STRATOS LRE300 LRE300T - SER No. 943926 and UP - PART No. 229289-040 (MAY 2007)

Service Manual en
LRE300, LRE300T
Valid from serial number: 943926-
Order number: 229289-040

Issued: 2007-05-02 ITS
© BT Europe AB
Document revisions:
Issue date Order Changes

number
2006-09-11 229289 Completely new issue.
2006-11-17 229289-xxx Tools, 0000, 3100, 5000
2007-05-02 229289-xxx Tools, 5000, 3100, 9000,
This manual covers following truck models:
T-code Model Serial number

808 LRE300 943926-
812 LRE300T 943926-
© BT Europe AB Service Manual LRE300, LRE300T

Table of contents
Order number Date Valid from serial number T-code
229289-040 2007-05-02 943926- 808, 812
1- Table of contents
1- Table of contents ................................................................................. 1-1
2- General ................................................................................................. 2-1

2.1 Technical data................................................................................ 2-1
2.2 General tightening torque............................................................... 2-2
3- Maintenance ........................................................................................ 3-1

3.1 Maintenance Schedule .................................................................. 3-1
3.2 Oils and greases ............................................................................ 3-6
4- Tools ..................................................................................................... 4-1

4.1 Super Seal connector..................................................................... 4-1
4.2 AMP connectors............................................................................. 4-2
4.3 AMP microtimer ............................................................................. 4-3
4.4 Other tools ..................................................................................... 4-4
4.5 Grease guns .................................................................................. 4-6
5- Chassis – 0000 ..................................................................................... 5-1

5.1 General .......................................................................................... 5-1
5.2 Fork carriage.................................................................................. 5-1
5.2.1 Disassembly .................................................................... 5-1
5.2.2 Replacing the tow bar ...................................................... 5-2
5.2.3 Adjusting the lateral play ................................................. 5-2
5.3 Dampers ........................................................................................ 5-3
5.3.1 Changing dampers .......................................................... 5-3
5.3.2 Tilt stops .......................................................................... 5-5
6- Motors – 1000 ...................................................................................... 6-1

6.1 Drive motor .................................................................................... 6-1
6.1.1 General ............................................................................ 6-1
6.1.2 Technical data ................................................................. 6-1
6.1.3 Removing the motor from the truck ................................. 6-1
6.1.4 Replacing bearings .......................................................... 6-2
6.1.5 Refitting the motor on the truck ....................................... 6-4
7- Drive transmission – 2000 .................................................................. 7-1

7.1 General .......................................................................................... 7-1
7.2 Technical data................................................................................ 7-1
7.3 Replacing the gear ring .................................................................. 7-2
7.4 Changing the oil ............................................................................. 7-3
7.4.1 Draining ........................................................................... 7-3
7.4.2 Refilling ............................................................................ 7-3
8- Brake – 3100 ........................................................................................ 8-1

8.1 General .......................................................................................... 8-1
8.1.1 LRE300 ............................................................................ 8-1
8.1.2 LRE300T ......................................................................... 8-2
8.2 Disassembly................................................................................... 8-3
8.3 Inspection ...................................................................................... 8-3
8.4 Assembly ....................................................................................... 8-4
© BT Europe AB Service Manual LRE300, LRE300T 1- 1

Table of contents
T-code Valid from serial number Date Order number
808, 812 943926- 2007-05-02 229289-040
8.5 Maintenance .................................................................................. 8-5

8.5.1 Adjusting the play ............................................................ 8-5
8.5.2 Wear ................................................................................ 8-6
8.5.3 Checking the braking force .............................................. 8-6
9- Wheels – 3500 ...................................................................................... 9-1

9.1 Drive wheels .................................................................................. 9-1
9.1.1 Technical data ................................................................. 9-1
9.1.2 Replacing the wheels ...................................................... 9-1
9.2 Fork wheels.................................................................................... 9-1
9.2.1 General ............................................................................ 9-1
9.2.2 Technical data ................................................................. 9-1
10- Steering system – 4000 ................................................................... 10-1

10.1 Steering servo.............................................................................. 10-1
10.1.1 General .......................................................................... 10-1
10.1.2 Technical data ............................................................... 10-2
10.1.3 Maintenance .................................................................. 10-2
10.1.4 Replacing the steering servo ......................................... 10-3
10.1.5 Replacing sensors ......................................................... 10-3
10.2 Steering generator ....................................................................... 10-4
10.2.1 General .......................................................................... 10-4
10.2.2 Replacing the steering generator .................................. 10-4
11- Electrical system – 5000 ................................................................. 11-1

11.1 General ........................................................................................ 11-1
11.1.1 Nomenclature ................................................................ 11-1
11.1.2 Software ........................................................................ 11-1
11.2 Components ................................................................................ 11-2
11.3 Wiring diagram............................................................................. 11-6
11.3.1 Symbols ......................................................................... 11-6
11.3.2 Overview ........................................................................ 11-7
11.3.3 Components diagram LRE300 ...................................... 11-8
11.3.4 Components diagram LRE300T .................................. 11-16
11.3.5 Functional description .................................................. 11-25
11.3.6 Principle of operation ................................................... 11-25
11.3.7 Login unit ..................................................................... 11-29
11.3.8 Service key CAN ......................................................... 11-34
11.3.9 Display ......................................................................... 11-34
11.3.10 Steering system ........................................................... 11-35
11.3.11 Brake system ............................................................... 11-36
11.4 Parameters ................................................................................ 11-37
11.4.1 General ........................................................................ 11-37
11.4.2 Showing/changing parameters .................................... 11-37
11.4.3 Driver parameter overview .......................................... 11-38
11.4.4 Driver parameter description ....................................... 11-38
11.4.5 Service parameter overview ........................................ 11-39
11.4.6 Service parameters description ................................... 11-40
11.5 Troubleshooting ......................................................................... 11-43
11.5.1 General ........................................................................ 11-43
11.5.2 Error history ................................................................. 11-43
11.5.3 Error codes .................................................................. 11-43
11.5.4 Safety logic .................................................................. 11-63
11.6 Traction controller ...................................................................... 11-64
11.6.1 General ........................................................................ 11-64
1- 2 Service Manual LRE300, LRE300T © BT Europe AB

Table of contents
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11.6.2 Technical data ............................................................. 11-65

11.6.3 Terminal connections and pole bolts ........................... 11-66
11.6.4 Programming ............................................................... 11-66
11.7 Electronic card ........................................................................... 11-67
11.7.1 General ........................................................................ 11-67
11.7.2 Terminal connections .................................................. 11-67
11.8 Battery ....................................................................................... 11-69
11.8.1 General ........................................................................ 11-69
11.8.2 Technical data/Parameter settings .............................. 11-69
11.8.3 Battery installation ....................................................... 11-69
11.8.4 Changing the battery ................................................... 11-70
11.8.5 Instructions for verifying the parameter setting ............ 11-71
12- Hydraulic system – 6000 ................................................................. 12-1

12.1 General ........................................................................................ 12-1
12.2 Technical data.............................................................................. 12-1
12.3 Hydraulics diagram ...................................................................... 12-1
12.3.1 Symbols ......................................................................... 12-1
12.3.2 Components diagram .................................................... 12-2
12.4 Components ................................................................................ 12-3
12.5 Description ................................................................................... 12-4
12.5.1 Lift .................................................................................. 12-4
12.5.2 Lowering ........................................................................ 12-4
12.5.3 Work pressure ............................................................... 12-4
12.5.4 Pressure limit valve ....................................................... 12-4
12.6 Adjustments ................................................................................. 12-4
12.6.1 Pressure limit valve ....................................................... 12-4
12.7 Replacing parts ............................................................................ 12-5
12.7.1 Hydraulic unit ................................................................. 12-5
12.7.2 Cylinder ......................................................................... 12-6
13- Extra equipment – 9000 .................................................................. 13-1

13.1 Dry powder extinguisher .............................................................. 13-1
13.2 Warning light ................................................................................ 13-2
13.3 Shockswitch ID/Impact Manager ID ............................................. 13-5
14- Destruction instructions ................................................................. 14-1

14.1 General ........................................................................................ 14-1
14.2 Procedure .................................................................................... 14-1
14.3 Abbreviations ............................................................................... 14-2
14.4 Sorting ......................................................................................... 14-2
14.5 Frame/chassis (0300) .................................................................. 14-3
14.5.1 Disassembly .................................................................. 14-3
14.6 Fork chassis (0380)...................................................................... 14-3
14.6.1 Disassembly .................................................................. 14-3
14.7 Driver’s seat, cushions (0620)...................................................... 14-3
14.7.1 Disassembly .................................................................. 14-3
14.8 Driver controls (0640)................................................................... 14-4
14.8.1 Disassembly .................................................................. 14-4
14.9 Interior fittings (0680) ................................................................... 14-4
14.9.1 Disassembly .................................................................. 14-4
14.10 Electric motors (1700) .................................................................. 14-5
14.10.1 Disassembly .................................................................. 14-5

Table of contents
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14.11 Drive assembly, transaxle (2500)................................................. 14-5

14.11.1 Disassembly .................................................................. 14-5
14.12 Wheels (3500).............................................................................. 14-5
14.12.1 Disassembly .................................................................. 14-5
14.13 Electric steering system (4300).................................................... 14-6
14.13.1 Disassembly .................................................................. 14-6
14.14 General electronic equipment (5100)........................................... 14-7
14.14.1 Disassembly .................................................................. 14-7
14.15 Power system, drive function (5400) ............................................ 14-7
14.15.1 Disassembly .................................................................. 14-7
14.16 Control system, working function (5500) ...................................... 14-7
14.16.1 Disassembly .................................................................. 14-7
14.17 Control and protective electronics (5700) .................................... 14-8
14.17.1 Disassembly .................................................................. 14-8
14.18 Hydraulic system (6000) .............................................................. 14-8
14.18.1 Disassembly .................................................................. 14-8

General
Technical data
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2- General
2.1 Technical data
Model LRE300 LRE300T

Driving speeds
Without load 15.1 km/h 19.9 km/h
With rated load 13.3 km/h 18.0 km/h
Lifting/lowering time
Lifting time without load 2s
Lifting time with rated load 2.1 s
Lowering time without load 2.4 s
Lowering time with rated load 1.7 s
Average power consumption (room temperature)
Driving with an additional 1,500 kg on the forks (from 206.5 A (298-115 A)
standstill)
Lifting with 1,500 kg on the forks 60 A 60 A
Weight
Truck without battery (fork length 3,590 mm) 1,720 kg 1,900 kg
Other technical data can be found under the relevant chapter.

General
General tightening torque
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2.2 General tightening torque

Millimetre threads M3 to M24. The following applies under ideal condi-
tions, e.g. steel against steel.
Table 1: General tightening torque [Nm]

M3 M4 M5 M6 M8 M10
B C B C B C B C B C B C
A 8.8 1.15 1.2 2.8 2.9 5.5 5.7 9.5 9.8 23 24 45 47
12.9 2.0 2.1 4.7 4.9 9.3 9.7 16.3 17.0 38.5 40.0 75.8 79.0
M12 M14 M16 M20 M24
B C B C B C B C B C
A 8.8 77.7 81 123 128 189 197 369.6 385 638.5 665
12.9 130.5 136 208 217 319.7 333 623 649 1,075 1,12
0
A = Strength class
B = Galvanised, non-oiled bolts
C = Untreated, oiled bolts
NOTE:
Experience has shown that if you adjust the torque wrench to the val-
ues for untreated bolts, you will also achieve the correct torque value
for galvanised bolts. Do not tighten more than the values set out in
the table otherwise the bolts may be destroyed.

Maintenance
Maintenance Schedule
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3- Maintenance
3.1 Maintenance Schedule
Table 2: Maintenance Schedule

Pos. Work to carry out Driver Service technician
Interval in hours – can vary depending 5 20 500 1,000 3,000
on the application
0000 Chassis
0380.1 Check for cracks and damage X X X
0380.2 Check that the tow bars are not bent or damaged X X X
0380.3 Check the play in bushings and rollers X X X
0380.4 Push grease into the grease nipples (20 in total) X X X
0480.1 Check the rubber dampers (6) and their attach- X X
ment
0480.2 Check the attachment of cover and dampers (4) X X
0500.1 Check door locking X X X
0500.2 Lubricate door hinges X X
0610.1 Check the seat mounting and adjustment func- X X
tions
0830.1 Check the distance between tilt stops and ground
(20 mm) (Applies to LRE300T)
0850.1 Check the signs and decals X X X
1000 Motors
1710.1 Check the pump motor’s carbon brushes X X
1740.1 Check cooling fans X X
1760.1 Clean the drive motor X X
1760.2 Check connections X X
1760.3 Check and tighten the drive motor’s mounting X X
bolts (23 Nm)
1760.4 Check for abnormal noise from the bearings in the X X X X
drive motor

Maintenance
808, 812 943926- 2007-05-02 229289-040

on the application
2000 Transmission, drive transmission
2550.1 Check oil level X X X
2550.2 Change the oil Xa
2550.3 Check for abnormal noise X X X X X
2550.4 Check for leakage X X X X X
2550.5 Check and tighten mounting bolts (79 Nm) X X
2550.6 Lubricate gear rings X X X
3100 Brakes
3100.1 Clean X X
3100.2 Check for wear on the brake disc X
3100.3 Check play in released position X X
3100.4 Check the braking force X X
3500 Wheels
3500.1 Remove string and other debris X X X X X
3500.2 Check for wear on drive wheel and related bolts X X
3500.3 Check for wear on the fork wheel X X X
3500.4 Check that the fork wheel rotates freely and that X X X
the axles are in the correct position
4000 Steering system
4100.1 Check mounting and locking of steering console X X X
4100.2 Check the strength and locking of the gas suspen- X X X
sion
5000 Electrical system
5000.1 Clean and check the mountings X
5000.2 Check the contacts and wiring X X X
5100.1 Check the battery’s electrolyte level, 10-15 mm X X X X
above the cell plates
5100.2 Check the connections to the battery, truck and X X X X
charger
5100.3 Check that the cell and terminal guards are X X X X
undamaged
5100.4 Check fluid density and temperature X X X
5100.5 Remove excess fluid from the battery tray X X X
5100.6 Check the battery lock X X X

Maintenance
229289-040 2007-05-02 943926- 808, 812

on the application
5200.1 Check error code log, operating times and all the X X X
segments on the display
5280.1 Check height switch for fork lifting X X
5300.1 Check the function of emergency switch X X X X X
5300.2 Check the function of all controls X X X X X
5400.1 Tighten cable connections (15 Nm) X X
5400.2 Check contactors X X
6000 Hydraulic system
6100.1 Check hoses, pipes and connections X X X
6100.2 Check oil level X X X
6100.3 Change the oil (1,4 l) Xb X
6600.1 Check leakage in the cylinder X X X
a.Only applies to first 500 h service
b.Only applies to first 500 h service

Maintenance
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0380.1
0380.3
0380.2
5300.1 0380.3
5300.2
5200.1 0380.4
0610.1 3500.1
4100 3500.3
0850.1 3500.4
5400.2
1740.1
5000.1
5100 5000.2
1710.1
5400.1
0500.2 5280.1
0500.1
0480.2
0830.1 3500.2

Maintenance
229289-040 2007-05-02 943926- 808, 812
2550.6
6600.1
6100.2
1760.1 6100.3
1760.4
3100
1760.2
6100.1
0480.1
2550.5
2550.3
1760.3 2550.4
2550.1
2550.2
1760.1
1760.2
1760.4
TWINDRIVE

Maintenance
Oils and greases
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3.2 Oils and greases
3 1

Maintenance
Oils and greases
229289-040 2007-05-02 943926- 808, 812
Table 3: Lubrication chart

Service check 500 h 1,000 h 3,000 h
1 Fork carriage bushings L L L
2 Drive transmission Oa
3 Gear rings L L L
4 Hydraulic system I, Ob I O
L = Lubricate, I = Inspect, O = Oil change
a.Only applies to first service. The drive transmission is then lubricated for life.
b.Only applies to first service.
Table 4: Oil and grease specification

Lubrica- Specification Product name Part number
tion type
1 Grease OKQ8 Rubens WB 213366
2 Transmis- SAE 75W-90 API GL5 OKQ8 T65 1 litre: 237232-001
sion oil 5 litres: 237232-002
3 Grease Klüber Grafloscon A-G1 225456
4 Hydraulic ISO-VG32 BT hydraulic oil 32 1 litre: 233328-001
oil >-15 °C Quality level: 5 litres: 233328-002
ISO 6743-4 category HM 20 litres: 233328-003
DIN 51524 part 2 category 208 litres: 233328-004
HLP Bulk: 233328-005
Hydraulic ISO-VG27.5 Statoil 131 1 litre: 233916-001
oil <-15°C Quality level: 5 litres: 233916-002
ISO 6743-4 category HV 20 litres: 233916-003
DIN 51524 part 3 category 208 litres: 233916-004
HVLP Bulk: 233916-005

Maintenance
Oils and greases
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This page is intentionally left blank

Tools
Super Seal connector
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4- Tools
4.1 Super Seal connector
3
3
Tool Number Use

159232 Tool for fitting pins/sleeves
159229 Tools for loosening locks (1)
159230 Tool for fitting secondary locks 2 pole (2)
159231 Tool for fitting secondary locks 4 pole (2)
159228 Tool for removing pins/sleeves (3)

Tools
AMP connectors
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4.2 AMP connectors

PT = Power Timer (4.8, 5.8, 6.3 mm)
JPT = Junior Power Timer (2.8 mm)
MPT = Micro Power Timer (1.5 mm)
Figure Number Use

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

2=163788 (JPT)
1=213336 (MPT)
1 2=213337 (MPT)
2
1=213336 (JPT) Tool for fitting pins
2=213549 (JPT) For 0.5-2.5 mm2
1
2

Tools
AMP microtimer
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4.3 AMP microtimer
Tool Number Use

141199 Tool for fitting pins/sleeves
650006 Tool for removing pins/sleeves

Tools
Other tools
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4.4 Other tools
Tool Number Use

156263 Service instrument (CAN)
1=163793 Service instrument for program

2=163792 changes
08-15444 Drive motor/Pump motor
Kpl = V1015191 Oil cleaning

1 = V10-15191-1 1 = Filter for cleaning
2 = V10-15191-2 2 = Filter for removing water
3 = V10-15191-3 3 = Pipe
-1
-2 4 = V10-15191-4 4 = Pipe
-3
-4

Tools
Other tools
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Tool Number Use

V11-1239/1 Lifting yoke, Min 2000 kg

Tools
Grease guns
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4.5 Grease guns
Tool Number Use

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

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

fif
charge pipe and nozzle.
755152 Two-hand grease gun with hose and

nozzle.
755146 Grease hose 450 mm.

