support arm down

DP DP Horn
D
• The figure with the fourth highest value is active

A
Segment Function
A Extra function 6
B Extra function 5
E D C B C Extra function 4
D Extra function 3
E Extra function 2
F Extra function 1
G
DP

Part number
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9.7 Part number

A
• Press S18 until Pn = part number is displayed.
• You have now selected Pn = part number and the symbol ”D” is lit as
an indication of what is now shown in the display. Initially, Pn =
E D C B number is displayed for the component’s entire unit.
• By scrolling with L1, you can get the following information:
• SPn = Part number for software.
• HPn = Part number for hardware.
• HSn = Serial number for hardware.
9.8 Transistor panel
STATUS
MODEL VOLTAGE
SERIAL CURRENT
9.8.1 General
B+ M-
Curtis 1243 is a regulator that controls shunt motors. What primarily
controls the speed is the variation in the voltage in the rotor. The volt-
age is varied by means of pulse width modulation (PWM). This also
includes variation in "on" time for the MOS transistors that regulate the
A1
M A2 rotor current.
The rotation direction is changed by changing the polarity in the field
winding (S1-S2). The regulator is equipped with a transistor-fitted four-
quadrant bridge for the field winding and a single-quadrant bridge for
the rotor winding.
S1 S2

Troubleshooting
225553-040 2005-05-11 723984- 660, 661, 662, 497
9.9 Troubleshooting
9.9.1 Error codes and troubleshooting
STATUS
MODEL VOLTAGE
SERIAL CURRENT
The table below describes the error codes that can be displayed with
the status light or read on the hand unit.
STATUS LED Text on hand Explanation Possible cause

unit
LED off - No voltage or error in Defective fuse, poor contact, not con-
the regulator. nected, error in the regulator.
LED on - Error in the regulator. Error in the regulator.
1,1 ¤¤ CURRENT Error in the built-in Error in the rotor current sensor in the
SHUNT FAULT current shunt. motor monitor.
1,2 ¤ ¤¤ HW FAILSAFE CAN timeout in The motor monitor is reporting an
power amplifier. unexpected data loss from the tiller
arm head.
1,3 ¤ ¤¤¤ M- SHORTED Internal M- short Problem with switch transistor in the
circuited to B-. rotor circuit inside the motor monitor.
3,1 ¤¤¤ ¤ CONT COIL/FLD Voltage too high for Attempt to extract more current than
SHORT contactor feed or the output device can manage.
short-circuited field Problem regulating the field current.
winding. Internal monitoring error.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding. Shunt field open, defective cable,
defective motor monitor.
4,1 ¤¤¤¤ ¤ LOW BATTERY Low battery voltage. 1. Battery voltage < 17 volt.
VOLTAGE 2. Battery poles affected by corrosion.
3. Loose battery or regulator connec-
tions.
4,2 ¤¤¤¤ ¤¤ OVERVOLTAGE Voltage too high. 1. Battery voltage > 33 volt.
4,3 ¤¤¤¤ ¤¤¤ THERMAL CUT- Too high/too low 1. Temp. > 85oC or < -25oC
BACK temperature reduc- 2. The truck is overloaded.
tion. 3. Incorrectly installed transistor
regulator.
4. Operation under extreme conditions.

Troubleshooting
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9.9.2 Reset error

When you want to clear an error, first turn S17 to the “OFF” position and
then “ON” again.
Error Reset when

OVERVOLTAGE The battery voltage is below 33 V.
THERMAL CUTBACK The temperature is within the permitted
interval.
THROTTLE FAULT 1, 2 The fault has been dealt with.
LOW BATTERY VOLTAGE When the battery voltage exceeds 16 V.
9.9.3 Safety
The regulator is a heavy current component. When it is used on a bat-
tery-powered vehicle, all necessary safety measures must be taken.
This means, among other things, that the driver must have suitable
training, use goggles, avoid loose clothing, take off watches and jewel-
lery and only use insulated tools. It may also be necessary to take other
measures.
WARNING !
Risk of short circuiting
Remove watches, jewellery and always use insulated tools only.

Technical specifications – Curtis 1243
225553-040 2005-05-11 723984- 660, 661, 662, 497
9.10 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.

