Description
Cesab LWI160 Repair Manual – Toyota Document 7660234-040
This is the full Toyota repair manual for the LWI160 low-lifter pallet truck, issued under document number 7660234-040 and written for the software generation referenced as 7662518. It is a workshop-level document rather than an operator booklet: it takes the truck apart system by system, gives the service procedures, tightening torques, parameter values and error-code diagnostics needed to put it back together correctly, and closes with complete wiring and hydraulic diagrams for the machine. The manual is in English and runs to 436 pages divided across 24 numbered chapters using the manufacturer’s C-code system.
File Details
- Manual type: Repair manual (workshop service manual)
- Brand: Toyota
- Model: LWI160
- Document number: 7660234-040
- Software reference: 7662518
- Language: English
- File format: PDF
- Extent: 436 pages, 24 numbered chapters
- Diagrams included: Wiring diagram 7654485 D and 7654487 D, plus a full hydraulic flow diagram
Chapters Covered
- 1 General introduction – images and other information, how to use this manual, warning levels and symbols, pictograms, abbreviations
- 2 General safety regulations – work safety, authorised personnel, truck modifications (types A, B and C), electrical system and electrostatic risks, battery handling, safe lifting, software, hydraulic system
- 3 Operating principle – keypad and display symbols, starting the battery, login via keypad, tiller arm positions, driving in fork and drive wheel directions, braking in neutral, reverse braking, mechanical braking, emergency reversal, fork lifting, Turtle function, Click-2-Creep, lowering limitation
- 4 Parameters – operator parameters, service parameters, factory parameters, calibration parameters, configurable optional functions
- 5 Installation – transporting the truck and fork carriage, lifting the truck, commissioning, PIN code management and defaults, setting parameters, function and safety checks
- 6 Maintenance – cleaning, high-pressure washers, degreasing agents, cleaning the exterior and motor compartment, electric components, optical sensors and reflectors, periodic maintenance schedule
- 7 Troubleshooting – initial and concluding troubleshooting, hydraulic system pressure checks, error code list with causes and actions
- 8 Chassis C0000 – hood mounts, frame and chassis inspection, motor compartment covers, front plates, cylinder cover, support arms and stabilizers, fork structure, safety equipment, signs and labels
- 9 Motors C1000 – electric drive motor, cleaning and inspection, tightening of mountings, replacement, temperature sensor, rotational speed sensor, bearings, toothed wheel, tightening torques
- 10 Transmission/Drive gear C2000 – drive unit overview, drive gear inspection, oil change, drive gear replacement, wheel hub seal, stud replacement, grease nipples and steering bearing lubrication
- 11 Brake/wheel/track system C3000 – brake types, electrically controlled service brake, travel brake function checks, parking brake cleaning, gap adjustment, emergency release and replacement, drive wheel, castor wheels, fork wheels, side guide wheels
- 12 Steering system C4000 – operating panel, safety reversing switch, sensilift, keypad, logic card, tiller arm handle, tiller arm, gas strut, tiller arm cover and housing
- 13 Electrical system C5000 – anti-static handling, TruckCom connection and software update, lithium-ion TMHMS battery system, BMS, battery replacement and modules, PMU, built-in battery charger, main contactor, instrument panel menus, hour counter, drive motor cables and fuses, motor control panel, wiring harnesses, I_Site, OCC, height and LSwLF sensors, emergency switch off
- 14 Hydraulics/Pneumatics C6000 – hydraulic hygiene rules, quick change connectors, hydraulic unit, oil tank level and oil change, air filter, pressure limiting valve adjustment, hydraulic unit replacement, main lift cylinders, tightening torques
- 15 Work function – lifting mast C7000
- 16 Auxiliary equipment, installation equipment C8000
- 17 Optional equipment/Extra equipment C9000 – low speed with low forks, fire extinguisher, Spider expansion unit
- 18 Instructions for disposal – recycling and transport, marking of plastics, pressure vessels and gas struts, sorting categories
- 19 Wiring diagram – colour code table, list of fuses, component lists and detailed diagrams
- 20 Hydraulic diagrams – symbol list, component list, flow diagram
- 21 Tools – tools for electric connectors, lubricating tools, special tools
- 22 Service data and grease specifications – general tightening torques, lubricants specification
- 23 Technical data – truck dimensions and truck data
- 24 Index
What makes this Cesab LWI160 repair manual useful is the way it moves from theory to bench work. The opening chapters explain how the truck behaves and how the control system is configured, which means the parameter and operating-principle sections can be read alongside the fault-finding chapter rather than in isolation. From there the manual switches to the C-code chapters, where each major assembly is broken down into removal, inspection, installation and torque figures. The troubleshooting chapter alone carries dozens of numbered error codes – from CAN communication and Hall sensor faults through to pump motor voltage, lowering valve and shock sensor messages – each with the likely cause and the recommended action. The manual closes with the wiring and hydraulic diagrams plus a full technical data table for the LWI160.