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

to apply grease in recessed nipples.
Fits grease guns with hose and dis-
charge pipe. Length 125 mm.
755140 Nozzle for neck nipples. Fits grease
guns with hose and discharge pipe.

Chassis – 0000
General
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5- Chassis – 0000
5.1 General
In order to be able to carry out repairs on the truck, a lifting device with
sufficient capacity is required. A mounting plate with two motors weighs
~400 kg.
5.2 Fork carriage
5.2.1 Disassembly
C
A
1. Remove the battery from the truck.

2. Loosen the hose from the lift cylinder (A) and remove the cable
from the switch (B).
3. Unscrew the cylinder and the bracket.
4. Fit lifting eyes (C) to the chassis and battery lock.
5. Lift the chassis up from the fork carriage.

Chassis – 0000
Fork carriage
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5.2.2 Replacing the tow bar

Below is a recommended procedure for obtaining the correct length of
the new tow bar.
1. Remove the old tow bar.
2. Place the old and new tow bars on a workbench.
3. Determine the length of the new tow bar by using the old tow bar
and existing axles.
4. Weld according to the drawing below.
7.5
a5
C (4x)
5.2.3 Adjusting the lateral play

The fork carriage has four lateral guides. To adjust any play, follow the
instructions below:
1. Remove the battery to access the screws. (See battery section in
chapter 5000 Electrical system.)
2. Loosen the nuts.
3. Adjust the screws until there is no play.
4. Screw the nuts on and replace the battery.

Chassis – 0000
Dampers
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5.3 Dampers
5.3.1 Changing dampers

Changing dampers take two to four hours, depending on the lifting tool
available.
C B D
1. Ensure that the drive wheels (A) point alongside the truck.
2. Remove the battery from the truck.
3. Fit lifting eyes to the chassis and battery lock (B).
4. Remove the plate (C) which covers the drive wheel.
5. Place spacers (D) under the mounting plate steering rings (E).
6. Unscrew the six screws through the rubber dampers (F).
7. Loosen wiring and contacts on drive and steering motor.
8. Lift up chassis so that the dampers are accessible.
9. Change dampers.

Chassis – 0000
Dampers
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H
10. Reassemble the parts in reverse order. Tightening torque for damp-
ers:
- Screws for attaching to the mounting plate (G): 79 Nm.
- Screws for attaching to the chassis (H): 204 Nm.

Chassis – 0000
Dampers
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5.3.2 Tilt stops

If LRE300T (twin drive) is equipped with a high battery, tilt stops are fit-
ted to the bumpers.
8x
2x 8x
Once the battery is fitted in the truck, the distance between the tilt stops
and the ground must be 20 mm. The distance between tilt stops and
ground should be inspected during the 1000-hour service or once a
year. Adjust if the distance deviates from 20 mm.
20 mm

Chassis – 0000
Dampers
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Motors – 1000
Drive motor
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6- Motors – 1000
6.1 Drive motor
6.1.1 General
The drive motor is a three-phase AC motor. The motor is fitted with a
temperature sensor which measures the motor temperature, and a
pulse sensor which measures the truck’s direction and speed.
If the truck is fitted with double drive motors, the truck’s brake is mount-
ed on one of the motors.
6.1.2 Technical data
Description LRE300 LRE300T

Output 9 kW 7.5 kW
Duty cycle S2 60 min S2 60 min
6.1.3 Removing the motor from the truck

1. Switch off the truck and remove the battery plug.
2. Disconnect the contacts to the temperature sensor [B1/B2] and
sensor [U11/U14], and power cables [U, V, W] from the traction
controller.
3. Fasten a lifting eye to the motor axle.
4. Loosen and remove the motor mounting bolts.
5. Lift out the motor using an overhead crane and place it on a clean
surface.
NOTE:
The fan and splines on the end of the motor are easily damaged. Care-
fully lift out the motor.
6. Cover the hole in the transmission to prevent anything from falling
inside the transmission housing.

Motors – 1000
Drive motor
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N-side 6.1.4 Replacing bearings

H
I Disassembly
J
E NOTE:
Ensure that a new fan is available. The fan can be damaged on disas-
F sembly.
1. If a brake is fitted on the motor:
- Loosen the brake’s screws so that the brake can be removed.
- Remove the outer locking ring from the motor axle.
- Remove the brake hub, key, plate and inner locking ring.
2. Remove the locking ring (A).
3. Pull off the fan (B) with a puller.
4. Unscrew the locking nuts (C) on the D-side, and remove the D-
R side’s bearing shield (D).
5. Remove the four stud screws (E).
6. Press out the N-side’s bearing shield (F), including the armature
(G).
K
L 7. Remove the key (H) and the locking ring (I) from the axle.
O
8. Pull off the sensor wheel (J) with a puller.
Q
N 9. Remove the locking ring (K).
P
10. Remove the bearing shim (L).
M
11. Press out the N-side’s bearing shield from the axle.
G
12. Remove the locking ring (M) and the bearing shim (N).
D 13. Press out the ball bearing (O) from the N-side’s bearing shield by
pressing the bearing’s inner ring.
S
C
B
A
D-side

Motors – 1000
Drive motor
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N-side Assembly
H
NOTE:
I Ensure all parts are intact and clean before assembly.
J
E 1. Press in the ball bearing (O) on the N-side’s bearing shield (F). Use
a tool and push on the ball bearing’s outer ring.
F 2. Fit the bearing shim (N) on the ball bearing.
3. Fit the locking ring (M) on the N-side’s bearing shield.
4. Ensure that the locking ring (P) and bearing shim (Q) are mounted
on the armature axle, close to the core.
5. Press the N-side’s bearing shield on the armature’s N-side with a
tool, and press on the ball bearing’s inner ring.
NOTE:
Do not press directly onto the bearing shield, as the bearing could be
damaged.
R
6. Fit the bearing shim (L) from the opposite side of the N-side’s bear-
ing shield.
7. Fit the locking ring (K) into the seal.
8. Press the sensor wheel (J) on the armature axle using a tool.
K
L 9. Mount the key (H) and the locking ring (I) on the axle.
O
10. Ensure that there are locking nuts and washers on the stud screws
Q (E). (Loctite 290 should be used on the screws if new locking nuts
N are used.) Also, ensure that the maximum measurement to the
P
nuts is 10 mm.
M
11. Place the rotor (G) (including bearing shield) in the stator (R).
G
12. Apply Loctite 5910 to the four tracks of the stator.
D 13. Mount the bearing shield (D) on the D-side of the stator and posi-
tion the stud screws. Ensure that the cable to the temperature sen-
sor is not damaged.
14. Place washers (S) on the stud screws.
15. Apply Loctite 290 to the stud screws.
S 16. Screw on the locking nuts (C) crosswise with increasing torque,
C eventually with 15 Nm.
B 17. Position the fan (B) using a tool and silicon hammer.
18. Fit the locking ring (M) on the D-side of the axle.
A 19. If a brake is to be fitted on the motor:
D-side - Check that the friction disc is centred in relation to the magnet
housing before installing the brake. It may be necessary to charge
the magnet coils with 48 VDC to position the brake disc.
- Fit the brake onto the motor. Check that the splines on the friction
disc are not damaged during installation.
- Tighten the mounting screws for the brake assembly.
- Mount the outer locking ring.

Motors – 1000
Drive motor
808, 812 943926- 2007-05-02 229289-040
6.1.5 Refitting the motor on the truck

1. Attach a lifting eye to the motor axle and lift the motor axle into the
transmission using an overhead crane.
NOTE:
When mounting a new motor, the coupling between the motor and the
transmission should be lubricated with 226158 Klüberplex BEM 34-
132.
NOTE:
The fan and splines on the end of the motor are easily damaged. Care-
fully lift in the motor.
2. Secure the motor in the transmission/mounting plate with a torque
of 23 Nm.
3. Connect the contacts to the temperature sensor [B1/B2] and sen-
sor [U11/U14], and power cables [U, V, W] from the traction control-
ler.
4. Remove the lifting eye.
5. Connect the battery plug.

Drive transmission – 2000
General
229289-040 2007-05-02 943926- 808, 812
7- Drive transmission – 2000
7.1 General
The drive transmission is combined with the motor and brake as a com-
plete drive assembly which can be steered 360°.
A complete renovation of the drive transmission is so extensive that it
must be done in the shop by specially trained personnel.
7.2 Technical data
Description Value
Gear ratio 20.2
Oil type Hypoid oil
Oil volume 3.3 litres
Temperature range -30-+40 °C
Weight (without oil, motor and drive 57 kg
wheel)

Replacing the gear ring
808, 812 943926- 2007-05-02 229289-040
7.3 Replacing the gear ring

The gear ring in the centre under the mounting plate is tightened to a
torque of 59 Nm.

Changing the oil
229289-040 2007-05-02 943926- 808, 812
7.4 Changing the oil

NOTE:
Handle the old oil in accordance with applicable environmental regu-
lations.
Warning!
Watch out for high oil temperature if the truck has been in use.
7.4.1 Draining
• Place the truck on an even surface and ensure that the brakes are
applied.
• Carefully clean the area around the hole for refilling (A) and draining
(B) oil.
• Place a container which is large enough to collect the oil under the
drainage hole.
A • Loosen the plug of the refilling hole using a 6 mm Allen key. Remove
the plug and the locking ring.
• Loosen the plug of the drainage hole using a 6 mm Allen key. Re-
move the plug and the locking ring.
• Allow all the oil to drain out into the collection container.
B
7.4.2 Refilling
• Clean the magnet on the plug of the drainage hole and replace the
plug. Always use a new locking ring. Torque: 22 Nm.
• Fill with new transmission oil (see Oil and grease specification). Use
an injection pump for quick and easy refilling.
• The correct oil level is obtained when the oil reaches the lower edge
of the plug of the refilling hole.
• Replace the plug of the refilling hole. Always use a new locking ring.
Torque: 22 Nm.
NOTE:
Remove spilt oil using a suitable adhesive.

Changing the oil
808, 812 943926- 2007-05-02 229289-040

Brake – 3100
General
229289-040 2007-05-02 943926- 808, 812
8- Brake – 3100
8.1 General
The brake is a single-stage electromagnetic spring-assisted brake
which is activated when its magnetic coil is not powered.
WARNING!
The brake is a safety component. Do not interfere with the brake com-
ponents.
8.1.1 LRE300
Technical data
Description LRE300
Nominal torque 62 Nm
Nominal play 0.3 +0.1/-0.05 mm
Maximum play 0.40 mm
Tightening torque for bolts 20 Nm
Minimum thickness for the friction disc 8.0 mm
Resistance of the coil 33 Ohm at 20 °C
1
2
7
8
3
9
10

Brake – 3100
General
808, 812 943926- 2007-05-02 229289-040
8.1.2 LRE300T
Technical data
Description LRE300T
Nominal torque 90 Nm
Nominal play 0.3 +0.1/-0.1 mm
Maximum play 0.50 mm
Tightening torque for bolts 20 Nm
Minimum thickness for the friction disc 10.5 mm
Resistance of the coil 48 Ohm at 20 °C
9
1
8
6
2
4
10

Brake – 3100
Disassembly
229289-040 2007-05-02 943926- 808, 812
8.2 Disassembly
1. Switch off the truck.
2. Remove the brake cable (8) to the truck's electrical system.
3. Loosen the brake unit's mounting bolts.
4. Lift the brake unit from the shaft and remove it from the truck.
5. Place the brake on a clean and dry workbench with the magnet
housing (1) facing upwards.
6. Undo the 3 assembly screws (9).
7. The brake unit can now be dismantled for inspection of the compo-
nent parts.
8.3 Inspection
1. Check whether the parts are damaged and/or worn.
2. Check the rotor disc (4) and the wear surfaces on the pressure
discs (2 and 5) extremely carefully. Check that the rotor disc's fric-
tion material is not worn or damaged.
3. 3. Check the springs are intact.
4. 4. Check for any damage to the keyway (7) or the splines on the
hub (3) and friction disc (4).

Brake – 3100
Assembly
808, 812 943926- 2007-05-02 229289-040
8.4 Assembly
1. Clean the parts carefully.
2. Assemble the brake in the reverse order to dismantling.
3. Bear in mind the following:
4. The hole in the pressure disc (2) must line up with the correspond-
ing hole in the magnet housing.
5. The right number of springs must be fitted.
6. The play must be set correctly. Some adjustment may be neces-
sary.
7. Mount the brake on the motor shaft.
8. Check before mounting the brake that the friction disc (4) is centred
in relation to the magnet housing.
9. It may be necessary to charge the magnetic coil with 48 VDC to po-
sition the brake disc correctly.
10. Mount the brake unit in the truck. Check that the splines on the fric-
tion disc have not been damaged during installation.
11. Insert the brake unit's mounting bolts and tighten them using a
torque of 20 Nm.
12. Check the amount of play between the magnet housing and the
pressure plate with the brake engaged.
13. Connect the brake cable (8) to the truck's electrical system.
14. Start the truck and release the parking brake.
15. Check that the friction disc rotates freely.
16. Cut the voltage and check that the pressure plate locks the friction
disc and that the play is correct.

Brake – 3100
Maintenance
229289-040 2007-05-02 943926- 808, 812
8.5 Maintenance
Maintenance comprises checking wear and braking force, inspection
and adjustment of the play between the pressure disc and the magnet
housing, and cleaning.
NOTE:
The friction surfaces must not come into contact with oil or grease as
this will seriously reduce the braking force.
8.5.1 Adjusting the play

LRE300
1. Adjust the play by replacing the friction disc.
2. The play may not exceed the maximum permitted value before ad-
justment is required. Use a feeler gauge to measure.
3. Maximum permitted play: LRE300: 0.40 mm
4. Nominal play: LRE300: 0.3 +/-0.1 mm
5. Remove the brake from the truck.
6. Insert in three M6 screws (the transport screws). Pull together to re-
lease the brake so that the springs cannot fly off.
7. Remove the three assembly screws (10) on the underside that hold
the brake package together.
8. Replace the friction disc.
9. Replace the assembly screws (10) on the underside. Use a torque
of 20 Nm.
10. Remove the three M6 screws after assembly.
LRE300T
1. Adjust the play using the adjustment screws.
2. The play may not exceed the maximum permitted value before ad-
justment is required. Use a feeler gauge to measure.
Maximum permitted play LRE300T: 0.50 mm.
Nominal play LRE300T: 0.3 +/-0.1 mm
3. Adjust the play using the adjustment screws (6).
4. If the minimum size of the friction disc is less than 10.5 mm, replace
it. Remove the three screws (10) on the underside of the brake to
release the brake package.
5. Turn anticlockwise to reduce the play and clockwise to increase it.
6. Tighten the assembly screws on the underside to 20 Nm.
7. Check the play again once the bolts have been tightened.
8. Repeat the adjustment stage until play is correct.
9. Check the play all the way around the pressure disc. The maximum
permitted deviation from the set play is 0.075 mm.

Brake – 3100
Maintenance
808, 812 943926- 2007-05-02 229289-040
8.5.2 Wear
Min 8,0/10,5
1. Dismantle the brake in accordance with the dismantling section.

2. Measure the thickness of the friction disc. Minimum thickness:
LRE300 = 8.0 mm.
LRE300T = 10.5 mm.
8.5.3 Checking the braking force

1. Lift up the truck so that the drive wheel is free of the ground.
2. Open the motor housing covers.
3. Tighten the M12 bolt into the hole (for lifting) in the motor shaft. Use
a torque wrench and an M12 flange bolt or a normal bolt with a flat
washer.
Torque wrench setting, LRE300: 62 Nm
Torque wrench setting, LRE300T: 90 Nm.
NOTE:
The bolt quality must be at least 10.9.
4. Turn the motor axle with the torque wrench until the brakes release.
5. The braking force is too low if the brake releases before the torque
wrench slips.
6. Adjust the brake play to the correct value – see instructions for ad-
justing play.
7. Check the braking force once more using the torque wrench.