660, 661, 662, 497 723984- 2005-05-11 225553-040

Electrical systems – 5000 LPE 240
Electrical parts
225553-040 2005-05-11 723984- 660, 661, 662, 497
10- Electrical systems – 5000

LPE 240
10.1 Electrical parts
S10
S17 S53 S21
Y1
M1
X1
A1
F50
M3
F51
X41
R1
Y41 F1
K10
F3
K30
P1 H1
M6
S19
S59

Electrical parts
660, 661, 662, 497 723984- 2005-05-11 225553-040
A7

Symbol list and electrical diagram
225553-040 2005-05-11 723984- 660, 661, 662, 497
10.2 Symbol list and electrical diagram
Symbol Description Function Notes

A1 Transistor regulator
A5 Electronic card
A6 Display
A7 Keypad PIN-number login Option
F1 Fuse Drive motor circuit 175 A

F3 Fuse Pump motor circuit 130 A
F 50 Fuse Operating circuit A5 7,5A
F 51 Fuse Operating circuit A1 7,5 A
F 52 Fuse Optional equipment Option
F64 Fuse Steering motor 20 A Option
G1 Battery 24 V
H1 Horn
K10 Contactor Main contactor

K30 Contactor Pump motor
M1 Motor Drive motor

M3 Motor Pump motor
M6 Motor Steering motor option
M12 Motor Fan Not cold store
P1 Potentiometer Load sensor
R1 PTC-resistor Power supply 15 Ohm

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Symbol Description Function Notes

S1 Switch Option
S2 Switch Option
S3 Switch Option
S4 Switch Option
S5 Switch Option
S6 Switch Option
S10 Switch Travel brake Brake lever
S17 Switch Key
S18 Switch Horn button
S19 Switch Man on platform
S20 Switch Switch for safety reversing
S21 Switch Emergency switch off
S31 Switch Lift height limiter
S34 Switch Fork lifting
S41 Switch Fork lowering
S53 Switch Gates
S59 Switch Platform in upper position
Y1 Brake
Y41 Magnetic valve Fork lowering
X1 Connector Battery
X41 Connection point CAN communication

225553-040 2005-05-11 723984- 660, 661, 662, 497
10.2.1 Electrical wiring diagram 1(5)

660, 661, 662, 497 723984- 2005-05-11 225553-040

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660, 661, 662, 497 723984- 2005-05-11 225553-040

225553-040 2005-05-11 723984- 660, 661, 662, 497

660, 661, 662, 497 723984- 2005-05-11 225553-040
10.2.6 Electrical wiring diagram Servo

(Option)

Functional description
225553-040 2005-05-11 723984- 660, 661, 662, 497
10.3 Functional description
10.3.1 Starting the truck

• Battery connector plugged in.
• S21 closed.
• S17 on.
A1 10.3.2 Driving without using platform and

B- gates, speed ≤ 6 km/h
S1
T1 • S59 open.
Ish S2
-
A2
M- • S10 closed.
+
Shunt
Ia
A • L1 activated in any direction.
A1
T2
K10 B+
10.3.3 Driving from platform without using
gates,speed ≤ 6 km/h
• S 19 closed.
• S10 closed.
• L1 activated in any direction.
10.3.4 Driving from platform and using gates,

speed ≥ 8 km/h
• S 19 closed.
• S 53 closed.
• S10 closed.
• L1 activated in any direction.
A1
10.3.5 Neutral speed reduction
B- • L1 to neutral position, motor starts to work as generator. Brake ener-
S1
T1
gy comes back to battery.
Ish S2
- M- • Load sensor P1 determines speed reduction force.

A2
+
Shunt
Ia
A • Y1 will be applied when the truck comes to a stand still even if the till-
A1
T2
er arm is in drive position.
K10 B+
• Energy back to the battery, see picture.
• The transistors (T2) for the generated brake current are not live.
T

Functional description
660, 661, 662, 497 723984- 2005-05-11 225553-040
10.3.6 Neutral speed reduction on slopes

If the driver release the speed leaver (L1) on a slope and the truck
doesn’t come to a stop within a certain time the electrical brake will be
applied.
10.3.7 Braking
The brake is always applied when the truck is started with the tiller arm
in it’s upper or lower position (S10 open). The brake is released in the
same moment as the conditions for driving are fulfilled and the truck
starts to move.
Conditions to brake the truck:
• S10 open or S19 open.
10.3.8 Lifting the forks

• S34 activated.
• S31 closed.
• Battery status ok (if battery capacity >20% left).
10.3.9 Lowering the forks

• S41activated.
10.3.10 Horn
• S18 activated.