Systems and Components Documented
- Drive motor with temperature sensor, RPM sensor, bearings and toothed wheel
- Drive gear and transmission housing, oil quantity and ratio data
- Electromagnetic parking brake, service brake and safety reversing switch
- Drive wheel, castor wheels, fork wheels and side guide wheels
- Steering arm, tiller arm, gas strut, keypad and tiller arm logic card
- Motor control panel, main contactor, fuses and motor wiring harnesses
- Lithium-ion battery system, battery modules, PMU, BMS and built-in charger
- Hydraulic unit, pump motor, lowering valve, pressure limiting valve and lift cylinder
- Position and protective sensors including OCC steering angle, height sensor and LSwLF
- Spider expansion unit for customised functions
Diagnostics, Parameters and Error Codes
The troubleshooting chapter lists error codes grouped by system – ICH and CAN faults, motor control faults, hydraulic and pump motor faults, charger and BMS faults – and pairs each code with the truck behaviour you will observe, the error cause, and the step-by-step action to take. Alongside this, the parameters chapter documents the operator, service, factory and calibration parameter ranges so a technician can set travel speed, acceleration, Turtle mode limits, fork lowering speed and optional function assignments through TruckCom or the truck keypad.
What This Manual Enables You to Do
With this Toyota LWI160 repair manual open on the bench you can diagnose a fault from the error code list, strip and rebuild the drive motor, replace the parking brake, service the drive gear and refill it to the correct oil quantity, adjust the pressure limiting valve, replace the hydraulic unit, work through the battery modules and PMU, and check every circuit against the wiring diagram rather than guessing at a connector. Torque values appear where they matter – brake retaining screws, motor mountings, drive wheel nuts, terminal pillars, copper bars – so fasteners go back to specification instead of feel.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Cesab LWI160 Repair Manual – Toyota 7660234-040 PDF Workshop Manual” are as follows:
+1 General introductionp. 7
1.1 Images and other informationp. 7
1.2 How to use this manualp. 7
1.3 Warning levels and symbolsp. 8
1.4 Pictogramsp. 8
1.5 Abbreviationsp. 9
+2 General safety regulationsp. 13
2.1 Work safetyp. 13
2.2 Authorised personnelp. 14
+2.3 Truck modificationsp. 14
2.3.1 Responsiblep. 14
2.3.2 What can be modified?p. 14
+2.4 Electrical systemp. 16
2.4.1 Electrostatic risksp. 16
2.4.2 Battery handlingp. 16
2.5 Safe liftingp. 17
2.6 Softwarep. 17
2.7 Hydraulic systemp. 18
+3 Operating principlep. 21
3.1 Symbols on keypad and displayp. 21
+3.2 Introductory descriptionp. 21
3.2.1 Start the batteryp. 21
3.2.2 Login via keypadp. 22
3.2.3 Tiller arm lowered for drivingp. 22
3.2.4 Driving in fork directionp. 22