Brake – 3100
Maintenance
229289-040 2007-05-02 943926- 808, 812
Troubleshooting chart
Fault Cause Action
The brake does Too low power supply Check the power supply
not release
Too large/too small play Adjust the play
Worn friction discs/rotor disc Replace/adjust play
Damaged coil Replace brake
Corrosion between the friction This fault may arise in damp environments
plates and the rotor when the truck has not been used for a
few days. Try to drive the truck carefully
until the corrosion is worn away. In such
cases, inspect the brake to check that the
friction material has not come loose. If the
fault cannot be remedied, the brake must
be replaced.
The brake is not The current is switched off Check the power supply
engaging
Grease on the friction surfaces Replace/adjust play
One of the springs is broken Replace brake
Unreliable Too low power supply Check the power supply
brake action

Brake – 3100
Maintenance
808, 812 943926- 2007-05-02 229289-040

Wheels – 3500
Drive wheels
229289-040 2007-05-02 943926- 808, 812
9- Wheels – 3500
9.1 Drive wheels

Drive wheel, vulcolan (2) Ø350x140 mm Ø350x140 mm
Maximum drive wheel axle pressure without load 2,430 kg 2,830 kg
Maximum drive wheel axle pressure with load 3,300 kg 3,490 kg
9.1.2 Replacing the wheels

The bolts holding the drive wheel should be tightened to a torque of
140 Nm.
9.2 Fork wheels
9.2.1 General
Intensive operation on poor surfaces generates high levels of heat.
This can lead to the tread becoming too hot and eventually releasing
from the hub.

Fork wheels, vulcolan (4) Ø90x110 mm Ø90x110 mm
Maximum fork wheel axle pressure without load 590 kg 680 kg
Maximum fork wheel axle pressure with load 2,720 kg 3,030 kg

Wheels – 3500
Fork wheels
808, 812 943926- 2007-05-02 229289-040

Steering system – 4000
Steering servo
229289-040 2007-05-02 943926- 808, 812
10- Steering system – 4000
10.1 Steering servo
10.1.1 General
A81
U1
M6
S65
The electric steering servo receives signals from an electronic card

[A5], which in turn receives signals from a generator [U1] in the steering
wheel. When the truck is started, a reference drive is carried out and
the drive wheel's position is calibrated using a reference sensor [S65].
LRE300T has two reference sensors.
The electric steering servo comprises a doubled potentiometer which is
coupled to an electronic unit [A81] in the motor compartment. The elec-
tronic module, also known as EPS (Electrical Power Steering), is
mounted directly onto a brushless permanent magnet servomotor
(BLPM). The motor has a power booster in the form of a two-speed
planetary transmission with a gear wheel mounted on a free-hanging
tap, locked with a nut. The gear wheel is in contact with the gear rings
on the drive wheel gears.
The steering system is fully electric – a Steer-By-Wire system. As a
result, there is no mechanical contact between the steering wheel and
the steering drive wheel.
The electronic module deals with all monitoring of the electrically-con-
nected parts. Monitoring takes place continually, so that any cable
breakage is detected immediately. Any electrical faults in the potenti-

Steering servo
808, 812 943926- 2007-05-02 229289-040
ometer, cables and electronic module result in the truck’s driving func-
tion stopping automatically.
For every start-up from switched off status, an automatic reference
drive is carried out. It is not possible to drive the truck at this time. The
reference drive provides a safety check of the system whilst also cali-
brating the position of the wheel.
Steering is progressive, which means that when the truck is operated at
low speed the steering gearing is higher than at high speeds. This
allows the truck to be operated in a safe and efficient manner.
Motor Value
Nominal DC voltage 48 VDC
Maximum continuous current 11 A
Continuous output 0.4 W
Resistance, phase per phase 0.15 Ohm
Drive/transmission Value
Continuous torque 55 Nm
Speed 65 rpm
10.1.3 Maintenance
The steering servo’s gear ring should be lubricated regularly in accord-
ance with the lubrication chart.
NOTE:
The gear rings must be cleaned thoroughly before lubrication.

Steering servo
229289-040 2007-05-02 943926- 808, 812
10.1.4 Replacing the steering servo

1. Unscrew the steering servo’s mounting bolts.
2. Unscrew the protective plate above the gear wheels.
3. Ensure that the gear wheels have no input voltage, for example by
lifting the truck so that the drive wheels hang freely. Check that
there is a little play when the drive wheels are turned.
4. Push up the steering servo from underneath. Choose one of the fol-
lowing options:
- - Place a jack under the steering servo and push it upwards.
- - Place spacers under the steering servo and lower the truck
carefully so that the steering servo is pushed upwards.
NOTE:
Do not pry the steering servo up with a crowbar or similar tools. The
servo must be pushed up without using side forces.
5. Push in the new steering servo and mount the protective plate over
the gear wheels.
6. Screw the fastening bolts into the truck’s mounting plate with a
torque of 46 Nm.
10.1.5 Replacing sensors

After replacing, screw the sensor into the truck’s mounting plate with a
torque of 59 Nm.

Steering generator
808, 812 943926- 2007-05-02 229289-040
10.2 Steering generator
10.2.1 General
The steering generator is located in the steering panel and has direct
contact with the steering wheel. When the steering wheel is turned, the
steering generator sends voltage to the electronic card, which forwards
signals to the steering servo.
10.2.2 Replacing the steering generator

Disassembly
1. Loosen the side screw (see picture) and lower the steering con-
sole.
2. Loosen the four screws holding the ring.
3. Disconnect the connector on the steering generator.
4. Dismantle the steering wheel by unscrewing the bolts around the
steering generator.
5. Loosen the bolts in the driving disc and remove it from the steering
generator.
6. Unscrew the bolts holding the steering generator on the steel
bracket.
Assembly
1. Bolt the steering generator onto the steel bracket.
2. Secure the driving disc on the steering generator’s shaft.
3. Replace the O-ring on the driving disc if necessary.
4. Bolt the steering wheel onto the steel bracket.
5. Connect the steering generator’s electrical connector.
6. Screw down the four screws holding the ring.
7. Raise the steering console and tighten the side screw.

Electrical system – 5000
General
229289-040 2007-05-02 943926- 808, 812
11- Electrical system – 5000

This chapter relates to software 232465-001 and later versions.
11.1 General
The truck’s battery voltage is nominally 48 V, but can vary constantly
between 33 VDC and 63 VDC, and momentarily between 24 VDC
(<50 ms) and 72 VDC (<100 µs).
11.1.1 Nomenclature
[ ] = reference to electrical component in the wiring diagram.
# = refers to the designation parameter number.
{high} = refers to a voltage level of around 48 V.
{low} = refers to a voltage level of around 0 V.
{green} = refers to the green start button on the keypad.
{red} = refers to the red stop button on the keypad.
11.1.2 Software
Electronic card [A5] is equipped with a flash memory on which the
truck’s program code is stored. In order to update the software, a new
version can be downloaded via CAN. For this, a PC with a CAN adapter
and specific software is required.
NOTE:
Error codes and parameters are stored in a separate memory. When
the software is updated, these remain.

Components
808, 812 943926- 2007-05-02 229289-040
11.2 Components
TWIN DRIVE
A2
F2 Y1
M2
B2
Y1
M2
U14
B2 U14
X1
G1
S89

Components
229289-040 2007-05-02 943926- 808, 812
S26
S21 S18
X42 R11
X41 A5
F60
R100 F61
F62
F63
K10
M13 R1 R3
S31
H1
S131
A6
A16
M3 K30 A1
F3
F1
A81
Y41
Y1
U11
M1
B1
R101
M6 S65

Components
808, 812 943926- 2007-05-02 229289-040
Table 5: Component list

Designation Function Component type
A1 Regulation of driving Traction controller
A5 Regulation of the truck Electronic card
A6 Display Display
A14 DC Converter48/12 VDC
A16 Login Keypad
A2* Regulation of driving Traction controller
A81 Integrated steering servo Electronics card + motor
B1 Sensing temperature in drive motor 1 Temperature sensor
B2* Sensing temperature in drive motor 2 Temperature sensor
F1 Protection against short circuit Fuse 250 A
F2* Protection against short circuit Fuse 250 A
F3 Protection for pump motor Fuse 130 A
F60 Protection for control voltage Fuse 10 A
F61 Protection for steering servo Fuse 30 A
F62 Protection against short circuit Fuse 10 A
F63 Protection for equipment connected to [X42] Fuse 10 A
G1 Current source Truck battery 48 V
H1 Horn Horn
K10 Main contactor Contactor
K30 Pump motor contactor Contactor
M1 Drive motor 1 Motor
M2* Drive motor 2 Motor
M3 Pump motor Motor
M6 Steering motor Motor
M13 Cooling fan (blows inwards) Motor
M14* Cooling fan (blows inwards) Motor
R1 Speed (accelerator) Potentiometer
R3 Brake (brake pedal) Potentiometer
R11 Fork position (lift and lower) Potentiometer
R100 Damping resistance for CAN Resistor
R101 Damping resistance for CAN Resistor
S18 Switch for horn Switch
S21 Emergency switch Switch
S26 Travel direction selector Two-position switch

Components
229289-040 2007-05-02 943926- 808, 812
Table 5: Component list

Designation Function Component type
S31 Forks in top position Inductive switch
S65 Reference for steering angle Inductive switch
S89 Seat switch Switch
S228 Door switch Switch
S131 Switch for parking brake Switch
U1 Steering (steering wheel) Generator
U11 Measuring speed for drive motor 1 Pulse transducer
U14* Measuring speed for drive motor 2 Pulse transducer
X1 Connection for battery Contact
X4 Power outlet 12VDC Contact
X41 Connection for CAN key Contact
X42 Connection for extra equipment Contact
Y1 Parking brake Electromechanical brake
Y41 Lowering the forks Solenoid valve
* = Only applies to LRE300T.

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
11.3 Wiring diagram
11.3.1 Symbols
Table 6: Symbol list

Symbol Description Symbol Description
Truck battery Horn
Fuse Emergency switch, NC
AC motor, 3 phase Brake magnetic coil, NC

M
DC motor Sensor, inductive, NO
Contactor Coil for hydraulic solenoid valve
Potentiometer (variable resist- Switch

ance)
Switch, button, not pre-ten- Temperature sensor

sioned, NO
Switch, button, pre-tensioned, NO Measuring point
Two-position switch Sensor
Battery contact Contact, 4-p
NO = normally open, NC = normally closed.

Wiring diagram
229289-040 2007-05-02 943926- 808, 812
11.3.2 Overview
TWINDRIVE 19 14
DRIVE MOTOR
B2 16 (1) B1 11 (1) DRIVE MOTOR
(6) (U/V/W) M (6) (U/V/W) M
15 10
17
(11) F2 A31 8 M2 12
(11) A1 F1 8 M1
U14 18 (13/14) (B+) 22 U11 13 (13/14) (B+) 22
SPEED MEASURING (9) R SPEED MEASURING (9)
(7/8/15/16) CAN (7/8/16) CAN
118/119/120
F63 X42 26
40
140
A10
141
50
(501) SPEED REFERENCE VALUE
R1
51
(502) BRAKE REFERENCE VALUE
27
7-7,5VDC (507)
R3
82 A5
U1 62 (503) FORK LIFT/LOWER
X1 A1
M
A2
129 (509) STEERING TACHO

(511) GND
28
+
G1 (508) 0VDC
R11
-
F60 21 64 S131
X1 40 (805/901) +48VDC PARKING BRAKE (802)
72/71/70 (902) GND
(603/602/601) BATT. INDI.
24
79 (807) KEY RELAY Y41
(109) FORK AT TOP 67 Y1
S21 LOWER VALVE (710)
S31
(110) DOOR SWITCH
S228 45
K30
S26 46 (104/105) DIRECTIONS 48
PUMP CON. (701)
49
(203) SEAT SWITCH
S89
22
K10
23 (809) +48VDC SUPPLIES 31
(808) MAIN CON. MAIN CON. (804)
(402/401/403/404) CAN (405/406/407/408) RS-485
F62 A6 DISPLAY A1 A2
M
F3 M3
54
F61
100
40 S18
(7/15) 0VDC (8/16)
+48VDC H1
119/120
(2/10) CAN M6
24 21 21
(6) ENABLE(B+) A81 M
A1
M
A2
S65 M13
(X3:2/X3:1) 96 97
+48VDC (11) STEER 0VDC
119/120 95 A1 A2
CAN (X3:4/X3:3) ANGLE +12VDC (3) M
M14
A16 KEYPAD X41
TWINDRIVE

11- 8
T-code
48V 808, 812
X1 G1 X1 SHUNT WIRE
1 + + - 40
Sh. 2 Sh. 2
Wiring diagram
ELECTRONIC CARD
MEASURING WIRES A5
72
603 INP. BATT. INDI. CURRENT -(+)
71
602 INP. BATT. INDI -, CURRENT -(-)
70
601
INP. BATT. INDI +

943926-
MAIN CONTACTOR
K10
A1 A2 31
804 OUT. MAIN CONTACTOR
Service Manual
10A
F62
2 1 23
808 INP. MAIN CONTACTOR
30A
Valid from serial number
F61
100
Sh. 4
8
Sh. 7
LRE300, LRE300T
Date
PUMP CONTACTOR
K30
A1 A2 48
701 OUT. PUMP CONTACTOR
2007-05-02
PUMP MOTOR
130A
M3 F3
A1 A2 9 2 1 20
M
EXTERNAL EQUIPMENT
10A X42
F63
26 1
26
11.3.3 Components diagram LRE300
Sh. 8
40 2
229289-040
Order number
1/8, Prod B
© BT Europe AB
240053
ELECTRONIC CARD
A5
229289-040
10A
F60
Order number
1 21
© BT Europe AB
Sh. 1 805 +48VDC
24
807 INP. KEY RELAY
ELECTRONIC CARD, KEYPAD
A16
Date
21
X3:2 +48VDC SUPPLY
2007-05-02
EMERGENCY SWITCH OFF

S21
21 21 X3:1 X3:6 24 1 2 22
Sh. 4 809 +48VDC SUPPLY OUTPUTS
40 40 45
X3:7 GND S26 104 INP. DRIVE, FORK DIRECTION, CREEP
943926-
Sh. 1 3
Service Manual
3
2
119/RED 119/RED
Sh. 4 X3:4 CAN H 1 46
105 INP. DRIVE, STEER WHEEL DIR., CREEP
120/Wh 120/Wh
Sh. 4 X3:3 CAN L
X3:5 OPERATION MODE PIN 1

LRE300, LRE300T
22 S89
Sh. 3 1 3 49
203 INP. SEAT SWITCH
T-code
808, 812
S31
Br Bl 79
109 INP. FORK AT TOP
Sv
2/8, Prod B
Wiring diagram
240053
11- 9
S18
54 1 2
22
11- 10
Sh. 2 5 + - T-code
IN HORN 808, 812
H1
Wiring diagram
FAN MOTOR AREA

M13
+ M
-
40
943926-
Sh. 2 4
Service Manual
ELECTRONIC CARD
DISPLAY A5
A6
LRE300, LRE300T
121
SERIE + 1 405 SERIE +
Date
122
2 406
2007-05-02
SERIE - SERIE -
RS 485
125
RX + 3 407 TX+
126
RX - 4 408 TX-
229289-040
Order number
3/8, Prod B
240053
© BT Europe AB
229289-040
ELECTRONIC CARD
Order number
A81
© BT Europe AB
40 40
Sh. 3 5 7 INP. POWER SUPPLY OV DC
40
15 INP. POWER SUPPLY OV DC
Date
100 100
Sh. 1 8 INP. POWER SUPPLY 48V DC
2007-05-02
100
16 INP. POWER SUPPLY 48V DC
119/RED 119/RED
Sh. 2 2 INP. CAN HIGH
943926-
Service Manual
120/Wh 120/Wh
Sh. 2 10 INP. CAN LOW
R101
120~E
M
STEER ANGLE REF. SWITCH

95
3 OUT. SUPPLY +12V DC
LRE300, LRE300T
S65
BN BK 96
11 INP. REFERENCE SWITCH
BU
97
12 OUT. SUPPLY OV DC
T-code
21 21
808, 812
Sh. 2 5 6 INP. ENABLE (B+)