Hour meter
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10.4 Hour meter

• Press S18 and turn S17 to on at the same time.
A • Press S18 until you read the H= hour meters.

• You have now choosen H=hourmeters the symbol “B” will be high-
lighted.
• You can now choose type of hourmeter by pressing L1.
1(A)= Key time.
E D C B
2(b)= Drive motor time.
3(c)= Pump motor time.
4(d)= Activity time.
5(s)= Time left to make service.
10.5 Error codes

• Press and hold S18 until E = error codes is displayed.
• When E is selected, the “E” symbol will light up as an indication of
what is shown in the display.
• The 50 most recent error codes are stored. The latest error is dis-
played first. The display shows the error code first, followed by the
time when the error occurred.
• The error codes are divided into two groups, C = caution and E = error.
• C codes are not stored. They are only cautions and remain lit in the
display as long as the fault remains.
• If there is only one error registered in the memory, the other empty
entry lines appear as follows: Error: E - - - and time: - - - - .
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

Error codes
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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
position.
2. Replace the electronic card.

Error codes
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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.

Error codes
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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.

Error codes
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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.
(Applies to P 24)
2. Check that the travel regulator is installed with
good contact with the chassis.

Error codes
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Code C90 (Option)

Code C91 (Option)

Code C92 (Option)

box (0)
Code C93 (Option)

box (1)
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.

Error codes
225553-040 2005-05-11 723984- 660, 661, 662, 497
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
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 cabling 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 possi-
ble to measure ohms for the field winding using a
standard universal instrument, since the winding
has a value as low as 0.3 ohm.

Error codes
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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.

Error codes
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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
Code E140
Description Error in control total.
Possible error Fault on the internal micro-monitoring (tiller arm
cause head), incorrect software or circuit board.

Error codes
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Code E141
Description Software problem.
Possible error Fault on the internal monitoring (tiller arm head),
cause incorrect software or circuit board.
2. Download the program again.
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
contacts.
Code E151
Description Tx error in data communication.
Possible error Travel regulator not responding.
cause
Code E157
Description Bus shut off.
cause

Error codes
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Code E159
Description Transgression error.
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

Error codes
660, 661, 662, 497 723984- 2005-05-11 225553-040
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

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
10.6 Parameters
A
• Press S18 until you read P= parameters.
• You have now choosen P=parameters the symbol “C” on display will
be highlighted to indicate what’s currently shown on display.
E D C B • Scroll to the parameter you want to change or look at by pressing the
L1 up or down.
• Press S18 ones to get access to the parameter.
• Set parameter value by pressing L1 up or down.
• Press S18 ones to confirm change.
• Turn S17 to off.
You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
NOTE !
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necesarry know-how.
10.6.1 Driver parameters
Parameter Name Unit Min Max Step Std Description

1 Speed, low % 10 100 5 100 10:low Speed
Speed 100:highest Speed
02 Speed, high % 10 100 5 100 10:low Speed
speed 100:highest Speed.
03 Acceleration 10 100 5 75 10:low acceleration
100:full acceleration
04 Neutral speed 5 100 5 80 Defines motor speed
reduction reduction force when
lever goes to neutral
position.
5: low reduction force
100: full reduction force
05 Logout 1min 0 20 1 20 The time it takes for the
truck to switch off when
the keypad is used. The
time counts down from
the moment the last
power-consuming unit
is used.
In steps of 1

Parameters
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Parameter 1
Possibility to adjust the speed in the low speed range (when the safety
gates are not used).
Parameter 2
Possibility to adjust the speed in the high speed range (when the safety
gates are used).
Parameter 3
The lower value of the parameter the longer time it takes to accelerate
the truck to top speed.
Parameter 4
Defines motor brake force when lever (L1) goes to neutral position.The
lower value of parameter the longer time to reduce speed.
Parameter 5
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.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
10.6.3 Service parameters