3.2.5 Driving in the drive wheel directionp. 22
3.2.6 Braking in neutralp. 23
3.2.7 Reverse brakingp. 23
3.2.8 Mechanical brakingp. 24
3.2.9 Emergency reversalp. 24
3.2.10 Fork liftingp. 24
3.2.11 Turtle function (option)p. 24
3.2.12 Click-2-Creepp. 25
3.2.13 Lowering limitationp. 25
+4 Parametersp. 29
4.1 Softwarep. 29
4.2 Parameters in generalp. 29
4.3 Parameter listp. 29
+5 Installationp. 55
+5.1 Transportp. 55
5.1.1 Transporting the Truckp. 55
5.1.2 Transporting the fork carriagep. 55
+5.2 Lifting the truckp. 56
5.2.1 Lifting the truckp. 56
+5.3 Commissioningp. 57
+5.3.1 General information regarding PIN codesp. 57
5.3.1.1 PIN code at deliveryp. 57
5.3.1.2 Programming PIN codesp. 57
5.3.1.3 PIN code defaultsp. 58
5.3.1.4 PIN code for resetting after a collisionp. 59
5.3.2 Setting parametersp. 59
5.3.3 Function and safety checksp. 60
+6 Maintenancep. 63
6.1 Introductionp. 63
+6.2 Maintenance instructionsp. 63
6.2.1 Cleaningp. 63
6.2.2 High-pressure washersp. 63
6.2.3 Degreasing agentsp. 64
6.2.4 Cleaning the exteriorp. 64
6.2.5 Cleaning the motor compartmentp. 64
6.2.6 Electric componentsp. 64
6.2.7 Optical sensors and reflectorsp. 65
6.2.8 Hydraulic systemp. 65
6.2.9 Signs, warnings and adhesive labelsp. 65
6.3 Periodic maintenancep. 65
+7 Troubleshootingp. 75
7.1 Initial troubleshootingp. 75
7.2 Concluding troubleshootingp. 76
+7.3 Auxiliary functionsp. 77
+7.3.1 Hydraulic pressurep. 77
7.3.1.1 Erroneous hydraulic system pressurep. 77
+7.4 Troubleshooting using error codesp. 77
7.4.1 First actions when an error code is displayedp. 77
7.4.2 List of error codesp. 77
+8 Chassis C0000p. 119
8.1 Inspect hood mountsp. 119
+8.2 Frame, chassis C0300p. 119
8.2.1 Checking the chassisp. 119
+8.2.2 Inspection covers C0340p. 119
+8.2.2.1 Motor compartment coversp. 119
8.2.2.1.1 Motor compartment covers Overviewp. 119
+8.2.2.1.2 Replacing the top coverp. 120
8.2.2.1.2.1 Removing the top coverp. 120
8.2.2.1.2.2 Installing the top coverp. 120
+8.2.2.1.3 Replacing the motor coverp. 120
8.2.2.1.3.1 Removing the motor coverp. 120
8.2.2.1.3.2 Installing the motor coverp. 121
+8.2.2.1.4 Replacing the chassis front platep. 121
8.2.2.1.4.1 Removing front platesp. 121
8.2.2.1.4.2 Installing front platesp. 122
+8.2.2.1.5 Replacing the cylinder coverp. 122
8.2.2.1.5.1 Removing the cylinder coverp. 122
8.2.2.1.5.2 Installing the cylinder coverp. 123
+8.2.3 Support arms, stabilizers C0350p. 123
8.2.3.1 Inspection of push rodsp. 123
8.2.3.2 Inspection of bushings and linksp. 123
+8.2.4 Fork structure (low-lifter) C0380p. 123
8.2.4.1 Inspect fork carriagep. 123
8.2.4.2 Checking the lifting and lowering functionp. 123
+8.3 Safety equipment C0800p. 124
+8.3.1 Signs, warnings, labels C0850p. 124
8.3.1.1 Inspect signs and labelsp. 124
8.3.1.2 Placement of plates and symbolsp. 124
+9 Motors C1000p. 129
+9.1 Electric motors C1700p. 129
+9.1.1 Electric drive motor C1760p. 129
9.1.1.1 Overviewp. 129