130
4/8, Prod B
Wiring diagram
240053
11- 11
11- 12
T-code
808, 812
ELECTRONIC CARD
A5
Wiring diagram
21 21
Sh. 4 901 +48VDC CAP CHARGE
40 40
Sh. 4 6 902 GND
22
Sh. 3 6
943926-
Service Manual
U1
Red Bk 62
M 509 INP. STEERING WHEEL TACHO +
129
511 GND FOR TACHO
LRE300, LRE300T
Date
S228
2007-05-02
Br Bl 132
110 INP. DOOR SWITCH
Sv
229289-040
Order number
5/8, Prod B
240053
© BT Europe AB
EMERGENCY MODE
S131
22 1 2
Sh. 5 7 ELECTRONIC CARD
A5
229289-040
Y1
40 64
Sh. 5 7 802 OUT. PARKING BRAKE
Order number
© BT Europe AB
Date
Y41
1 2 67
2007-05-02
710 OUT. LOWER VALVE
27
507 OUT. POT FEED 7-7,5 VDC
943926-
Service Manual
50
R1 501 INP. SPEED REFERENCE VALUE
2
28
508 OUT. OV DC
1
51
LRE300, LRE300T
R3 502 INP. BRAKE REFERENCE VALUE
3
2
T-code
808, 812
82
R11 503 INP. FORK LIFT / LOWER
3
6/8, Prod B
Wiring diagram
240053
11- 13
11- 14
T-code
808, 812
Wiring diagram
250A
F1
8
Sh. 1 B + +
5
U DRIVE MOTOR
40
Sh. 6 8 B - M1
U
THERMO ELECTRICAL SENSOR IN M1 6 V M
X26 V
14 W M
3~A
1
B1 7
W
11
943926-
6
A1
ELECTRONIC CARD
10 A5
11
Service Manual
SPEED MEASURING IN M1
U11 117
401 OUT. CAN +15VDC
Red Bu 12
TRANSISTORPANEL, DRIVE 1
13
+ B
118/Bu
7 402
OUT. CAN GND

Bk Wh 13
14
- |R A
119/RED
8 403 OUT./INP. CAN H
LRE300, LRE300T
22 120/Wh
Sh. 6 9 16 404 OUT./INP. CAN L
Date
SERVICE KEY INTERFACE

2007-05-02
X41
1 117
2 118/Bu
3 119/RED 119
4 120/Wh 120
229289-040
R100
Order number
120~E
7/8, Prod B
240053
© BT Europe AB
229289-040
Order number
© BT Europe AB
Date
2007-05-02
OPTION
DC/DC CONVERTER DC/DC CONVERTER
A10
943926-
Service Manual
X42
26 26
Sh. 1 6 INP. +48VDC
X42
40 40
Sh. 7 3 INP. GND
X4
140 140
1 OUT. +12VDC
LRE300, LRE300T
X4
141 141
2 OUT. GND (GALV. SEPARATED)

T-code
808, 812
1 OUT. +12VDC
8/8, Prod B
240053
Wiring diagram
11- 15
11- 16
T-code
808, 812
48V
X1 G1 X1 SHUNT WIRE
Wiring diagram
1 + + - 40
Sh. 2 Sh. 2
ELECTRONIC CARD
MEASURING WIRES A5
72
603 INP. BATT. INDI. CURRENT -(+)
71
602 INP. BATT. INDI -, CURRENT -(-)
943926-
70
601 INP. BATT. INDI +
MAIN CONTACTOR
Service Manual
K10
A1 A2 31
10A
F62
2 1 23
30A
F61
100
Sh. 4
LRE300, LRE300T
8
Sh. 7
Date
PUMP CONTACTOR
2007-05-02
K30
A1 A2 48
701 OUT. PUMP CONTACTOR
PUMP MOTOR
130A
M3 F3
A1 A2 9 2 1 20
M
EXTERNAL EQUIPMENT
10A X42
F63
26 1
11.3.4 Components diagram LRE300T
229289-040
40 2
Order number
26
Sh. 9
1/9, Prod B
© BT Europe AB
222162
229289-040
ELECTRONIC CARD
Order number
A5
© BT Europe AB
10A
F60
1 1 2 21
Sh. 1 805 +48VDC
24
Date
807 INP. KEY RELAY

ELECTRONIC CARD, KEYPAD
A16
2007-05-02
21
X3:2 +48VDC SUPPLY
EMERGENCY SWITCH OFF

S21
21 21 X3:1 X3:6 24 1 2 22
Sh. 4 809 +48VDC SUPPLY OUTPUTS
943926-
Service Manual
40 40 45
Sh. 1 3 X3:7 GND S26 104 INP. DRIVE, FORK DIRECTION, CREEP
3
2
119 119
Sh. 4 X3:4 CAN H 1 46
105 INP. DRIVE, STEER WHEEL DIR., CREEP
120 120
Sh. 4 X3:3 CAN L
LRE300, LRE300T
T-code
808, 812
22 S89
Sh. 3 1 3 49
S31
Br Bl 79
109 INP. FORK AT TOP
Sv
2/9, Prod B
Wiring diagram
222162
11- 17
S18
54 1 2
11- 18
22
T-code
Sh. 2 5 + -
808, 812
IN HORN
H1
Wiring diagram
FAN MOTOR AREA

M13
+ M
-
FAN MOTOR AREA

M14
943926-
+ M
-
Service Manual
40
Sh. 2 4
ELECTRONIC CARD
DISPLAY A5
A6
LRE300, LRE300T
121
Date
SERIE + 1 405 SERIE +
122
2007-05-02
SERIE - 2 406 SERIE -

RS 485
125
RX + 3 407 TX+
126
RX - 4 408 TX-
229289-040
Order number
3/9, Prod B
222162
© BT Europe AB
229289-040
Order number
© BT Europe AB
ELECTRONIC ASSY, STEER SERVO
A81
40 40
Sh. 3 5 7 INP. POWER SUPPLY OV DC
Date
40
15 INP. POWER SUPPLY OV DC
2007-05-02
100 100
Sh. 1 8 INP. POWER SUPPLY 48V DC
100
16 INP. POWER SUPPLY 48V DC
119 119
Sh. 2 2 INP. CAN HIGH INTEGR. STEER MOTOR
943926-
Service Manual
M6
120 120
Sh. 2 10 INP. CAN LOW M
R101
120~E
95
3 OUT. SUPPLY +12V DC
LRE300, LRE300T
S65
BN BK 96
11 INP. STEER REFERENCE SWITCH 1
BU
97
12 OUT. SUPPLY OV DC
T-code
21 21
808, 812
Sh. 2 5 6 INP. ENABLE (B+)

130
4/9, Prod B
Wiring diagram
222162
11- 19
11- 20
T-code
808, 812
ELECTRONIC CARD
A5
21 21
Wiring diagram
Sh. 4 901 +48VDC CAP CHARGE
40 40
Sh. 4 6 902 GND
22
Sh. 3 6
U1
943926-
Red Bk 62
Service Manual
129
511 GND FOR TACHO
S228
BN BK 132
110
LRE300, LRE300T
INP. DOOR SWITCH
Date
BU
2007-05-02
S232
BN BK 131
209 INP. STEER REFERENCE SWITCH 2
BU
229289-040
Order number
5/9, Prod B
222162
© BT Europe AB
EMERGENCY MODE
S131
22 1 2
Sh. 5 7 ELECTRONIC CARD
A5
Y1
229289-040
40 64
Sh. 5 7 802 OUT. PARKING BRAKE 1
Order number
© BT Europe AB
Date
Y41
1 2 67
2007-05-02
27
943926-
Service Manual
1
50
2
28
508 OUT. OV DC
LRE300, LRE300T
51
3
2
T-code
808, 812
82
R11 503 INP. FORK LIFT / LOWER
3
6/9, Prod B
Wiring diagram
222162
11- 21
11- 22
T-code
808, 812
Wiring diagram
TRANSISTORPANEL,DRIVE2
A31
325
F2
8 2
Sh. 7 B+ + U DRIVE MOTOR 2
M2
943926-
U
40 3 V M
Sh. 7 9 B- - V
W M
3~A
Service Manual
4
5 W
THERMO ELECTRICAL SENSOR IN M2
19
1
B2
16 118
6 7 Sh. 7
15
11
LRE300, LRE300T
U14
Date
Red Bu 17 119
13 8 Sh. 7
+ B
2007-05-02
Bk Wh 18 120
14 16 Sh. 7
- |R A
22
Sh. 7 9
229289-040
Order number
7/9, Prod B
222162
© BT Europe AB
229289-040
Order number
© BT Europe AB
Date
TRANSISTORPANEL,DRIVE2
A31
2007-05-02
325
F2
8 2
Sh. 7 B+ + U DRIVE MOTOR 2
M2
U
40 3 V M
Sh. 7 9 B- - V
W M
3~A
943926-
Service Manual
4
5 W
THERMO ELECTRICAL SENSOR IN M2
19
1
B2
16 118
6 7 Sh. 7
15
11
LRE300, LRE300T
U14
Red Bu 17 119
13 8 Sh. 7
+ B
Bk Wh 18 120
14 16 Sh. 7
A
T-code
- |R
808, 812
22
Sh. 7 9
8/9, Prod B
Wiring diagram
222162
11- 23
11- 24
T-code
808, 812
Wiring diagram
943926-
OPTION
DC/DC CONVERTER DC/DC CONVERTER
A10
Service Manual
X42
26 26
Sh. 1 6 INP. +48VDC
X42
40 40
Sh. 8 3 INP. GND
X4
140 140
1 OUT. +12VDC
LRE300, LRE300T
X4
141 141
Date
2
2007-05-02
OUT. GND (GALV. SEPARATED)
1 OUT. +12VDC
229289-040
9/9, Prod B
Order number
222162
© BT Europe AB
Wiring diagram
229289-040 2007-05-02 943926- 808, 812
11.3.5 Functional description

The electronic card [A5] controls all the truck’s logical functions. The
power is supplied from the truck’s 48 V battery with its own voltage reg-
ulator. Input signals come from sensors and the operating body, and
output signals are sent to valves, contactors, regulators, etc.
Energising the logic card gives a delay of approximately 4 s while the
traction controller’s capacitors are charged.
11.3.6 Principle of operation

This section provides a basic description of the truck’s main functions in
table form. The truck’s various basic functions are described simply.
• Heading – Indicates the function referred to. The headings are num-
bered.
• Previous event – Indicates which event must have taken place first.
• Action – Describes what the driver must do.
• Influencing factors – Describes electrical components which affect
the action, conditions which must be met and parameter settings.
• Result – Describes what happens when everything works correctly.
Note that “result” in the following tables relates to what is assumed to
occur when there is no error condition.
Event 1 – Battery connected

Previous event -
Action Connect battery [G1] to battery contact [X1].
Influencing factors Battery [G1].
Battery contact[X1].
Main fuses [F1], [F2], [F3].
Working fuses [F60], [F61], [F62], [F63].
Result
Event 2 – Start of truck (with PIN-code)

Previous event 1.
Action Log in with valid PIN code and {green} [A16].
Influencing factors Emergency switch [S21] not activated, [A5:+48VKey] {high}.
Battery [G1] is sufficiently charged.
Result Main contactor [K10] closes.
The green LED lights up.

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
Event 3 – Seat switch activated

Previous event 2.
Action Activate seat switch [S89] in driver’s seat.
Influencing factors Seat switch [S89].
Result Input 203 on electronic card [A5] {high}.
Event 4 - Door switch activated

Previous event 2.
Action Activate door switch S228 by closing the door.
Influencing factors Door switch S228.
Event 5 – Driving in fork direction

Previous event 3.
Action Ensure that the travel direction indicator points in the direction of the
forks. If not, move the travel direction selector [S26] in the direction
of the forks.
Depress the accelerator.
(Alternatively, the travel direction selector can be activated for 1 s
without the accelerator being activated, giving movement at creep
speed. This requires that the parking brake is first released by
pressing the accelerator.)
Influencing factors Travel direction selector [S26].
Accelerator/acceleration potentiometer [R1].
#2 and #11.
Input 501 on electronic card [A5] goes from approximately 3.7 V in
neutral to a minimum of approximately 1.7 V on full acceleration.
Output 802 on electronic card [A5] {high}, brake [Y1] releases.
traction controller [A1] (and [A31]) energises motor [M1] (and [M2]).

Wiring diagram
229289-040 2007-05-02 943926- 808, 812
Event 6 – Driving in drive wheel direction

Previous event 3.
Action Ensure that the travel direction indicator points in the direction of the
drive wheel. If not, move the travel direction selector [S26] in the
direction of the drive wheel.
Depress the accelerator.
(Alternatively, the travel direction selector can be activated for 1 s
without the accelerator being activated, giving movement at creep
speed. This requires that the parking brake is first released by
pressing the accelerator.)
#2 and #11.
Input 501 on electronic card [A5] goes from approximately 3.7 V in
neutral to a minimum of approximately 1.7 V on full acceleration.
Output 802 on electronic card [A5] {high}, brake [Y1] releases.
Traction controller [A1] (and [A31]) energises motor [M1] (and [M2]).
Event 7 – Neutral braking

Previous event 4 or 5.
Action When the truck is in motion, release the accelerator.
Influencing factors Accelerator/acceleration potentiometer [R1].
#4.
Result The drive motor functions as a generator and, via the traction con-
troller [A1], converts the truck’s kinetic energy into electrical energy.
This reduces speed, and the electrical energy is fed to the battery.
Event 8 – Reversing braking

Action When the truck is in motion, move the travel direction selector [S26]
in the opposite direction and depress the accelerator.
#5.
Result The drive motor functions as a generator and, via the traction con-
troller [A1], converts the truck’s kinetic energy into electrical energy.
This reduces speed, and the electrical energy is fed to the battery.
The brake power increases in proportion to the position of the accel-
erator.

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
Event 9 – Mechanical braking

Action Depress the brake pedal.
Influencing factors Brake pedal/brake potentiometer [R3].
Result Input 502 on electronic card [A5] goes from approximately 1.7 V in
neutral to a maximum of approximately 4.1 V on full braking.
The drive motor works as with reversing braking.
With extremely hard braking, the motor brake is reduced and the
brake [Y1] is activated.
Event 10 – Steering
Previous event 2.
Action Turn the steering wheel.
Influencing factors Steering wheel/steering potentiometer [U1].
Steering servo [A81].
Result Steering servo [A81] turns the drive wheel.
Event 11 – Fork lift

Previous event 3.
Action Move the mini lever in the direction of the drive wheel.
Influencing factors Hydraulic potentiometer [R11].
Pump contactor [K30].
Pump motor [M3].
Lift switch [S31] not activated.
Result Hydraulic potentiometer [R11] receives a lower voltage value.
Voltage at input 503 on electronic card [A5] 1.7-3.7 V.
Output 701 on electronic card [A5] {high}.
Pump contactor [K30] closes.
Pump motor [M3] starts.

Wiring diagram
229289-040 2007-05-02 943926- 808, 812
Event 12 – Fork lowering

Previous event 3.
Action Move the mini lever in the direction of the forks.
Influencing factors Hydraulic potentiometer [R11].
Hydraulic valve [Y41].
Result Hydraulic potentiometer [R11] receives a higher voltage value.
Voltage at input 503 on electronic card [A5] 3.7-5.5 V.
Output 710 on electronic card [A5] {high}.
Hydraulic valve [Y41] opens.
11.3.7 Login unit
1 5
6 9
8
Fig. 1 Front (left) and back (right) of login unit [A16]
Pin number Function

X3:1 Relay in
X3:2 Battery +
X3:3 CAN L
X3:4 CAN H
X3:5 Coding pin 1
X3:6 Relay out
X3:7 Battery -
X3:8 Not used
X3:9 Coding pin 2

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
Table 7: Login unit symbols

Symbol Function
LED shows when truck is activated or stopped.
Numerical buttons for logging in and program-

ming.
Logging out – red button mentioned {red}.
Logging in – green button mentioned {green}.
Login unit [A16] contains a total of 100 preset login codes, divided into
10 blocks numbered 0-9. Within each block there are 10 codes, where
each code corresponds to a driver profile 0-9.
On delivery of the truck, block 0 is activated and login for driver profile 1
is obtained by pressing 1 followed by {green}. The same applies to driv-
er profiles 2 and 3, which are also pre-programmed.
The leading zeros in the PIN code do not need to be included.
Approved login lights a green LED, while incorrect login lights a red
LED.

Wiring diagram
229289-040 2007-05-02 943926- 808, 812
Different login functions

Four different login functions can be set up for the login unit. This is
done by connecting connections X3:5 and X3:9 to minus in different
ways.
• Function 0
- Connection 1 and 2 (X3:5, X3:9) not connected to minus.
- Parameter 39 is set to 3 or 4.
- Login unit driver codes are used.
- Login with correct PIN code (1-4 digits + {green}).
- The driver profiles on the A5 card are used.
- If a CAN service key is used, no driver code is required.
- Log out with {red}.
• Function 1
- Connection 1 (X3:5) connected to minus.
- Parameter 39 is set to 1 or 2, only with key (key = option).
- Login unit driver codes are used.
- Driver profile 1 on the A5 card is used.
- No CAN communication with [A5].
• Function 2
- Connection 2 (X3:9) connected to minus.
- Parameter 39 is set to 3 or 4.
- Driver codes in the login unit are not used but are verified in the
TLS (TLS = option). The TLS sends a signal back approving the
driver.
- If a CAN service key is used, no driver code is required.
- The driver profiles on the A5 card are used.
• Function 3
- Connections 1 and 2 (X3:5, X3:9) connected to minus.
- Test function for relay.
Enter code 1234567890 + {green} to close the relay in the login
unit.
- Open the relay using {red}.