A • Connect CAN-key in X41
• Press S18 until you read P= parameters.
• You have now choosen P=parameters the symbol “C” on display will
be highlighted to indicate what’s currently shown on display.
E D C B • Scroll to the parameter you want to change or look at by pressing the
L1 up or down.
• Press S18 ones to get access to the parameter.
• Set parameter value by pressing L1 up or down.
• Press S18 ones to confirm change.
• Turn S17 to off.
You have now completed a parameter change and the next time you
start the truck the new parameter setting will be valid.
NOTE !
Truck handling.
Modifying specific truck parameters will change the driving charac-
teristics of the truck.
Do not change any parameters without the necesarry know-how.
Parameter Description Unit Min Max Step Std Description

. . .
10 PIN-code 0 9999 1 1 Facility for specifying up to 10
PIN codes (10 different drivers).
14 Crawling -10 10 1 0 The amount of power the mon-
speed itor should emit when you
reach the first speed sensor
can be specified here.
-10: low speed for the first
speed sensor.
10: high speed for the first
speed sensor
15 Non-config- See “Option parameters” on page 29, Servicemanual
urable option
0 to 9
16 Configurable See “Option parameters” on page 29, Servicemanual
option #1
17 Configurable
option #2
18 Configurable
option #3
19 Configurable
option #4
20 Hour meter 1 5 1 2 Select hour meter.
option

Parameters
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Parameter Description Unit Min Max Step Std Description

. . .
21 Battery size 1 20 1 5 Selection of battery size.
22 Inductive 0 1 1 1 0: Mechanical switch
sensor 1: Inductive sensor
25 Service inter- 1h 0 2000 50 100 Option for setting service timer
val
28 Lift button 1 3 1 1 Button selection
selection
39 Password 1 12 1 1 States which level of authoriza-
tion the driver has for the
parameters.
Odd values specify open driver
parameters, even values spec-
ify that driver parameters must
be opened using the CAN key

Parameter 10
NOTE!
The functionality of parameter #10 is set aside if the value of parame-
ter #39 is set to 5,6,7 or 8. The PIN codes are managed using the so-
called expanded keypad. See section Expanded keypad - General on
page 41 for more detailed information.
Ten drivers can have their own PIN code to gain access to the truck.
Each driver can set all driver parameters individually.
On delivery the PIN code is set to 1 and this only applies for driver no. 1.
Code 0 is not accepted as a solitary code.
When you wish to start the truck enter your code and press the green
button numbered 1.
When you want to switch off the truck, press the red button numbered 0.
When the CAN key is connected, you can start the truck by simply
pressing the green button numbered 1. Switch off by pressing the red
button numbered 0.
Parameter 14
Specifies the speed you will have when you reach the first speed sensor.
Parameter 15 - Non-configurable option



Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497



Option parameters
WARNING !
Do not try to change these parameter unless you have specific knowl-
edge of the truck options or truck modifications. This service manual
only covers the truck’s standard equipment. Specially modified
trucks may require you to have access to particular service informa-
tion. Incorrect adjustment of option parameters may result in incor-
rect function.
General
Parameters #15 to #19 have been reserved in the truck control system
for extra options and/or specific product modifications. These parame-
ters are normally configured by the manufacturer on modification or
customisation of the truck. It is recommended that the parameter set-
tings be loaded up from the truck when carrying out any modification. If,
for example, the main logic card [A2] must be replaced, the original
parameter settings can then be simply transferred to the new card,
which ensures that all the special options function correctly.
Parameter #15 Non-configurable options

Up to 16 so-called sub-parameters are stored under parameter #15.
Their status is either ON or OFF and they do not require any other
adjustments. They are therefore called non-configurable options.

Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040
Changing non-configurable options

• Select parameter #15 using [L1].

The first set-up of sub-parameters is displayed
The next set-up of sub-parameters is displayed if you continue to acti-
vate the speed control L1. Ensure that only the relevant sub-parame-
ters are displayed.
The value of the sub-parameters is displayed after 1 second.
The parameter symbol flashes. .
• Enter the sub-parameter value by repeatedly operating the speed

control L1 in either direction. See Table 6: for more information.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
The non-configurable option is now activated.