9.1.1.2 Cleaning the drive motorp. 130
9.1.1.3 Checking the drive motorp. 130
9.1.1.4 Checking the drive motorp. 130
9.1.1.5 Listen for any abnormal noise in the drive motor bearings and in the drive gearp. 130
9.1.1.6 Control tightening of drive motor mountingsp. 130
9.1.1.7 Check for leaks in the drive motorp. 130
+9.1.1.8 Replacing the drive motorp. 130
9.1.1.8.1 Removing the drive motorp. 130
9.1.1.8.2 Installing the drive motorp. 131
+9.1.1.9 Replacing the temperature sensorp. 131
9.1.1.9.1 Installing the temperature sensorp. 131
+9.1.1.10 Replacing the rotational speed sensorp. 132
9.1.1.10.1 Removing a RPM sensorp. 132
9.1.1.10.2 Installing a RPM sensorp. 132
+9.1.1.11 Replacing the bearingp. 132
9.1.1.11.1 Removing the motor bearingsp. 132
9.1.1.11.2 Removing the motor bearingsp. 133
9.1.1.11.3 Installing motor bearingsp. 135
+9.1.1.12 Replacing the toothed wheelp. 135
9.1.1.12.1 Removing a toothed wheelp. 135
9.1.1.12.2 Installing a toothed wheelp. 137
9.1.1.13 Drive motor tightening torquesp. 138
9.1.1.14 Drive motor tightening torquesp. 138
+10 Transmission/Drive gear C2000p. 141
+10.1 Drive unit, final gear C2500p. 141
+10.1.1 Drive unit/gear C2550p. 141
10.1.1.1 Overviewp. 141
10.1.1.2 Inspect drive gearp. 141
+10.1.1.3 Drive gear oil changep. 142
10.1.1.3.1 Empty the drive gear oilp. 142
+10.1.1.4 Replacing the drive gearp. 142
10.1.1.4.1 Removing the drive gearp. 142
10.1.1.4.2 Installing the drive gearp. 143
+10.1.1.5 Replacing the wheel hub sealp. 143
10.1.1.5.1 Removing the wheel hub sealp. 143
10.1.1.5.2 Installing the wheel hub sealp. 145
+10.1.1.6 Stud replacementp. 145
10.1.1.6.1 Removing a studp. 145
10.1.1.6.2 Installing a studp. 146
10.1.1.7 Fit grease nipples, steering bearingp. 146
10.1.1.8 Lubricate steering bearings (Option)p. 147
+11 Brake/wheel/track system C3000p. 151
+11.1 Travel brake system C3100p. 151
+11.1.1 Descriptionp. 151
+11.1.1.1 Brake typesp. 151
11.1.1.1.1 Travel brakep. 151
11.1.1.1.2 Emergency brakep. 151
11.1.1.1.3 Parking brakep. 151
+11.1.2 Electrically controlled service brake C3180p. 152
11.1.3 Checking the function of the travel brakep. 152
11.1.4 Checking the parking brake, service brake and switch for safety reversingp. 153
+11.2 Parking brake details C3300p. 153
+11.2.1 Electrical parking brake, magnet brake C3370p. 153
11.2.1.1 Cleaning the parking brakep. 153
11.2.1.2 Adjusting the parking brake gapp. 153
11.2.1.3 Emergency release of the parking brakep. 154
+11.2.1.4 Replacing the parking brakep. 154
11.2.1.4.1 Removing the parking brakep. 154
11.2.1.4.2 Fitting the parking brakep. 155
+11.3 Wheels C3500p. 156
+11.3.1 Drive wheel C3530p. 156
11.3.1.1 Check-tightening the drive wheel attachmentp. 156
11.3.1.2 Inspect drive wheelp. 156
+11.3.1.3 Replacing the drive wheelp. 157
11.3.1.3.1 Disassembling the drive wheelp. 157
11.3.1.3.2 Installing a drive wheelp. 157