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
Programming
• LED status
- During login
Function Green LED Red LED

Buttons 0-9 are used Lights up when button is
pushed
Logout Lights up ~0.8 s
Relay in the keyboard is closed Lights up and remains on
Incorrect driver code entered Lights up ~0.8 s
- During programming
Function Green LED Red LED

Login unit in programming mode Lights up for ~0.8 s and then
flashes at two second inter-
vals
Buttons 0-9 are used Lights up when button is
pushed
Correct value entered Lights up ~0.8 s
Incorrect value entered Lights up ~0.8 s

Wiring diagram
229289-040 2007-05-02 943926- 808, 812
Driver codes
The table shows the driver 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 applies
for all blocks in the same column and is programmed as per driver
parameters 1-5.
Profile: 0 1 2 3 4 5 6 7 8 9
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
To access programming mode:

• Connect service key
• Enter 341671 and push {green}.
Programming Function Notes

1 + green button Reset to factory settings
2 + block no. + green button The driver parameters in
the block can be used
3 + block no. + green button The driver parameters in
the block cannot be used
4 + block no. + profile no. + NNNN + green Programming of new NNNN = Driver code
button driver code
5 + TT + green button Programming of stop TT = 01-20 in minutes.
time for the truck, after 00 = 4 hours
last use Standard = 20 minutes

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
11.3.8 Service key CAN

Communication between electronic card [A5], traction controllers [A1]
and [A31], steering servo [A81] and login unit [A16] takes place via
CAN (Controller Area Network). The communication pins CANH and
CANL can cope with voltages between -3 and +60 V.
The service key, which also communicates via CAN, is connected to
contact [X41]. When the service key is connected, you need only press
{green} to start the truck.
11.3.9 Display
Fig. 2 CAN contact [X41]
5 1 2 11
4
3
7 8 9 10
The display provides the following information in normal mode:
• Clock (1) – shows the current time.
• Hour counter (2) – shows the time (in hours) for which the truck has
been active. Settings are carried out with #20. The counter can show
the time for:
- a. Logged in.
- b. Drive motor, hydraulic motor, steering or fork lowering active.
- c. Drive motor active.
- d. Hydraulic motor active.
- S. Service counter. (Counts in the same way as hour counter b,
but the time is counted down from a starting value which is set us-
ing #25 (service interval). The time counts down to 0 hours and
continues to a minimum of -999 hours. A negative service time
gives a warning code. The service counter is restarted by chang-
ing the status of #25 and then confirming the selection.
• Battery status (3) – Shows in 10 stages how much charge remains in
the battery.
• Wheel angle (4) – Shows in 30° stages the direction in which the
drive wheel is pointing.
• Indicators – Shows which type of information is changed when set-
tings are made.
- Travel direction indicator (5). Shows the direction in which the
truck is going. When the drive wheel passes 6 o’clock and 12
o’clock, the indicator changes direction.

Wiring diagram
229289-040 2007-05-02 943926- 808, 812
- Parking brake (6). Lit when parking brake is activated.

- Error code (7). Lit when error codes are shown.
- Weight on the forks (8). Not used.
- Parameter (9). Lit when parameter mode is active.
- Hour meter (10). Lit when hour meter selection is shown.
• Selected driver (11) – Shows which driver profile is active.
If an error occurs, an error code is shown in the numerical field.
Settings
In order to access the settings menu, hold the travel direction selector
in the direction of the forks whilst starting the truck. (If the service key is
connected, you need only press {green}.)
As long as the travel direction selector is held down, the settings menu
scrolls through the various options. In order to make a selection,
release the travel direction selector. Change values with the lift/lower
lever and press the travel direction selector to confirm. Restart the truck
when the settings are ready.
NOTE:
A simpler alternative for truck settings is to use TruckCom.
The settings menu contains the following:
• Cl – Clock.
- Show hours.
- Show minutes.
• P – Parameters For settings see “11.4 Parameters” on page 37.
• Pn – Software part number. Due to the length of the part number, it is
shown in two parts.
• H – Hour meter.
• E – Error codes. For display see “11.5.2 Error history” on page 43.
11.3.10 Steering system

The steering works by the steering wheel powering a generator [U1],
the output voltage of which depends on the steering wheel speed, and
the polarity of which depends on the direction of rotation. The signal is
then processed by the electronic card [A5] in order for sufficient amplifi-
cation to be achieved. When the truck is operated at low speed the
steering gearing is higher than at high speeds. The signal is then sent,
via the CAN bus, to the control unit [A81] which regulates the steering
servo motor.
Wheel angle indicator

In order to determine the direction of the steering wheel, the steering
servo has built-in sensors [A81].

Wiring diagram
808, 812 943926- 2007-05-02 229289-040
11.3.11 Brake system

The truck employs various braking methods:
• Automatic braking when the accelerator is released.
• Reversing with the travel direction selector.
• Foot pedal braking.
The truck also has a parking brake, which is activated when the truck
stands still, or when the seat switch [S89] is inactive.

Parameters
229289-040 2007-05-02 943926- 808, 812
11.4 Parameters
11.4.1 General
The truck’s control system can store various different parameters:
These are used to configure the truck according to the task. The param-
eters are split into two groups:
• Driver parameters – The driver parameters (1-5) are used to adapt
the truck’s characteristics to a specific driver or task. Up to ten driver
parameters can be stored. Driver parameters are shown and
changed only for selected drivers, but if the service key is connect-
ed, all drivers’ parameters can be shown and changed.
• Service parameters – The service parameters (11 - 42) are used to
adapt the truck’s performance/characteristics and cover all other pa-
rameters not defined as driver parameters. The service parameters
can ONLY be changed when a suitable CAN service key is connect-
ed to the truck.
11.4.2 Showing/changing parameters

In order to access the parameters, hold the travel direction selector in
the direction of the forks whilst starting the truck. (If the service key is
connected, you need only press {green}.) As long as the travel direction
selector is held down, the settings menu scrolls through the various
options. Release the travel direction selector when P (Parameter
mode) is displayed.
Use the lift/lower lever to step up and down through the parameter list.
Stepping up gives driver parameters for driver 1, then driver 2, etc. After
passing driver 0, the service parameters are reached.
To change a parameter, press the travel direction selector to change
the selected parameter. When the parameter is in change mode, the
parameter number flashes which means that the parameter can be
changed using the lift/lower lever. The parameter value is saved by
moving the travel direction selector in line with the direction of the forks.

Parameters
808, 812 943926- 2007-05-02 229289-040
11.4.3 Driver parameter overview
Table 8: Driver parameters

No. Name Min. Max. Step Std. Unit Notes
1 Steering sensitiv- 1 6 1 3 1 = several steering wheel turns.
ity 5 = few steering wheel turns.
6 = no progression.
2 Speed 10 100 5 100 %
3 Acceleration 10 100 5 100 %
4 Automatic braking 20 100 5 50 % 0 = no automatic braking.
5 Reversing 35 100 5 80 %
11.4.4 Driver parameter description

#1 – Steering sensitivity
Regulates the truck’s steering wheel movement. A higher value means
that fewer turns of the steering wheel are required for a certain steering
movement. If the parameter is set to 6, the steering works without pro-
gression, i.e. it does not become less sensitive at high speed.
#2 – Speed
Regulates the truck’s maximum driving speed.
#3 – Acceleration
Regulates the truck’s maximum acceleration. A lower value means that
it takes longer to reach the desired speed.
#4 – Automatic braking
Automatic braking works by controlling the speed of the AC motors. If
the accelerator is released when the truck is at high speed, full braking
is obtained. If the accelerator is partly released, reduced braking is
obtained. When the truck is operated at low speed, the braking is
always reduced.
The parameter regulates the braking power where a lower value means
longer braking distance. If the value is set to 0, the automatic braking is
fully disconnected.
#5 – Reversing
Reversing braking is achieved when the truck is in motion, the direction
selector is activated in the opposite direction and the accelerator is
depressed. The braking works by controlling the speed of the AC
motors and the strength is regulated by the position of the accelerator.
The parameter regulates the braking power where a lower value means
longer braking distance.

Parameters
229289-040 2007-05-02 943926- 808, 812
11.4.5 Service parameter overview
Table 9: Service parameters

No. Name Min. Max. Step Std. Unit Notes
20 Hour meter 1 5 1 2
21 Battery 1 20 1 9 Battery size/type setting. See the
comments below.
22 Type of truck 1 2 1 2 Selection of truck type
1 = one drive motor
2 = two drive motors
24 Door switch 0 1 1 0 Door switch:
0 = not installed
1 = installed
25 Service inter- 0 2,000 50 0 h 0 = no service counter.
val 50 = 50 hours
100 = 100 hours
etc.
Selecting change position and con-
firming restarts the service counter.
28 Output 208 0 4 1 0 0 = hydraulics.
1 = driving.
2 = driving in drive wheel direction.
3 = driving in fork direction.
4 = buzzer for shock sensor.
30 I/O unit 0 2 1 0 0 = no I/O unit.
1 = output 1 hydraulics, output 2
drive motor.
2 = output 1 driving in drive wheel
direction, output 2 driving in fork
direction.
38 Calibration 0 1 1 0 Calibration mode. Calibration
occurs on next start-up. The value
returns to 0.
39 Driver param- 3 4 1 3 1 = ignition open (option).
eter access 2 = ignition locked (option).
3 = open.
4 = locked.
40 Year 0 99 1 0 Date – year.
41 Day 0 31 1 0 Date – day.
42 Month 0 12 1 0 Date – month.

Parameters
808, 812 943926- 2007-05-02 229289-040
11.4.6 Service parameters description

#20 – Hour meter
Controls the time shown by the hour meter.
1: Shows the time someone has been logged in. The display shows (A.).
2: Shows the time the drive motor, hydraulic motor, steering or fork low-
ering has been active. The display shows (b.).
3: Shows the time the drive motor has been active. The display shows (c.).
4: Shows the time the hydraulic motor has been active. The display
shows (d.).
5: Shows the service counter. The display shows (S.).
#21 - Battery
Indicates the size and type of the battery in use. A higher value will
cause deeper battery discharging.
Model Battery type Capacity Weight #21

LRE300 Valve-regulated gel battery 644 Ah 1280 8
Freely ventilated battery 840 Ah/864 Ah 1320 kg/ 9
1280 kg
LRE300T Double valve-regulated gel battery 2x469 Ah 1840 6
1280 kg
AGM Champion 1000 Ah 8
WARNING!
If the parameter is set too high, the battery discharge could become
excessive and cause damage to the battery.
#22 – Type of truck

The parameter is set according to the type of truck.
1 = truck with one drive motor
2 = truck with two drive motors
#24 – Door switch

Describes if a door switch is installed on the truck.
0 = not installed
1 = installed
If the parameter is set to 1, the accelerator is set to 0 after 2 seconds if
the door is opened.

Parameters
229289-040 2007-05-02 943926- 808, 812
#25 – Service interval

Regulates the time (in hours) between services from 50 to 2,000 hours
in 50-hour intervals. When resetting the value, the hour counter is set to
zero and starts to count the truck activity time (drive motor, hydraulic
motor, steering or fork lowering active). The time counts down to 0
hours and continues to a minimum of -999 hours. A negative service
time gives a warning code on the display.
If the value is set at 0, the service counter is turned off.
#28 – Output 208

Selects function on output 208.
0: Hydraulics activated.
1: Driving function activated.
2: Driving direction of travel activated.
3: Driving direction of forks activated.
4: Additional warning sound if Shock Lockout activated. This means it is
possible to connect a buzzer which sounds when the shock sensor
gives a reading.
#30 – I/O unit

Regulates function of I/O unit (option).
0: No I/O unit connected.
1: Hydraulics activated to output 1 and driving function activated to
output 2.
2: Driving direction of travel activated to output 1 and driving direction
of forks activated to output 2.
#38 – Calibration
Calibration of accelerator and brake pedal neutral position. When the
value is set to 1, the truck will be in calibration mode on the next start-
up and the value returns to 0. Be careful not to move the pedals when
the truck is started.
#39 – Driver parameter access

Defines whether the driver has access to parameter settings.
3: Driver parameters accessible (without CAN key).
4: Driver parameters not accessible (without CAN key).
#40 – Year
Specifies the date’s year as used in the error code log.

Parameters
808, 812 943926- 2007-05-02 229289-040
#41 – Day
Specifies the date’s day as used in the error code log.
#42 – Month
Specifies the date’s month as used in the error code log.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812
11.5 Troubleshooting
11.5.1 General
The truck has a built-in control system for error management. This
means that when an error arises in the truck, an error code is shown on
the display. Error codes 0-99 give a 2 Hz warning signal, and the other
error codes give a 4 Hz warning signal.
The error codes are split into two groups:
• Warnings – Error codes 0-99 are shown with the letter “C”.
• Errors – Error codes 100 upwards are shown with the letter “E”.
11.5.2 Error history

The last 50 errors are stored in an error log together with the date and
time when the error occurred. However, no warning codes are stored in
the error code log, only error codes (numbers 50 upwards). Initially, the
log is supplied with number 255, which means “no error”.
In order to access the error codes, hold the travel direction selector in
the direction of the forks whilst starting the truck. (If the service key is
connected, you need only press {green}.) As long as the travel direction
selector is held down, the settings menu scrolls through the various
options. Release the travel direction selector when E (Error mode) is
displayed.
The latest error code is shown in the numerical field of the display. The
first figure shows the order number (1-50) where 1 is the latest error.
The lift/lower lever is used to scroll between the error codes and the
travel direction indicator is used to show the date when the error
occurred (yy.mm.dd and hh.mm).
11.5.3 Error codes
Table 10: Error codes

Code Description Possible cause
Event Action
C003 Shock Lockout from TLS. The driver has driven into something.
The truck’s speed is signifi- Reset the error using special login code.
cantly reduced.
C004 Out of use from TLS. Stop code.
The truck’s speed is signifi- Reset the error using special login code.
cantly reduced.

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
C005 No communication with the 1. CAN cable or CAN connection defective.
I/O unit. 2. Incorrect parameter setting.
3. Defective I/O unit.
I/O unit not working. 1. Check contacts and wiring. Replace the CAN cable if
necessary.
2. Check parameter setting. See “ #30 – I/O unit” on
page 41.
3. Replace I/O unit.
C014 Seat switch active despite Seat switch [S89] strapped or defective.
no truck function for 20 min-
utes.
Check that the switch [S89] and its wiring are working cor-
rectly. Replace the switch or wiring if necessary.
22
809 +48VDC SUPPLY OUTPUTS
ELECTRONIC CARD A5
49
S89
C016 Accelerator neutral position 1. Accelerator depressed or dislodged from position on

incorrect on login. start-up.
2. Calibration error.
3. Potentiometer [R1] not working.
1. Check that the accelerator is not stuck in the depressed
position.
2. Recalibrate. See “ #38 – Calibration” on page 41.
3. Check that [R1] is correctly connected. Voltage may not
deviate by more than 0.2 V from calibrated level.
27
50 ELECTRONIC CARD A5
28
508 OUT. 0 VDC

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
C017 Brake pedal zero position 1. Brake pedal depressed or dislodged from position on
incorrect on login. start-up.
2. Calibration error.
3. Potentiometer [R3] not working.
1. Check that the brake pedal is not stuck in the depressed
position.
2. Recalibrate. See “ #38 – Calibration” on page 41.
deviate by more than 0.2 V from calibrated level.
27
28
508 OUT. 0 VDC
C018 Clock circuit battery has low Clock battery flat.

voltage level.
The truck’s internal clock No action. The electronic card still works. The alternative is
stops. to change the electronic card [A5].
C019 Basic parameter warning. The machine’s parameter values have been lost.
The truck parameter normal Check all parameter settings.
values are loaded.
C021 Lifting/lowering zero posi- 1. Activated lifting/lowering controls at start-up.
tion incorrect on login. 2. Lifting/lowering potentiometer [R11] not working.
1. Check that lifting/lowering controls have not become
stuck in the activated position.
deviate by more than 0.4 V from calibrated level. (Calibra-
tion occurs each time the truck is started.)
27
R11 503 INP. FORK LIFT/LOWER
28
508 OUT. 0 VDC
C025 Error at the output stage. See C050-C052 for more information.