• Check that the function works correctly before the truck is put back
in operation.
P
Table 6: 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 - - -
Parameter #16 to 19 configurable optional functions

Parameter no. #16, #17, #18 & #19 can be adjusted to activate up to a
maximum of 4 pre-programmed functions and configure these to suit
optional equipment or customisation of the truck. See “Table 7:List of
configurable optional functions” on page 33. These are thus called the
configurable optional functions.
• Each parameter can be programmed to cover a specific optional
function.
• Each optional function can have up to 4 independent variables asso-
ciated with it.
• Each independent variable has a value you can change to configure
the function.

Parameters
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Parameter no. (range 16-19)

Independent variable: #0 is the option designation
Independent variable value (range 0-63)
0= no option has been activated for this parameter
1 to 63 = Pre-programmed option number. See separate table.)
16 - 0 - 1
SETTING THE OPTIONAL FUNCTION
Independent variable: #1, #2, #3 & #4 contain the optional function valu
Independent variable value (the range depends on the function referred
The value depends on the option and independent variable selected.
See separate table
16 - 1- 1
CONFIGURING THE OPTIONAL FUNCTION

Fig. 2Summary – option parameter
Changing configurable optional functions

In order to activate a configurable optional function, it must first be
assigned a parameter from #16 to #19. This is done by changing inde-
pendent variable #0 to the pre-programmed option number. Once this
has been done, the independent variable for the option must be config-
ured. This is done by changing the values for independent variables #1,
#2, #3 and #4.
• Select parameter #16, #17, #18 or #19 using [L1].

Independent variable #0 is displayed
The independent variable value is displayed after 1 second. The value
“0” means that an optional function has not been assigned to this
parameter, and the speed control L1 in this case displays the next
parameter if you continue to activate it.

speed control L1 in either direction. See Table 7:

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
• Select independent variable #1 by activating the speed control L1.

Independent variable value #1 is displayed after 1 second.

speed control L1 in either direction. See the list of optional functions
in Table 7:
Adjust independent variables #2, #3 and #4 in the same way as above.

The optional function is now activated.
• Check that the optional function works correctly before the truck is
put back in operation.

Independent Independent Independent Independent
variable #1 variable #2 variable #3 variable #4
Independent variable #0 = 1: The option button controls the spider output
0:Spider 0 0:Digital output 1 1-6:option button 1-6 Type of function:
1:Spider 1 1:Digital output 2 0:instantaneous
2: :Digital output 3 1:butterfly switch
3: :Digital output 4
Independent variable #0 = 2:Reduced running speed controlled by the spider’s digital input
0:Spider 0 0-7:Digital input 1-8 0-12:reduced speed 0:high-speed range
1:Spider 1 40-100% 1:low-speed range
(i.e. 40+5*arg3 e.g. 2: both ranges
4: 40+5*4=60%)
Independent variable #0 = 3:Activate the spider output for specific movements
0:Spider 0 0:Digital output 1 Select movements. Initial position:
1:Spider 1 1:Digital output 2 See Table 8: 0: shines constantly

Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040

Independent Independent Independent Independent
variable #1 variable #2 variable #3 variable #4
Independent variable #0 = 4:Activate the main contactor controlled by the spider’s digital input
0:Spider 0 0-7:Digital input 1-8 0-30:Holding time 0- Not used
1:Spider 1 30 minutes
Independent variable #0 = 5: Lift/lowering controlled by the spider’s digital inputs
0:Spider 0 0: Lift, digital input 1 0: Blocking of lower- 0: Fork lift/lowering
1:Spider 1 Lowering, digital input 2 ing disconnected 1: Support arm lift/lower-
Blocking of lowering, 1: Blocking of lowering
input 3 ing connected
Lowering, digital input 3
Blocking of lowering,
input 4
input 5
input 6
input 7
input 8
Independent variable #0 = 6:Lift height limitation with by-pass
0:Spider 0 0-7: Limit 1-6: By-pass, Not used
1:Spider 1 switch for option switch 1-6
digital input 1-8