+11.3.2 Support arm wheels/castor wheels C3540p. 158
11.3.2.1 Overviewp. 158
11.3.2.2 Overview, Wheel cradle in chassisp. 158
11.3.2.3 Castor wheel suspension C-brix, 50 Ah systemp. 159
11.3.2.4 Castor suspension E-brix, 105/150 Ah systemp. 159
11.3.2.5 Inspect castor wheelsp. 160
11.3.2.6 Checking the castor wheelsp. 160
+11.3.2.7 Replacing the castor wheelp. 160
11.3.2.7.1 Disassembling the castor wheel cradlep. 160
11.3.2.7.2 Installing castor wheel cradlep. 160
+11.3.3 Fork wheels/support arm wheels C3550p. 161
11.3.3.1 Overviewp. 161
11.3.3.2 Overviewp. 162
11.3.3.3 Overview 2p. 163
11.3.3.4 Cleaning the fork wheelsp. 163
11.3.3.5 Inspect fork wheelsp. 164
+11.3.4 Side guide wheels C3580p. 164
+12 Steering system C4000p. 167
+12.1 Mechanical steering system C4100p. 167
+12.1.1 Steering arm/wheel/lever C4110p. 167
+12.1.1.1 Operating panelp. 167
+12.1.1.1.1 Controlsp. 167
+12.1.1.1.1.1 Replacing the safety reversing switchp. 167
12.1.1.1.1.1.1 Removing the safety reversing switchp. 167
12.1.1.1.1.1.2 Fitting the safety reversing switchp. 167
+12.1.1.1.1.2 Replacing the sensiliftp. 167
12.1.1.1.1.2.1 Removing the sensiliftp. 167
12.1.1.1.1.2.2 Installing sensiliftp. 168
12.1.1.1.1.3 Changing the position of the controls – support arm lift/fork liftp. 169
+12.1.1.1.1.4 Replacing the keypadp. 169
12.1.1.1.1.4.1 Removing the keypadp. 169
12.1.1.1.1.4.2 Installing a keypadp. 170
+12.1.1.1.2 Replacing the logic cardp. 170
12.1.1.1.2.1 Removing the logic cardp. 170
12.1.1.1.2.2 Installing a logic cardp. 171
+12.1.1.2 Tiller arm handlep. 173
12.1.1.2.1 Overview, tiller arm handlep. 173
+12.1.1.2.2 Replacing the handle to the tiller armp. 174
12.1.1.2.2.1 Removing the tiller arm handlep. 174
12.1.1.2.2.2 Fitting the handle to the tiller armp. 175
+12.1.1.3 Tiller armp. 176
12.1.1.3.1 Overview tiller armp. 176
+12.1.1.3.2 Replacing the tiller armp. 177
12.1.1.3.2.1 Removing the tiller armp. 177
+12.1.1.3.3 Replacing a gas strutp. 177
12.1.1.3.3.1 Removing a gas strutp. 177
12.1.1.3.3.2 Installing a gas strutp. 177
+12.1.1.3.4 Replacing the tiller arm coverp. 178
12.1.1.3.4.1 Removing the tiller arm coverp. 178
12.1.1.3.4.2 Installing the tiller arm coverp. 179
+12.1.1.3.5 Replacing the tiller arm housingp. 180
12.1.1.3.5.1 Removing the tiller arm housingp. 180
12.1.1.3.5.2 Fitting the tiller arm housingp. 181
12.1.1.4 Checking steering and tiller armp. 181
+13 Electrical system C5000p. 187
13.1 Using the anti-static carpetp. 187
13.2 Inspect electrical systemp. 187
+13.3 Programming toolsp. 187
+13.3.1 TruckComp. 187
13.3.1.1 Connect the CAN interface to the truckp. 187
+13.3.2 Softwarep. 188
13.3.2.1 Software updatep. 188
+13.4 General electric equipment C5100p. 188
+13.4.1 Battery lithium-ion TMHMS C5110p. 188
13.4.1.1 Authorised personnelp. 188
13.4.1.2 Disconnecting the batteryp. 189
13.4.1.3 Using the charging/discharging unit (CDU)p. 189
+13.4.1.4 Battery system overviewp. 190