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
C026 Error at the input stage. See C090-C094 for more information.
C027 Voltage measurement con- 1. No voltage to the battery indicator.

nection to truck battery pro- 2. Poor contact on battery measurement cables.
vides no contact. 3. Battery [G1] voltage too low.
Battery status symbol is 1. Check voltage measurement (+48 VDC) to the battery
flashing. indicator.
2. Check that the cables and their contacts are intact and
provide good contact from the shunt.
3. Check that battery [G1] provides full voltage (+48 VDC).
Recharge the battery or replace if necessary.
X1
MEASURING
+
G1 WIRES70
-
601 INP. BATT. INDI. +

X1 71
602 INP. BATT. INDI. -, CURRENT -(-)
SHUNT 72 ELECTRONIC CARD A5
WIRE 603 INP. BATT. INDI. CURRENT -(+)
40
902 GND
C028 Emergency switch acti- 1. Emergency switch [S21] activated.

vated. 2. Defective switch/wiring [S21].
3. Defective electronic card [A5].
The truck stops. 1. Check that emergency switch [S21] is shut off. Otherwise
turn the switch off and restart the truck.
2. Check that emergency switch [S21] and wiring are intact.
Otherwise replace with a new one.
3. Replace electronic card [A5].
EMERGENCY
SWITCH OFF
24 S21 22
X3:6 809 +48VDC SUPPLY OUTPUTS
ELECTRONIC ELECTRONIC
CARD, 24 CARD A5
807 INP. KEY RELAY
KEYPAD A16
C029 Service counter shows time Time for service.

for service.
Resetting #25 after service. See “ #25 – Service interval” on
page 41.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
C035 Temperature warning steer- The temperature of the steering servo is greater than
ing servo. +68°C.
Check that the steering is not jamming in bearings and gear
wheel. Also check that the ventilation is OK.
C040 Warning temperature drive 1. Drive motor [M1] is overheated.
motor 1. 2. Temperature sensor [B1] or its wiring is defective. Indica-
tion is immediate when starting the truck.
Current is reduced linearly 1. Check that nothing is jamming mechanically and that the
to 0 A when the tempera- ventilation is OK.
ture goes from 145 °C to 2. Check the contacts and wiring. Replace if necessary.
165 °C.
B1 X26 14
1
TRANSISTOR PANEL, DRIVE 1

11 A1
6
C041 Warning temperature trac- 1. Cooling fan or traction controller capacitance [A1] is over-
tion controller 1. heated.
2. Cooling fan temperature sensor is defective.
Current is reduced linearly 1. Check that the ventilation is OK.
to 0 A when the tempera- 2. Replace traction controller [A1].
ture goes from 85 °C to 125
°C.
C042 Current calibration error Traction controller [A1] defective.
traction controller 1.
Replace traction controller [A1].
C043 Speed sensor not con- 1. Contacts or wiring defective.
nected to traction controller 2. Speed sensor [U11] defective.
1.
The truck stops but can be 1. Check the contacts and wiring. Replace if necessary.
driven slowly in short 2. Change speed sensor [U11].
bursts.
11
6
10
11
12 TRANSISTOR PANEL, DRIVE 1
Red Bu
13 A1
Bk + B Wh 13
- A 14
U11

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
C045 Warning temperature drive 1. Drive motor [M2] is overheated.
motor 2. 2. Temperature sensor [B2] or its wiring is defective. Indica-
tion is immediate when starting the truck.
to 0 A when the tempera- 2. Check the contacts and wiring. Replace if necessary.
ture goes from 145°C to
165°C.
B2 19
1
TRANSISTOR PANEL, DRIVE 2

16 A31
6
C046 Warning temperature trac- 1. Cooling fan or traction controller capacitance [A31] is
tion controller 2. overheated.
2. Cooling fan temperature sensor is defective.
to 0 A when the tempera- 2. Replace traction controller [A31].
ture goes from 85 °C to 125
°C.
C047 Current calibration error Traction controller [A31] defective.
traction controller 2.
Replace traction controller [A31].
C048 Speed sensor not con- 1. Contacts or wiring defective.
nected to traction controller 2. Speed sensor [U14] defective.
2.
The truck stops but can be 1. Check the contacts and wiring. Replace if necessary.
driven slowly in short 2. Change speed sensor [U14].
bursts.
11
6
10
11
12 TRANSISTOR PANEL, DRIVE 2
Red Bu
13 A31
+ B 13
Bk Wh
- A 14
U14

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
C050 Error in output to lowering 1. Contacts or wiring defective.
valve. 2. Valve [Y41] or electronic card [A5] defective.
The forks cannot be low- 1. Check the contacts and wiring. Replace if necessary.
ered. 2. Replace valve [Y41] or electronic card [A5].
67
Y41
ELECTRONIC CARD A5
40
902 GND
C052 Error in output to pump 1. Contacts or wiring defective.

motor. 2. Electronic card [A5] defective.
The forks cannot be raised. 1. Check the contacts and wiring. Replace if necessary.
PUMP CONTACTOR
K30
48
PUMP 701 OUT. PUMP CONTACTOR
MOTOR 130A 10A
M3 F3 F62
A2 A1
M
40 808 INP. MAIN CONTACTOR
902 GND
K10
C080 Steering servo – reference The current from the reference sensor [S65] is less than
sensor not connected. 100 µA.
1. Interruption in current feed to sensor.
2. Reference sensor [S65] defective internally.
3. Reference sensor [S65] mechanically crushed by cam
profile or dirt on the gear ring.
The symbols for direction of 1. Check that there is voltage to the reference sensor [S65].
travel and wheel angle can The voltage should nominally be 12 V and may not be less
show incorrect information. than 10 V. Also, check that the truck is logged on so that the
steering servo [A81] is activated.
2. Check wiring and resistance to reference sensor [S65].
3. Dismantle the sensor and check that it is intact. Replace
if necessary.

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
C081 Steering servo – 12 V error. 1. Steering servo [A81] is receiving incorrect input voltage.
2. Steering servo [A81] defective.
1. Check that pin 3 gives an output voltage of 9.8-13.5 V. If
not, check that the input voltage (between pins 7 and 8) is
48 V.
2. Replace steering servo [A81].
F61 100
119 (8/16) +48VDC
(2) CAN HIGH
120
21
(10) CAN LOW A81 M
(6) ENABLE(B+)
S65
96 97
(11) STEER ANGLE0VDC 95
40
(7/15) 0VDC +12VDC (3)
C082 Steering servo – high power Power consumption has been too high for 80% of the per-
consumption. mitted time.
1. The truck stands still on high-friction surfaces, and the
drive wheel rotates rapidly.
2. Steering is jamming.
1. Repeat the steering activity. Drive the truck forwards/
backwards a little while steering.
2. Check that the steering is not jamming in bearings and
gear wheels. The wheel should be able to be turned by
hand on a raised and switched off machine.
C090 Error in lifting potentiome- 1. Contacts or wiring defective.
ter. 2. Potentiometer [R11] defective.
The forks cannot be raised 1. Check the contacts and wiring. Replace if necessary.
or lowered. 2. Check potentiometer [R11]. The voltage should be
between 0.3 and 7.0 V. Replace potentiometer if necessary.
27
R11 503 INP. FORK LIFT/LOWER
28
508 OUT. 0 VDC

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
C094 Error in speed potentiome- 1. Contacts or wiring defective.
ter. 2. Speed potentiometer [R1] defective.
The accelerator does not 1. Check the contacts and wiring. Replace if necessary.
work. 2. Check potentiometer [R1]. The voltage should be
between 0.4 and 4.6 V. Replace potentiometer if necessary.
27
28
508 OUT. 0 VDC
E104 Error in output to brake 1. Error in wiring to and from brake [Y1].
2. Electronic card [A5] or brake [Y1] defective.
The truck stops. When 1. Check wiring and replace if necessary.
restarting, the truck is in 2. Check voltage on output 802. Replace electronic card
emergency driving mode. [A5] or brake [Y1] if necessary.
S131 22
809 +48VDC SUPPLY OUTPUTS
Y1
802 OUT. PARKING BRAKE
40
902 GND
E106 Error in output to main con- 1. Error in wiring to and from main contactor [K10].
tactor. 2. Electronic card [A5] or main contactor [K10] defective.
The truck stops. When 1. Check wiring and replace if necessary.
restarting, the truck is in 2. Check voltage on output 804. Replace electronic card
emergency driving mode. [A5] or main contactor [K10] if necessary.
40
902 GND
X1
MAIN
-
G1
CONT. ELECTRONIC CARD A5
+
K10 31
X1 A1 A2 10A 804 OUT. MAIN CONTACTOR
F62 23
1 2

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
E107 Main contactor not closed 1. Problem with contactor points or wiring.
(on login). 2. Fuse [F62] defective.
3. Contactor output from electronic card [A5] sends incor-
rect signal.
The truck stops. When 1. Check contactor [K10] and its cabling. Replace if neces-
restarting, the truck is in sary.
emergency driving mode. 2. Check if fuse [F62] is defective. Replace if necessary.
3. Restart the truck and check that output 804 is {low}
before login. If not, replace electronic card [A5].
K10 31
A1 A2
10A
F62 23 ELECTRONIC CARD A5
- +
X1 G1 X1
40
902 GND
E108 Main contactor does not 1. Problem with contactor points or wiring.
open (on logout). 2. Fuse [F62] defective.
3. Contactor output from electronic card [A5] sends incor-
rect signal.
The truck stops. When 1. Check contactor [K10] and its cabling. Replace if neces-
restarting, the truck is in sary.
emergency driving mode. 2. Check if fuse [F62] is defective. Replace if necessary.
3. Check that output 804 goes {low} on logout. If not, dis-
connect battery [G1] briefly and restart the truck. If this does
not help, replace the electronic card [A5].
K10 31
A1 A2
10A
F62 23 ELECTRONIC CARD A5
- +
X1 G1 X1
40
902 GND

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
E109 Login unit – relay short- Electronic card [A5] has no data communication with login
circuited. unit [A16].
1. The login unit is operated in function 1.
2. #39 entered incorrectly.
3. Login unit [A16] relay short-circuited.
The truck is in emergency 1. Check that the login unit’s connections are correctly con-
driving mode. nected. See “11.3.7 Login unit” on page 29.
2. Make sure #39 is set correctly. (1 and 2 valid only with
key.)
3. If electronic card [A5] still has voltage after logout,
replace login unit [A16].
E111 Problem with brake pedal. 1. Contacts or wiring defective.
2. Brake pedal potentiometer [R3] gives incorrect value.
The truck stops. 1. Check that contacts and wiring are intact. Replace if nec-
essary.
2. Check that the voltage at input 502 is 0.4-4.6 V, and that
the voltage across potentiometer [R3] is around 7-7.5 V.
Replace potentiometer [R3] if necessary.
27
28
508 OUT. 0 VDC
E112 Error during brake input Internal error in electronic card [A5].
test.
The truck stops. Replace electronic card [A5].
E113 Steering servo – general An unidentified error has arisen in steering servo [A81].
error. 1. Interference in electronics or processor.
The truck stops. When 1. Restart the truck. If the error persists, check the connec-
restarting, the truck is in tor. If necessary, loosen the connector and blow clean. If
emergency driving mode. the error persists, replace steering servo [A81] and note
how the truck was behaving before the error arose.
E114 Steering servo – phase A phase to the steering servo motor [A81] is missing.
error. 1. Interference due to extremely uneven floor or other exter-
nal influence on the steering.
2. Poor contact between motor cable and electronics.
The truck stops. When 1. Restart the truck and try again.
restarting, the truck is in 2. Open the electronics module and check the three motor
emergency driving mode. connections in the steering motor [A81].

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
E115 Steering servo – initiation 1. Incorrect parameter settings.
error. 2. Internal logic error.
The truck stops. When 1. Check parameter settings.
restarting, the truck is in 2. Disconnect battery [G1] briefly and restart the truck.
emergency driving mode. Replace steering servo [A81] if necessary.
E116 Steering servo – check sum Incorrect check sum to entire memory. Can occur when
error. new software has been loaded into the truck.
The truck stops. When Disconnect battery [G1] briefly and restart the truck.
restarting, the truck is in
emergency driving mode.
E117 Steering servo – CAN time Steering servo [A81] does not transmit message on the
out. CAN bus.
The truck stops. When Check the CAN connections on steering servo [A81], espe-
restarting, the truck is in cially cables 119 and 120. Check carefully that the pin is
emergency driving mode. properly attached. If necessary, remove the connector and
blow clean. Reconnect and try to start the truck again.
117
A5
401 OUT. CAN +15 VDC
118
A81 119 119
402 OUT. CAN GND
INP. CAN HIGH 2 120 403 OUT./INP. CAN H
120
INP. CAN LOW 10 404 OUT./INP. CAN L
6 ENABLE(B+)
21 R101
120 OHM R100
120 OHM
120
117
118
119
E118 Steering servo – hall sensor 1. Poor contact in wiring to hall sensors.
error. 2. Steering servo [A81] defective.
The truck stops. When 1. Check cabling.
restarting, the truck is in 2. Replace steering servo [A81].
E119 Steering servo – voltage Voltage to steering servo [A81] is greater than 70 V.
error. 1. Error in voltage source (battery [G1]) if the error arises
when starting the truck.
2. High voltages are generated by the driving or lift function
if the error arises when driving the truck.
The truck stops. When 1. Check that the battery [G1] is of the right type, and meas-
restarting, the truck is in ure its voltage.
emergency driving mode. 2. Check the voltage level to steering servo [A81] between
pins 7 and 8 in the connector when the error is generated.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
E120 Steering servo – short-cir- The current in the steering servo’s drive stage is greater
cuit. than 95 A.
1. Error in connections.
The truck stops. When 1. Check the contacts and wiring.
restarting, the truck is in 2. Check that the steering is not jamming mechanically.
emergency driving mode. 3. Restart the truck. If the fault persists, replace steering
servo [A81].
E121 Steering servo – power Check if the steering servo power supply [A81] is outside
supply error. the permitted range.
1. At start-up, an external force affects the steering.
2. Internal error in steering servo [A81] power supply.
The truck stops. When 1. Check that nothing is trying to turn the steering mechani-
restarting, the truck is in cally. Try releasing the drive wheel from the ground and
emergency driving mode. starting the truck.
2. Disconnect battery [G1] briefly and restart the truck. If the
fault persists, replace steering servo [A81].
E122 Steering servo – tempera- The temperature in the steering servo [A81] is less than –40
ture error. °C or greater than +85 °C.
1. High ambient temperature.
3. Defective wiring.
The truck stops. When 1. Check the ventilation.
restarting, the truck is in 2. Check that the steering is not jamming mechanically.
emergency driving mode. 3. Check the contacts and wiring. Replace if necessary.
E124 Steering servo – under-volt- Voltage to steering servo [A81] power connection is less
age. than 24 V.
The truck stops. When Check that the battery [G1] holds correct voltage. Check
restarting, the truck is in the contacts and wiring. If the error arises during driving,
emergency driving mode. check the voltage level to steering servo [A81] between
pins 7 and 8 in the connector when the error is generated.

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
E125 Error in steering generator 1. Contacts or wiring defective.
or its connections. 2. Steering generator [U1] defective.
The truck stops. When 1. Check the contacts and wiring. Replace if necessary.
restarting, the truck is in 2. Check the steering generator [U1]. Replace if necessary.
U1 62
Red Bk
ELECTRONIC CARD A5
129
511 GND FOR TACHO
E126 Steering servo – high power 1. If the error arises after warning C082 has been dis-
consumption. played, the steering servo [A81] may be over strained.
2. If the error arises after warning C082 has been dis-
played, something may be jamming the steering.
3. If the error arises after warning C082 has been dis-
played, it may mean that the steering servo is oscillating or
being affected by external mechanical stresses.
The truck stops. When 1. Switch off the truck and wait at least 30 s for the error to
restarting, the truck is in disappear. Restart the truck and repeat the steering activity.
emergency driving mode. Drive the truck forwards/backwards a little while steering.
2. Check that the steering is not jamming in bearings and
gear wheels. The wheel should be able to be turned by
hand on a raised and switched off machine.
3. Switch off the truck and wait at least 30 s for the error to
disappear. Restart the truck. Check the floor where the fault
arose. If the steering oscillates, replace steering servo
[A81].
E127 Steering servo – check Message via CAN incorrect. Can arise when loading new
sum. software.
The truck stops. When Disconnect battery [G1] briefly and restart the truck.
E130 Communications error with Electronic card [A5] dislodged or defective.
I/O processor (option).
The truck stops. When Restart the truck. Replace electronic card [A5] if necessary.
E136- Error in main safety relay. Error in electronic card [A5] relay.
E137 The truck stops. Restart the truck. Replace electronic card [A5] if necessary.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
E140 Incorrect check sum in soft- 1. Electronic card [A5] dislodged.
ware memory or parameter 2. Electronic card [A5] defective.
memory on start-up.
The truck stops. When 1. Restart the truck. Change a parameter and restart. If this
restarting, the truck is in does not help, download new software.
emergency driving mode. 2. Replace electronic card [A5].
E141 Software error. 1. Software defective.
2. Electronic card [A5] defective.
1. Download new software.
2. Replace electronic card [A5] if necessary.