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497

variable #3
- 0
Driving forward 1
Driving backward 2
Driving forward or backward 3
Fork lift 4
Fork lift or driving forward 5
Fork lift or driving backward 6
Fork lift or driving forward or driving backward 7
Fork lowering 8
Fork lowering or driving forward 9
Fork lowering or driving backward 10
backward
Fork lift or fork lowering 12
Fork lift or fork lowering or driving forward 13
driving backward
All other movements (AOM) 16
Driving forward or AOM 17
Driving backward or AOM 18
Driving forward or driving backward or AOM 19
Fork lift or AOM 20
Fork lift or driving forward or AOM 21
Fork lift or driving backward or AOM 22
Fork lift or driving forward or driving backward 23
or AOM
Fork lowering or AOM 24
Fork lowering or driving forward or AOM 25

Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040

variable #3
Fork lowering or driving backward or AOM 26
backward or AOM
Fork lift or fork lowering or AOM 28
Fork lift or fork lowering or driving forward or AOM 29
Fork lift or fork lowering or driving backward or 30
AOM
driving backward or AOM
Parameter 20
You decide yourself what the hour meter will show.
1A = Key time
2b = Movement time
3c = Drive motor time
4d =Pump motor time
5s = Time for service
Parameter 21
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.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497

ventilated batteries
Parameter 21 Battery size LPE240

1
Less dis- 2
charge 3
4
5
6
7
8 570Ah - 640Ah
Standard value
9 510Ah - 560Ah
10 430Ah - 500Ah
11 370Ah - 420Ah
12 300Ah - 360Ah
Greater dis- 13
charge
14
15
16
17
18
19
20
WARNING !

Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040

• 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.
rameter setting.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497

valve-controlled batteries (VRLA)
Parameter 21 Battery size LPE200-8

1
Less discharge 2
3
4
5 570Ah - 640Ah
6 510Ah - 560Ah
7 430Ah - 500Ah
8 370Ah - 420Ah
9 300Ah - 360Ah
10
11
12
13
Greater discharge
14
15
16
17
18
19
20
WARNING !

Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040

• 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.
rameter setting.
Battery type Battery voltage at rest, Uend

Hawker Evolution 24,24 V
Parameter 22
You must specify the type of brake switch the truck is equipped with.
Mechanical switch = 0
Inductive sensor= 1
Parameter 25
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.
Parameter 28
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

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
Parameter 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)
ters accessible (without CAN service key)
ters NOT accessible (without 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.
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
10:). 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 10:
These PIN codes can be changed to any value, but you should avoid
the same PIN code in different driver profiles.

Parameters
660, 661, 662, 497 723984- 2005-05-11 225553-040
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 9:
Table 9: Programming command - expanded keypad

Progamming Function Notes
Reset to factory settings Block 1 - 9 is deactivated.
Press “1” + Original PIN codes reset
as per Table 10:
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 han-
dling.
Table 10: shows the PIN codes available as standard in the program.
These can be activated for use or changed according to the driver’s
wishes.
One or more of these blocks can be activated.
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.

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
Table 10: Standard PIN code assignment with the expanded

keypad
Driver profile 0 1 2 3 4 5 6 7 8 9
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
_
Service indication
A • Connect CAN key to X41 and start the truck
• Battery status is shown and symbol “D” is lit
• Press S18 to go to display mode.
See the table below.
E D C B
Flashing symbol Data
B A speed reference value has been sent
to Curtis
C Digital inputs to Curtis and hall sensors.
* See explanation below
BC Battery voltage (V)
D Armature voltage (A)
BD Field current (A)
CD PWM (pulse width modulation) armature
in percentage
BCD Status of Curtis
*These are displayed by segments of three of the figures being marked (A).

Parameters
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• The figure with the highest value is active (marked with an arrow).
• Power amplifier, inputs.
A T
Segment Function
A
B
E D C B
C S31, input A1:15
D S10, input A1:12
A
E
F B
G F
G S10, input A1:5
E C
DP DP
D
• The figure with the second highest value is active (marked with an
arrow).
A • Power amplifier, inputs
Segment Function
A
E D C B B
C Y41, output A1:2
D Y1, output A1:3
A E K10, output A1:4

F H1, output A1:7
F B
G G Y1, output A1:5
E C DP K30, output A1:6

DP
D

Parameters
225553-040 2005-05-11 723984- 660, 661, 662, 497
• The figure with the third highest value is active