13.4.1.4.1 Overview 50 Ahp. 190
13.4.1.4.2 Overview 105/150 Ah Rightp. 191
13.4.1.4.3 Overview 105/150 Ah Leftp. 191
13.4.1.4.4 Overview 150 Ah, right heaterp. 192
13.4.1.4.5 Overview 150 Ah, left heaterp. 193
13.4.1.4.6 Overview of wiring harness, heater 105, 150 Ahp. 195
13.4.1.5 Description of the battery systemp. 196
+13.4.1.6 The battery systemp. 196
13.4.1.6.1 On/off buttonp. 196
13.4.1.6.2 Status check on the battery systemp. 196
13.4.1.6.3 Keypad status checkp. 197
13.4.1.6.4 Sleep modep. 197
13.4.1.6.5 Sleep modep. 198
13.4.1.6.6 Battery charger safety switch-offp. 198
13.4.1.6.7 Balancing the battery systemp. 198
+13.4.1.7 Troubleshootingp. 198
13.4.1.7.1 Initial troubleshootingp. 198
+13.4.1.7.2 Troubleshooting using error codesp. 199
13.4.1.7.2.1 List of error codesp. 199
13.4.1.7.2.2 Protective modeIDp. 219
+13.4.1.8 Battery Management System, BMSp. 220
13.4.1.8.1 Battery Management System, BMSp. 220
+13.4.1.9 Battery replacementp. 220
13.4.1.9.1 Removing the 50 Ah batteryp. 220
13.4.1.9.2 Installing the 50 Ah batteryp. 221
+13.4.1.10 Battery modulep. 222
13.4.1.10.1 Battery modulep. 222
13.4.1.10.2 Cleaning and protective grease applicationp. 224
+13.4.1.10.3 Replacing a battery modulep. 225
13.4.1.10.3.1 Removing the battery module, right-hand side (105/150 Ah)p. 225
13.4.1.10.3.2 Fitting the battery module (105/150 Ah)p. 229
+13.4.1.11 Power Module Unit (PMU)p. 234
+13.4.1.11.1 Replacing the PMU (105 Ah)p. 234
13.4.1.11.1.1 Removing the PMU (105/150 Ah)p. 234
13.4.1.11.1.2 Removing the PMU (105/150 Ah) without Heaterp. 238
13.4.1.11.1.3 Fitting the PMU (105/150 Ah) without Heaterp. 242
13.4.1.11.1.4 Fitting the PMU (105/150 Ah)p. 246
+13.4.1.12 TruckCom lithium-ion TMHMSp. 250
13.4.1.12.1 Connecting to the battery systemp. 250
13.4.1.12.2 Information about the battery systemp. 255
13.4.1.12.3 Truck report with battery logp. 259
13.4.1.12.4 Configuring the battery systemp. 260
13.4.1.12.5 Software updatep. 268
13.4.1.12.6 Protective modep. 269
13.4.1.12.7 Diagnosticsp. 272
+13.4.1.13 Maintenancep. 277
13.4.1.13.1 Storing the battery systemp. 277
13.4.1.13.2 Inspecting the battery locking systemp. 278
+13.4.1.14 Recycling and transportp. 278
13.4.1.14.1 Recycling and transportp. 278
+13.4.1.15 Technical datap. 278
13.4.1.15.1 Technical datap. 278
+13.4.2 General alarm signals (audible/visual) C5160p. 279
+13.4.2.1 Hornp. 279
13.4.2.1.1 Overview, hornp. 279
13.4.2.1.2 Checking the horn functionp. 279
+13.4.2.1.3 Replacing the hornp. 279
13.4.2.1.3.1 Removing the hornp. 279
13.4.2.1.3.2 Fitting a hornp. 281
+13.4.3 Battery charger (built-in) C5170p. 283
13.4.3.1 Battery charger overviewp. 283
+13.4.3.2 Descriptionp. 283
13.4.3.2.1 Installation recommendations for the “connection point” on a lorryp. 283
+13.4.3.3 Replacing the battery charger (onboard)p. 284
13.4.3.3.1 Removing the battery charger (onboard)p. 284