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
E150 CAN – No communication 1. No voltage feed to traction controller.
with traction controllers on 2. CAN wiring defective.
start-up. 3. 15 V not present.
4. Defective traction controller.
5. Defective electronic card.
The truck stops. 1. Check that the traction controllers’ green lamp is flash-
ing. If not, check the current feed to the traction controllers.
2. Check that the wiring is intact and not short-circuited.
Also check resistors [R100] and [R101] by measuring the
resistance between cables 119 and 120 in the service con-
nector. (Take care to disconnect battery [G1] first.) The
resistance should be around 60 Ohm. Otherwise, a resistor
is defective.
3. Check that output 402 on the electronic card [A5] pro-
vides +15 V.
4. Start the truck in parameter mode and try to connect with
TruckCom. If this works, check if any traction controller can-
not be communicated with. If so, replace.
117
A5
A1 118 118
7 119 402 OUT. CAN GND
119
8 120 403 OUT./INP. CAN H
120
16 404 OUT./INP. CAN L
R101
A31 8 118
120 OHM
7 119 119
A81
15 120 2 INP. CAN HIGH
120
16 10 INP. CAN LOW
A16 119
CAN H X3:4 R100
120
CAN L X3:3 120 OHM
120
117
118
119
E151 CAN – No communication See E150.

with traction controller 1 on
start-up.
The truck stops. See E150.
with traction controller 1
during operation.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
with traction controller 2 on
start-up.
with traction controller 2
during operation.
E155- CAN – Internal CAN error. 1. Dislodged electronic card.
E163 2. CAN unit incorrectly connected.
3. CAN wiring defective.
The truck stops. 1. Restart the truck to reset any interference.
2. Check that the CAN bus is connected correctly to all
units.
is defective.
117
A5
A1 118 118
7 119 402 OUT. CAN GND
119
8 120 403 OUT./INP. CAN H
120
16 404 OUT./INP. CAN L
R101
A31 8 118
120 OHM
7 119 119
A81
15 120 2 INP. CAN HIGH
120
16 10 INP. CAN LOW
A16 119
CAN H X3:4 R100
120
CAN L X3:3 120 OHM
120
117
118
119

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
E164 No communication with 1. No voltage feed to steering servo [A81].
steering servo on start-up. 2. CAN wiring defective.
4. Electronic card [A5] defective.
The truck stops. 1. Check the voltage level to steering servo [A81] between
pins 7 and 8 in the connector. Also check that pin 6 has
voltage (48 V).
is defective.
3. Start the truck in parameter mode and try to connect with
TruckCom. If this does not work, check that the steering
servo [A81] can be communicated with. If not, replace.
117
A5
118
A81 119 119
402 OUT. CAN GND
INP. CAN HIGH 2 120 403 OUT./INP. CAN H
120
INP. CAN LOW 10 404 OUT./INP. CAN L
6 ENABLE(B+)
21 R101
120 OHM R100
120 OHM
120
117
118
119
E165 No communication with See E164.

steering servo during oper-
ation.
E200 traction controller 1 – short- 1. Motor cables incorrectly connected.
circuit. 2. traction controller [A1] defective.
The truck stops. 1. Check that the motor cables are intact and correctly con-
nected.
2. Replace traction controller [A1].
E201 Traction controller 1 – DC Capacitors in traction controller [A1] not charged after 10 s.
bus not charged.
The truck stops. Check the voltage between B+ and B- on traction controller
[A1] once the truck has been turned off to see if the capaci-
tors have been charged. Otherwise, replace traction con-
troller [A1]. Also check that the electronic card [A5] has
voltage at input 808.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
E202 Traction controller 1 – cur- Current sensor incorrectly calibrated.
rent sensor calibration
error.
The truck stops. Restart the truck. Replace traction controller [A1] if neces-
sary.
E203 Traction controller 1 – volt- Internal 15 V voltage too low.
age too low (15 V). 1. Incorrect input voltage.
2. Internal error in traction controller.
The truck stops. 1. Check that the input voltage from cable 8 is +48 V. Check
battery [G1] if necessary.
2. Disconnect battery [G1] briefly and restart the truck. If the
fault persists, replace traction controller.
E204 Traction controller 1 – volt- See E203.
age too low or too high
(5 V).
E205 Traction controller 1 – over- 1. Motor [M1] heavily loaded.
heated drive motor 1. 2. Contacts, wiring or temperature sensor [B1] defective.
The truck stops. 1. Check the ventilation in the motor compartment, particu-
larly fan [M13].
2. Check contacts and wiring to drive motor [M1]. Replace if
necessary.
E206 Traction controller 1 – 1. Excessive current at the outputs.
excessive current at the 2. Traction controller [A1] defective.
outputs.
The truck stops. 1. Disconnect battery [G1] briefly and restart the truck.
E207 Traction controller 1 – over- 1. Traction controller [A1] overheated.
heated heatsink. 2. Traction controller [A1] defective.
The truck stops. 1. Check ventilation.
2. Replace traction controller [A1] if necessary.
E208 Traction controller 1 – AC 1. Motor cables incorrectly connected.
current too high. 2. Traction controller [A1] defective.
nected.
E209- Traction controller 1 – Error 1. Hardware or software error on electronic card in traction
E211 on internal DC bus. controller [A1].
2. Traction controller [A1] defective.

Troubleshooting
808, 812 943926- 2007-05-02 229289-040

Event Action
E214 Traction controller 1 – no No communication with the CAN bus.
communication over CAN.
The truck stops. Check CAN wiring and contacts.
E220 Traction controller 2 – 1. Motor cables incorrectly connected.
short-circuit. 2. Traction controller [A31] defective.
nected.
E221 Traction controller 2 – DC Capacitors in traction controller [A31] not charged after
bus not charged. 10 s.
The truck stops. Check the voltage between B+ and B- on traction controller
[A31] once the truck has been turned off to see if the capac-
itors have been charged. If not, replace traction controller
[A31]. Also check that electronic card [A5] has voltage at
input 808.
E222 Traction controller 2 – cur- Current sensor incorrectly calibrated.
rent sensor calibration
error.
The truck stops. Restart the truck. Replace traction controller [A31] if neces-
sary.
age too low (15 V).
age too low or too high
(5 V).
E225 Traction controller 2 – over- 1. Motor [M2] heavily loaded.
heated drive motor 2. 2. Contacts, wiring or temperature sensor [B2] defective.
The truck stops. 1. Check the ventilation in the motor compartment, particu-
larly fan [M14].
2. Check contacts and wiring to drive motor [M2]. Replace if
necessary.
E226 Traction controller 2 – 1. Excessive current at the outputs.
excessive current at the 2. Traction controller [A31] defective.
outputs.

Troubleshooting
229289-040 2007-05-02 943926- 808, 812

Event Action
E227 Traction controller 2 – over- 1. Traction controller [A31] overheated.
heated heatsink. 2. Traction controller [A31] defective.
The truck stops. 1. Check ventilation.
2. Replace traction controller [A31] if necessary.
E228 Traction controller 2 – AC 1. Motor cables incorrectly connected.
current too high. 2. Traction controller [A31] defective.
nected.
E229- Traction controller 2 – Error 1. Hardware or software error on electronic card in traction
E231 on internal DC bus. controller [A31].
2. Traction controller [A31] defective.
E234 Traction controller 2 – no No communication with the CAN bus.
communication over CAN.
The truck stops. Check CAN wiring and contacts.
11.5.4 Safety logic

In the event of loss of function, take action in accordance with the fol-
lowing table.
Action Emergency Steering Travel Computer

cut-out error error regulator error error
Main contactor releases X X X X
1-stage brake releases X X X
Reversing with traction con- - X - -
troller
Steering shuts off X X X X
Hydraulics shut off - - - -
X = Corrective action
-- = Function not possible

Traction controller
808, 812 943926- 2007-05-02 229289-040
11.6 Traction controller
11.6.1 General
The traction controller is fitted with a green LED that indicates OK sta-
tus. On start-up, it flashes twice and then remains on. Basic software to
control the drive motor is stored in the traction controller.
The traction controller has internal monitoring of CAN communication,
DC voltage levels, its own temperature and motor temperature.
Any function errors are registered by the traction controller and the
information is sent via CAN to electronic card A5, which registers the
error code and shows the corresponding code on the instrument panel
display.
The traction controller can be reprogrammed via CAN.
1 8
9 16

Traction controller
229289-040 2007-05-02 943926- 808, 812
Parameter Value Description

Operating voltage 48 V
Maximum voltage 62.4 V Overvoltage point
Minimum operating voltage 33.6 V Undervoltage point
Frequency 8/12 kHz
Contactor voltage 48 V
Ambient operating temperature -40 – +55°C
Current limit, down-regulation with overheating of the 85 °C 0 A at 125°C
heatsink
Current limit, down-regulation at excessively low heat- -20 °C 60% current limiting at start
sink temperature
Current limiting 350 A 2 minutes
Speed 100% Modulation

Traction controller
808, 812 943926- 2007-05-02 229289-040
11.6.3 Terminal connections and pole bolts
Connection Cable A1/A31 Designation Active In/Out

1 14/19 Motor temperature In
2 -
3 -
4 -
5 16 Choice of ID 0V In
6 11/16 Earth 0V Out
7 118 CAN - 0V In
8 119 CAN H 0-5 V In/Out
9 22 Off/On 48 V In
10 -
11 10/15 Sensor + 12 V, 50 mA Out
12 -
13 12/17 Pulse transducer, 12 V, 1 kOhm In
phase 1
14 13/18 Pulse transducer, 12 V, 1 kOhm In
phase 2
15 -
16 120 CAN L 0-5 V In/Out
B+ 8 Battery + 48 V In
B- 40 Battery - 0V In
U 2/5 Motor winding U 0-33 V Out
V 3/6 Motor winding V 0-33 V Out
W 4/7 Motor winding W 0-33 V Out
11.6.4 Programming
Use the service program TruckCom to download new programs to the
electronic card. See the TruckCom user manual for more information.

Electronic card
229289-040 2007-05-02 943926- 808, 812
11.7 Electronic card
11.7.1 General
Parameter settings and error codes are stored on the electronic card.
11.7.2 Terminal connections

The LEDs on the terminal connections are designated as below:
Green LED = Input
Red LED = Output
Green LED = Voltage feed

Electronic card
808, 812 943926- 2007-05-02 229289-040
Table 11: Electronic card connections

Con- Cable Designation Active In/Out
nec-
tion
104 45 Travel direction selection fork direction, creep speed 48 V In
105 46 Travel direction drive wheel direction, creep speed 48 V In
109 79 Switch, forks in top position 48 V In
203 49 Seat switch 48 V In
401 117 CAN +15 VDC -
402 118 CAN GND -
403 119 CAN H -
404 120 CAN L -
405 121 RS485, serial + -
406 122 RS485, serial - -
407 125 RS485, TX+, transmits data -
408 126 RS485, TX-, transmits data -
501 50 Potentiometer driving (neutral-full acceleration) 3.7-1.7 V In
502 51 Potentiometer braking (neutral-full braking) 1.7-4.1 V In
503 82 Potentiometer fork movement (lift-neutral-lower) 0-3.68-7.35 V In
507 27 Potentiometer feed 7.35 V Out
508 28 GND to potentiometers 0V Out
509 62 Steering tachometer +/-3 V In
511 129 Steering tachometer GND 0V Out
601 70 Battery measurement voltage + 48 V In
602 71 Battery measurement voltage/current - 0V In
603 72 Battery measurement current + In
701 48 Pump contactor 48 V Out
710 67 Valve, fork lowering 48 V Out
802 64 Parking brake 0V Out
804 31 Main contactor 48 V Out
805 21 Battery voltage 48 V In
807 24 Battery voltage after login relay 48 V In
809 22 Battery voltage after emergency switch 48 V In
902 40 GND 0V In

Battery
229289-040 2007-05-02 943926- 808, 812
11.8 Battery
11.8.1 General
When the battery needs charging, the two red LEDs at the bottom of the
battery indicator field start to blink. This means that the fork lifting
speed, among others, will be reduced.
If the battery voltage indicator has not been connected correctly, this is
indicated by all LEDs in the battery indicator display blinking.
11.8.2 Technical data/Parameter settings
Model Battery type Capacity Weight #21

LRE300 Valve-regulated gel battery 644 Ah 1280 8
1280 kg
LRE300T Double valve-regulated gel battery 2x469 Ah 1840 6
AGM Champion 1000 Ah 8
1280 kg
NOTE:
It is important that #21 is correctly set. If the parameter is set too high,
the battery discharge could become excessive and cause reduced
battery service life.If the parameter is set too low, the number of oper-
ating hours between charging events will be reduced.
See the table above for the correct value of #21.
11.8.3 Battery installation

NOTE:
Parameter 21 must always be checked and adapted to the battery in-
stalled in the truck. The parameter setting depends on the battery
type, machine type and also the battery size.

Battery
808, 812 943926- 2007-05-02 229289-040
11.8.4 Changing the battery

NOTE:
When cleaning the battery, it is not necessary to remove it.
To remove the battery, proceed as follows:
NOTE:
A lifting device with sufficient lifting capacity is required for this pro-
cedure.
1. Disconnect the battery connector.
2. Remove the battery compartment cover.
3. Unscrew the battery connector from the chassis.
4. Unscrew the battery locking device.
5. Hook the lifting bridle to the lifting eyes on the battery. Connect one
side from outside the chassis and the other side from inside the
battery compartment. (The lifting bridle must be rated for at least
2000 kg.)
6. Place two pallets next to the truck.

7. Lift the battery from the battery compartment floor.
8. Move the battery to the side where the lifting bridle is outside the
truck chassis (see picture).
9. Lower the battery onto the pallets when the lifting bridle comes into
contact with the chassis.
10. Undo the lifting bridle hooks that are inside the chassis and instead
connect them from the outside.
11. Lift the battery again and once it reaches the centre of the pallets,
lower it.

Battery
229289-040 2007-05-02 943926- 808, 812
12. Reverse the procedure when installing a battery.

NOTE!
When installing a new battery, always verify the setting of #21. The pa-
rameter setting depends on the battery type, machine type and bat-
tery size.
11.8.5 Instructions for verifying the

parameter setting
WARNING!
Battery service life will be reduced if the value of parameter 21 is set
too high. Please always check that the parameter setting is correct
by referring to the instructions below.
To verify the charging state of a discharged 48 V battery, measure the
open-circuit voltage (i.e. voltage at no load) following a period of inac-
tivity. At open-circuit voltage, the indication should be zero.
See the instructions for each battery type below.
Hawker Evolution and AGM Champion

• Charge the battery
• Operate the truck in its normal application until the battery indicator
indicates a discharged battery (0% in the display).
• Disconnect the battery from the truck and allow it to rest for at least
two hours. NOTE: Do not allow any charging or discharging during
this time.
• Measure the open-circuit voltage (i.e. voltage at no load) of the bat-
tery at room temperature. If the voltage is less than Uend (see the
table below), the parameter value must be reduced. If the value
exceeds Uend considerably, the risk of causing damage to the bat-
tery is reduced. At the same time, however, the operating time of
the truck decreases. If an extended operating time is desired,
slightly increase the parameter value.
• Each change should be followed up by a new verification of the
parameter setting.
Battery type Battery voltage when idle, Uend
Hawker Evolution 48.48 V
AGM Champion 48,48 V

Battery
808, 812 943926- 2007-05-02 229289-040
Freely ventilated batteries

To inspect the charge condition of a freely ventilated battery, measure
the specific gravity.
• Charge the battery
• Operate the truck as normal until the battery indicator shows 0.
• Measure the specific gravity. It should be 1.15 g/cm3.
• If the measured value >1.15 g/cm3, it is possible to increase the pa-

rameter value to extend the battery operating time. However, this will
increase battery wear.
• If the measured value <1.15 g/cm3, it is possible to decrease the pa-
rameter value to extend the battery service life.

Hydraulic system – 6000
General
229289-040 2007-05-02 943926- 808, 812
12- Hydraulic system – 6000
12.1 General
The hydraulic system comprises a compact hydraulics unit including a
solenoid valve for lowering the forks and a pressure limit valve.
12.2 Technical data
Description Value
Output 2 kW
Duty cycle S2 3 min
Duty cycle S3 (at 160 bar) 4%
Minimum carbon brush length 5 mm
Pressure at rated load 170 bar
Overflow pressure 210 bar
Pump flow at 190 bar 7.1 l/min
Tank volume 3.3 l
12.3 Hydraulics diagram
12.3.1 Symbols
Symbol Description Symbol Description

Cylinder Non-return valve
Flow regulator Pressure limit valve

valve
Lowering valve Pump and motor
Filter

Hydraulics diagram
808, 812 943926- 2007-05-02 229289-040
12.3.2 Components diagram
2
Y41
4 3
P M3

Components
229289-040 2007-05-02 943926- 808, 812
12.4 Components
1
M3, P
2
3
6
Y41 4
Pos. Designation
1 Lift cylinder
2 Non-return valve
3 Flow regulator valve
4 Pressure limit valve
5 Intake filter (suction filter)
6 Air bleed valve, oil filling
M3 Pump motor
P Pump
T Tank
Y41 Lowering valve

Description
808, 812 943926- 2007-05-02 229289-040
12.5 Description
12.5.1 Lift
In order to lift the forks, the pump motor (M3) is operated. When the
load is in the lifted position, it is retained by the non-return valve (2) and
the closed lowering valve (Y41).
12.5.2 Lowering
In order to lower the forks, the lowering valve (Y41) is opened. The flow
regulator valve (3) regulates the lowering speed. A pressure limit valve
(overflow valve) prevents overloading whilst protecting the pump from
overpressure.
12.5.3 Work pressure

Work pressure at the rated load is 170 bar.
12.5.4 Pressure limit valve

The pressure limit valve opens at 210 bar.
12.6 Adjustments
12.6.1 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 complete hydraulics unit is
replaced. The truck should be able to lift a load of between 3,200 and
3,300 kg.
• Place a load of 3,200 kg on the forks.
• Check that the truck can lift the load.
If the truck cannot lift 3,200 kg:
• Turn the adjuster screw clockwise until the truck can lift the load.
If the truck can lift 3,200 kg:
• Place an additional 100 kg on the forks.
• Check that the truck cannot lift the load.
If the truck can lift 3,300 kg:
• Turn the adjuster screw anticlockwise until the truck cannot lift the
load.

Replacing parts
229289-040 2007-05-02 943926- 808, 812
12.7 Replacing parts
12.7.1 Hydraulic unit

When the hydraulics unit’s parts are replaced, these must be screwed
down using torque as per the picture and the table below.
3
2 6
4 7
Tightening torque (Nm)

1 2 3 4 5 6 7 8
10+5 25+5 25+5 3+1 5 20+5 20+5 10+3

Replacing parts
808, 812 943926- 2007-05-02 229289-040
12.7.2 Cylinder
2
1
• Full access to the cylinder is obtained through the service cover (1)
on the fork carriage.
• The two-part steering (3) is positioned in the track before the piston
rod is pushed in.
• All O-rings and seals are inserted by hand. However, the wiper (2) is
pushed into position using a sleeve.