A • Digital input from control sensors.
Segment Function
A
E D C B
B
C
A D Forks up
E Forks down
F B
G F Support arm up
E C G Support arm down

DP DP Horn
D
• The figure with the fourth highest value is active (marked with an arrow).
A
Segment Function
A Extra function 6
B Extra function 5
E D C B C Extra function 4
D Extra function 3
E Extra function 2
F Extra function 1
G
DP

Part numbers
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10.7 Part numbers

A • Press S18 and turn S17 to on at the same time.
• Press S18 until you read Pn= partnumbers.
• You have now choosen Pn= part numbers the symbol “D” on display
will be highlighted to indicate what’s currently shown on display. In
the start the Pn = part number complete unit will be shown.
E D C B
• By scrolling with the L1 you can get the following information:
• SPn= Software part number.
• HPn= Hardware part number.
• HSn= Hardware serial number.
10.8 Transistor panel
STATUS
MODEL VOLTAGE
SERIAL CURRENT
B+ M- 10.8.1 General
Curtis 1243 is a regulator for controlling shunt motors. Varying the volt-
age applied through the armature primarily controls the speed. The
voltage is varied through use of pulse-width modulation (PWM). This
A1
M A2
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.
S1 S2

Diagnostic and troubleshooting
225553-040 2005-05-11 723984- 660, 661, 662, 497
10.9 Diagnostic and troubleshooting
10.9.1 Error codes and troubleshooting
STATUS
MODEL VOLTAGE
SERIAL CURRENT
The table below depicts the error codes that may be shown by the STA-
TUS LED or read using the handheld terminal.
STATUS LED Handheld ter- Explanation Possible cause

minal display
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 currrent.
winding Internal controller fault.
3,3 ¤¤¤ ¤¤¤ FIELD OPEN Open field winding Shuntfield 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
regulator
4. Operation under extreme conditions

Diagnostic and troubleshooting
660, 661, 662, 497 723984- 2005-05-11 225553-040
10.9.2 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
10.9.3 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!
Risk of short-circuiting.
Remove all watches, jewellery and always use insulated tools only.

225553-040 2005-05-11 723984- 660, 661, 662, 497
10.10 Technical specifications –

Curtis 1243
Value Unit Explanation

Rated operating voltage 24 Volts
Overvoltage limit 33 Volts
Undervoltage limit 16 Volts Minimum operating voltage
Electrical insulation towards cold 500 V AC Minimum
body
PWM frequency 16 kHz
Max. current of armature winding * 300 Amps for 2 minutes
100 Amps for 1 hour
Max. current of field winding 35 Amps for 2 minutes
20 for 1 hour
Contactor voltage 24 Volts Same as battery voltage
Contactor current 2 Amps Max (current limit at 2.5 amps)
KSI input voltage, Min. 16.8 Volts
KSI input current 50 mA
Logic input voltage >7.5; High Volts
<1; Low
Logic input current 15 mA
Operating temperature -40 to +50 °C
Overtemperature, reduction 85 °C
Undertemperature, reduction -25 °C
* During specific test conditions.

660, 661, 662, 497 723984- 2005-05-11 225553-040

Hydraulic/Pneumatik – 6000 LWE 180/200 LPE 200
General
225553-040 2005-05-11 723984- 660, 661, 662, 497
11- Hydraulic/Pneumatik – 6000

LWE 180/200 LPE 200
11.1 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.
11.2 Hydraulic chart and list of symbols

LWE180, LWE200
n
Y41
4
M3 P 5
11.2.1 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
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11.3 Adjustments LWE180
11.3.1 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
225553-040 2005-05-11 723984- 660, 661, 662, 497
11.3.2 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, 497 723984- 2005-05-11 225553-040
11.4 Adjustments LWE200
11.4.1 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
225553-040 2005-05-11 723984- 660, 661, 662, 497
11.5 Hydraulic chart and list of symbols

LPE200-6, LPE200-8
n
1 2
Y41
5
M3
P 6
11.5.1 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, 497 723984- 2005-05-11 225553-040
11.6 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.