Extra equipment – 9000
Dry powder extinguisher
229289-040 2007-05-02 943926- 808, 812
13- Extra equipment – 9000
13.1 Dry powder extinguisher

The truck can be equipped with a fire extinguisher/powder extinguisher.
The following information and instructions can be read on the extin-
guisher — follow the instructions carefully.
2 kg ABC Powder
13A 89B C
The letters signify:
A: Wood, paper, textiles
B: Liquids, oils
C: Gases
Extinguishing agent: Prestolit Ultra
Propellant: Nitrogen 15 bar
Functional range: -30° C to +60° C
CE-0409
The digits 13 and 89 represent the fire extinguisher’s capacity for fires
involving the specified materials.
In the event of fire, the powder extinguisher should

be employed as follows:
1. Remove the safety catch.
2. Aim the nozzle at the base of the flames
3. Press the handle down
13.1.1 Regular checks of the powder

extinguisher – truck driver
The following points can be found on the powder extinguisher and
these can also be found in the driver’s manual for the truck.
• Check regularly that the pressure gauge indicator is in the green
field. If the indicator is in the red field, the apparatus is useless and
must be recharged.
• Recharge the extinguisher immediately after use. Contact an au-
thorised service company.
• Make sure that the extinguisher is checked once a year by a quali-
fied service engineer (from an authorised service company for fire
protection) and that a workshop review is carried out every 10 years.
Only material/parts approved by the manufacturer may be used.
© BT Europe AB Servicemanual LRE300, LRE300T 13- 1

Warning light
T-kod Gäller från maskinnr. Datum Beställningsnr.
808, 812 943926- 2007-05-02 229289-040
13.1.2 Inspection of powder extinguisher in

service inspection of the truck
The powder extinguisher must be checked once a year in connection
with servicing of the truck.
• Check that the pressure gauge indicator is in the green field. If the in-
dicator is in the red field, the apparatus is useless and must be re-
charged.
• Check that the powder extinguisher is intact and in working order
and is in the correct location in the truck.
• If the extinguisher does not appear to function satisfactorily, make
sure that an authorised service company is contacted.
13.2 Warning light

The truck can be equipped with warning light.
13- 2 Servicemanual LRE300, LRE300T © BT Europe AB

229289-040
Order number
© BT Europe AB
Date
ELECTRONIC CARD SHOCKSWITCH MAIN UNIT

A5 A20
2007-05-02
X20
21 21/RED
OUT. SUPPLY VOLTAGE +48 VDC 805 1 INP. SUPPLY VOLTAGE + 48 VDC
X20
40 40/BLACK
OUT. SUPPLY VOLTAGE 0 VDC 806 4 INP. SUPPLY VOLTAGE 0 VDC
Servicemanual
943926-
X20
21/WHITE
2 INP. KEY RELAY
24 24/ORANGE
INP. KEY RELAY 807 3 OUT. KEY RELAY
LRE300, LRE300T
X20
21/YELLOW
5 INP. SUPPLY WARNING LIGHT + VDC
T-code
808, 812
X20
202 202/GREEN
6 OUT. WARNING LIGHT + VDC
SCOCK SWITCH READER MODULE

A23
Warning light
245513, 1/1
13- 3
Warning light
T-kod Gäller från maskinnr. Datum Beställningsnr.
808, 812 943926- 2007-05-02 229289-040
245513, 1/1
133
1
S111
5
26
X42
X42
26
10A
F63
40
1
13- 4 Servicemanual LRE300, LRE300T © BT Europe AB

Shockswitch ID/Impact Manager ID
229289-040 2007-05-02 943926- 808, 812
13.3 Shockswitch ID/Impact Manager ID

Some trucks may be equipped with a Shock Switch ID/Impact Manager
ID. These trucks have a separate indicator for the shock switch. If a
truck like this will not start, it is necessary to determine if this is due to a
fault in the shock switch or a fault in the truck.
Truck will not start
Connect a jumper between

inputs 2 and 3 at connector
8 on the A20 logic card
(see the electric wiring diagram).
Does the truck start?
YES! NO!
Defective shock switch. Truck error.

REPLACE! Proceed with troubleshooting as
Order a new one from BT. described in the service manual.
Connect a key switch between

inputs 2 and 3 at connector 8
8 on the A20 logic card.
Please order spare parts from BT. Service inquiries regarding the shock
switch should be addressed to the supplier:
Blankens control
Phone; +31 55 505 83 00
© BT Europe AB Servicemanual LRE300, LRE300T 13- 5

13- 6
T-kod
808, 812
ELECTRONIC CARD SHOCKSWITCH MAIN UNIT

A5 A20
X20
21 21/RED
OUT. SUPPLY VOLTAGE +48 VDC 805 1 INP. SUPPLY VOLTAGE + 48 VDC
B
X20
40 40/BLACK
943926-
OUT. SUPPLY VOLTAGE 0 VDC 806 4 INP. SUPPLY VOLTAGE 0 VDC

Shockswitch ID/Impact Manager ID
Servicemanual
X20
Gäller från maskinnr.
21/WHITE
2 INP. KEY RELAY
B
24 24/ORANGE
INP. KEY RELAY 807 3 OUT. KEY RELAY
Datum
X20
LRE300, LRE300T
21/YELLOW
5 INP. SUPPLY WARNING LIGHT + VDC
2007-05-02
X20
202 202/GREEN
6 OUT. WARNING LIGHT + VDC
SCOCK SWITCH READER MODULE

A23
229289-040
Beställningsnr.
NOTE: IF CONNECTED TO TRUCKMODEL WHICH USUALLY ARE EQUIPPED WITH KEYPAD, PUT PARAMETER 39 TO 1.
© BT Europe AB
Destruction instructions
General
229289-040 2007-05-02 943926- 808, 812
14- Destruction instructions
14.1 General
These instructions have been drawn up as part of the supplier’s envi-
ronmental management programme. An important consideration is
saving on resources, whilst taking nature into consideration. In other
words, you should try to recycle materials as far as possible. This is to
minimise the discharge of environmentally-hazardous substances.
The dismantling instructions are designed for an F-code (truck family)
and then divided into different C-codes. These C-codes are:
• 0000 Chassis
• 1000 Motors
• 2000 Transmission/drive transmission
• 3000 Brakes/belt/wheel system
• 4000 Steering system
• 5000 Electrical system
• 6000 Hydraulics/pneumatics
• 7000 Working function – lift frame
• 8000 Auxiliary/installation equipment
• 9000 Accessories/extra equipment
The instructions do not tell you the type of material the parts are made
of, but refer you to different material containers where the parts should
be collected. Some plastics are marked, which means the instructions
refer to the marking to determine the collection container to use.
14.2 Procedure
When sorting a component part you must know what plastic parts, liq-
uids, environmentally-hazardous substances and metals it includes.

Abbreviations
808, 812 943926- 2007-05-02 229289-040
14.3 Abbreviations
Abbreviations for Service Manuals and plastic materials are used in the
dismantling instructions. The abbreviations used are:
SM = Service Manual
PE = Polythene
PP = Polypropylene
PUR = Polyurethane
PVC = Polyvinyl chloride
PC = Polycarbonate
PMMA = Plexiglass
ABS = Acrylonitrile-butadiene-styrene
14.4 Sorting
The sorting method for component parts is based on how you can recy-
cle the parts and whether they must be taken care of in a special way.
• Plastics must first and foremost be sorted into recyclable and non
recyclable plastics. Plastics that can be recycled must be subdivided
to differentiate between the different types of plastic. Instructions ei-
ther indicate in which container the plastic should be placed or there
is a reference to the material marking on the plastic component. In
those cases where it is stated in which container the plastic part
should be placed, this is done by stating the abbreviation for the
plastic in question. Sorting is not necessary for non-recyclable plas-
tics. These are placed in a container intended for the combustible
material.
• Iron and steel scrap are sorted separately.
• Composite scrap that is difficult to dismantle and which contains dif-
ferent metals such as steel, aluminium, copper and other materials,
e.g. plastics, should be sorted separately.
• Oil should be collected in the intended container.
• Oil filters should be collected in the intended container.
• Parts contaminated by oil, such as hydraulic hoses and tanks,
should be sorted separately.
• Batteries should be returned to the manufacturer, either directly to
the manufacturer or through the supplier.
• Electronic scrap should be sorted from other scrap.
• Cables should be removed and collected separately.
• Small parts such as screws, bolts, nuts, washers, etc. are not includ-
ed in the dismantling instructions. These should be placed in the
container intended for iron and steel scrap.

Frame/chassis (0300)
229289-040 2007-05-02 943926- 808, 812
14.5 Frame/chassis (0300)
14.5.1 Disassembly
• Unscrew everything from the chassis.
Material handling
The chassis should be treated as iron and steel scrap.
14.6 Fork chassis (0380)
14.6.1 Disassembly
• Remove the fork wheels.
Material handling
The fork chassis and tow bars should be treated as iron and steel
scrap.
14.7 Driver’s seat, cushions (0620)
14.7.1 Disassembly
• Remove the seat.
• Remove the seat and back cushions from the seat frame.
Material handling
The seat frame should be placed in the container intended for iron and
steel scrap.
The seat and back cushions should be placed in the container intended
for combustible material.

Driver controls (0640)
808, 812 943926- 2007-05-02 229289-040
1 14.8 Driver controls (0640)

14.8.1 Disassembly
2 • Remove the pedal unit.
• Remove the pedal rubber (1) from the pedals.
• Remove the potentiometer (2).
Material handling
The pedal unit should be placed in the container intended for iron and
steel scrap.
The pedal rubber should be placed in the container intended for com-
bustible material.
The potentiometer should be placed in the container intended for elec-
tronic scrap.
14.9 Interior fittings (0680)

3
1
14.9.1 Disassembly
• Remove the elbow cushions (1).
• Remove the panels (2).
• Remove the rubber guards (3).
Material handling
The elbow cushions should be placed in the container intended for
combustible material.
The panels should be placed in the container intended for combustible
material.
The rubber guards should be placed in the container intended for com-
bustible material.
Electric motors (1700)
229289-040 2007-05-02 943926- 808, 812
2 1 14.10 Electric motors (1700)
14.10.1 Disassembly
• Remove the cables.
• Remove the pump motor including pump and tank (1) (see C-code
6100).
• Remove the drive motor (2) from the transmission.
• Remove fan (3).
Material handling
3 Cables should be placed in the container intended for cables.
Motors should be placed in the container intended for complex waste.
The fan wings should be placed in the container intended for combusti-
ble material.
14.11 Drive assembly, transaxle (2500)
14.11.1 Disassembly
• Empty the oil from the gearbox.
• Remove the gearbox from the drive motor.
• Remove the drive wheel (see C-code 3500).
Material handling
The oil should be poured into the container intended for oil (classified
as hazardous waste within the EU).
The gearbox should be placed in the container intended for iron and
steel scrap.
14.12 Wheels (3500)
14.12.1 Disassembly
• Remove the drive wheel and the fork wheel.
Material handling
If possible, remove the vulcanisation from the rims. The vulcanisation
should be placed in the container intended for combustible material and
the rims in the container intended for iron and steel scrap. Otherwise,
the wheels should be placed in the container intended for complex
waste.

Electric steering system (4300)
808, 812 943926- 2007-05-02 229289-040
14.13 Electric steering system (4300)
5 2
6 3
14.13.1 Disassembly
• Remove the wrist support (1).
• Remove the wheel spinner (2), steering wheel (3) and generator (4).
• Remove the steering servo (5) and sensor (6).
Material handling
The wrist support and wheel spinner should be placed in the container
intended for combustible material.
The generator and steering wheel should be placed in the container
intended for complex waste.
The steering servo and sensor should be placed in containers intended
for electronic scrap.
Other parts should be placed in the container intended for combustible
material or complex waste.

General electronic equipment (5100)
229289-040 2007-05-02 943926- 808, 812
14.14 General electronic equipment

(5100)
14.14.1 Disassembly
• Remove the battery.
Material handling
Cables should be placed in the container intended for cables.
The battery (classified as hazardous waste within the EU) should be
returned to the battery manufacturer or the manufacturer’s representa-
tive (see the rating plate on the battery). The battery can also be hand-
ed in to a BT representative, who bears responsibility for returning the
battery to the manufacturer.
14.15 Power system, drive function

(5400)
14.15.1 Disassembly
• Remove the traction controller.
Material handling
The regulator should be placed in the container intended for electronic
scrap.
14.16 Control system, working function

(5500)
4
14.16.1 Disassembly
1
3 • Remove the switch (1), keypad (2), display (3), potentiometer (4)
and associated cables.
2
Material handling
The component parts should be placed in the container intended for
electronic scrap.
Control and protective electronics (5700)
808, 812 943926- 2007-05-02 229289-040
14.17 Control and protective

electronics (5700)
14.17.1 Disassembly
• Remove the electronic card.
Material handling
Cables are to be placed in the container intended for cables.
The electronic card should be placed in the container intended for elec-
tronic scrap.
14.18 Hydraulic system (6000)
14.18.1 Disassembly
4 • Empty the tank (1) of oil.
5 • Remove the hydraulic cables (2).

• Remove the valve block (3).
3 • Remove the oil tank.
• Remove the hydraulic unit (motor + pump) (4).
• Remove the cylinder (5).
• Empty the cylinder of oil.
1 2 • Cut the cylinder in half.
Material handling
The oil should be poured into the container intended for oil (classified
as hazardous waste within the EU).
Hydraulic hoses should be placed in the container intended for oil-con-
taminated components.
Valve blocks should be placed in the container intended for complex
waste.
The tank should be placed in the container intended for PE.
The motor, together with the pump, should be placed in the container
intended for complex waste.
The cylinder should be placed in the container intended for iron and
steel scrap.

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

STRATOS LRE300 LRE300T - SER No. 943926 and UP - PART No. 229289-040 (MAY 2007)

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STRATOS LRE300 LRE300T - SER No. 943926 and UP - PART No. 229289-040 (MAY 2007)

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Service Manual en

Order number: 229289-040

Issue date Order Changes

This manual covers following truck models:

T-code Model Serial number

© BT Europe AB Service Manual LRE300, LRE300T

2- General ................................................................................................. 2-1

3- Maintenance ........................................................................................ 3-1

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

5- Chassis – 0000 ..................................................................................... 5-1

6- Motors – 1000 ...................................................................................... 6-1

7- Drive transmission – 2000 .................................................................. 7-1

8- Brake – 3100 ........................................................................................ 8-1

© BT Europe AB Service Manual LRE300, LRE300T 1- 1

8.5 Maintenance .................................................................................. 8-5

9- Wheels – 3500 ...................................................................................... 9-1

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

11- Electrical system – 5000 ................................................................. 11-1

1- 2 Service Manual LRE300, LRE300T © BT Europe AB

11.6.2 Technical data ............................................................. 11-65

12- Hydraulic system – 6000 ................................................................. 12-1

13- Extra equipment – 9000 .................................................................. 13-1

14- Destruction instructions ................................................................. 14-1

© BT Europe AB Service Manual LRE300, LRE300T 1- 3

14.11 Drive assembly, transaxle (2500)................................................. 14-5

1- 4 Service Manual LRE300, LRE300T © BT Europe AB

2.1 Technical data

Model LRE300 LRE300T

Other technical data can be found under the relevant chapter.

© BT Europe AB Service Manual LRE300, LRE300T 2- 1

2.2 General tightening torque

Table 1: General tightening torque [Nm]

2- 2 Service Manual LRE300, LRE300T © BT Europe AB

3.1 Maintenance Schedule

Table 2: Maintenance Schedule

© BT Europe AB Service Manual LRE300, LRE300T 3- 1

Table 2: Maintenance Schedule

3- 2 Service Manual LRE300, LRE300T © BT Europe AB

Table 2: Maintenance Schedule

© BT Europe AB Service Manual LRE300, LRE300T 3- 3

3- 4 Service Manual LRE300, LRE300T © BT Europe AB

© BT Europe AB Service Manual LRE300, LRE300T 3- 5

3.2 Oils and greases

3- 6 Service Manual LRE300, LRE300T © BT Europe AB

Table 3: Lubrication chart

Table 4: Oil and grease specification

© BT Europe AB Service Manual LRE300, LRE300T 3- 7

This page is intentionally left blank

3- 8 Service Manual LRE300, LRE300T © BT Europe AB

4.1 Super Seal connector

Tool Number Use

159229 Tools for loosening locks (1)

159230 Tool for fitting secondary locks 2 pole (2)

159231 Tool for fitting secondary locks 4 pole (2)

159228 Tool for removing pins/sleeves (3)

© BT Europe AB Service Manual LRE300, LRE300T 4- 1

4.2 AMP connectors

Figure Number Use

213296 (JPT) Tool for removing pins/sleeves

213298 (MPT) Tool for removing pins/sleeves

1=163787 (JPT) Tool for fitting sleeves

4- 2 Service Manual LRE300, LRE300T © BT Europe AB

4.3 AMP microtimer