Hydraulic, pneumatic – 6000 LPE 240
General
225553-040 2005-05-11 723984- 660, 661, 662, 497
12- Hydraulic, pneumatic – 6000

LPE 240
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.
12.1.1 Hydraulic diagram
Y41
7 6
P M3
5 5
T

General
660, 661, 662, 497 723984- 2005-05-11 225553-040
12.1.2 Symbol list
Symbol Descrip- Function Notes

tion
1 Lift cylin- Fork lift
ders
2 PowerTrak Increases the pulling capacity
cylinder with a loaded machine
3 Pressure Input signal to transistor panel
sensor that a flow limit change is to
be made
4 Flow valve
5 Filter One filter on the pump's suc-
tion side and one on the return
6 Pressure
relief valve
7 Non-return
valve
M3 Motor Pump motor
P Pump 2.5 ccpr
T Tank 1.2 litre
Y41 Valve Lowering valve for forks
M3
5
T P
6 4 3
Y41

Adjustments
225553-040 2005-05-11 723984- 660, 661, 662, 497
12.2 Adjustments
12.2.1 Adjustment of the pressure limit valve

may need to be adjusted if the valve or complete hydraulic unit is
replaced.
The truck should be able to lift a load of between 2250-2300 kg.
Pos. Description Notes

1 Cover nut
2 Adjuster screw, Adjustment clockwise results
pressure limit in increased pressure
Adjustment anticlockwise
results in reduced pressure
• Unscrew the cover nut (1) with a spanner, 13 mm.

• Place a load, 2200 kg, on the forks and check that the machine lifts
this.
• If the machine can lift 2200 kg, place a further 100 kg on the forks.
Check whether machine can lift the load.
• If the machine can lift 2300 kg, adjust the pressure limit valve by
screwing the adjuster screw (2) anticlockwise using a 4 mm allen
key until the machine cannot lift the load.

Cleaning the filter
660, 661, 662, 497 723984- 2005-05-11 225553-040
12.3 Cleaning the filter
3
1
2 4
5
• Dismantle the hydraulic unit from the machine.
• Empty the oil from the tank.
• Loosen and remove the hose clip (1).
• Loosen and remove the two tank holders (2).
• Loosen the suction filter (5) and the return filter (3).
• Clean the filter in an environment friendly cleaning agent.
Assemble in the reverse order.

Cleaning the filter
225553-040 2005-05-11 723984- 660, 661, 662, 497

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

Lwe 180

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Service Guide en

LWE180, LWE200, LPE200, LPE240

Order number: 225553-040

This manual covers following truck models:

T-code Model Serial number

Maintenance schedule .................................. 1

Lubrication schedule ..................................... 6

Maintenance schedule .................................. 1

Oil and grease specifica tion – P3

Oil and grease specification – P3

Super Seal connectors .................................. 1

AMP connectors ............................................ 2

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 1

Electrical System – 5000

Error codes .................................................. 17

1- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 3

Electrical systems – 5000

Electrical parts .............................................. 1

Symbol list and electrical diagram................. 3

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 1- 5

Hydraulic, pneumatic – 6000

1- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 2- 1

Model LWE180 LWE200, LPE200-8

2- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

Model LWE180 LWE200, LPE200-8

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 2- 3

This page is intentionally left blank

2- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3- 1

Wheel pressure at rated load, kg/cm2 30

Tightening torque wheel bolts, Nm 130

Wheel pressure at rated load, kg/cm2 47-55

Swivel wheel, mm 150x50

Wheel pressure at rated load, kg/cm2 12-37

3- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3- 3

3- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 3- 5

This page is intentionally left blank

3- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

4.1 Maintenance schedule

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4- 1

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

4- 2 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

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

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4- 3

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

4- 4 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 4- 5

4.2 Lubrication schedule

Pos. No. Service point Interval/Operating hours Type of

0380 Lubricating nipples (Option) L E

6100 Hydraulic system O5 O B

L = Lubrication C = Check O = Oil change

4- 6 Service Guide LWE180, LWE200, LPE200, LPE240 © BT Europe AB

5.1 Maintenance schedule

I: Inspect, correct and replace if necessary. T: Tighten C: Clean L: Lubricate

Pos. Work to carry out

0380.4 Check the lift limit switch I

1700.2 Check the carbon brushes in the drive motor M

© BT Europe AB Service Guide LWE180, LWE200, LPE200, LPE240 5- 1