13.4.3.3.2 Fitting the battery charger (onboard)p. 285
+13.4.4 Battery cut out switch, main contactor C5190p. 286
13.4.4.1 Overview, main contactorp. 286
+13.4.4.2 Main contactorp. 287
13.4.4.2.1 Tighten the connections of the contactorp. 287
+13.4.4.2.2 Replacing the main contactorp. 287
13.4.4.2.2.1 Removing the main contactorp. 287
13.4.4.2.2.2 Fitting the main contactorp. 289
+13.5 Instrument panel, display C5200p. 290
+13.5.1 Menup. 290
13.5.1.1 Menusp. 290
13.5.1.2 Menu navigationp. 290
13.5.1.3 Menu overviewp. 291
13.5.1.4 Menu informationp. 291
13.5.1.5 Show hour meter valuesp. 291
13.5.1.6 Show error codesp. 292
13.5.1.7 Show part numbers for software/hardwarep. 292
13.5.1.8 Built-in test ICHp. 293
13.5.1.9 Show collisionsp. 293
13.5.1.10 Show/change parametersp. 293
13.5.1.11 Emergency driving modep. 293
13.5.1.12 Calibrationp. 293
13.5.1.13 Show/change PIN codep. 293
+13.5.1.14 PIN codesp. 294
13.5.1.14.1 Generalp. 294
13.5.1.14.2 PIN code for resetting the truckp. 294
13.5.1.14.3 Programming PIN codesp. 295
13.5.1.14.4 PIN code at deliveryp. 296
13.5.1.14.5 PIN code defaultsp. 297
+13.5.2 Hour counter, tachograph C5290p. 298
13.5.2.1 Checking error log and operating hoursp. 298
+13.6 Power system travel function C5400p. 298
+13.6.1 Drive motor cables/resistors/fuses C5430p. 298
13.6.1.1 Overview, drive motor wiring harnessp. 298
13.6.1.2 List of fusesp. 299
+13.6.2 Motor control C5460p. 300
13.6.2.1 Overview, motor control panelp. 300
13.6.2.2 Checking the cable connectionsp. 301
13.6.2.3 Checking the transistor panel mountingp. 301
+13.6.2.4 Replacing the motor control panelp. 302
13.6.2.4.1 Removing the motor control panelp. 302
13.6.2.4.2 Installing the motor control panelp. 305
+13.7 Control system, working function C5500p. 308
+13.7.1 Work function harnesses/fuse C5590p. 308
13.7.1.1 Overview, main wiring harness 50 Ahp. 308
13.7.1.2 Overview, main wiring harness 150 Ahp. 309
13.7.1.3 BMS overviewp. 310
13.7.1.4 Inspecting the wiring harnessesp. 310
+13.8 Power system working function C5600p. 311
+13.8.1 Battery/motor cables, fuse C5680p. 311
13.8.1.1 Overview, battery 105/150 Ah with wiring harnessp. 311
13.8.1.2 Overview, battery charger wiring harness, externalp. 311
13.8.1.3 Overview, battery charger wiring harness, external with heaterp. 312
13.8.1.4 Overview, battery charger wiring harness, truckp. 312
13.8.1.5 Overview, pump motor wiring harnessp. 313
13.8.1.6 Overview, battery lockp. 313
13.8.1.7 Overview, battery wiring harness 50 Ahp. 314
+13.8.1.8 Replacing the battery cablesp. 314
13.8.1.8.1 Disconnect the battery wiring harnessesp. 314
13.8.1.9 Inspecting the wiring harnessesp. 314
+13.9 Control/protection electronics C5700p. 315
+13.9.1 Transmitting/receiving equipment C5760p. 315
+13.9.1.1 I_Sitep. 315
13.9.1.1.1 Overviewp. 315
13.9.1.1.2 I_Sitep. 315
+13.9.1.1.3 Replacing the DHUp. 316
13.9.1.1.3.1 Removing the DHUp. 316
13.9.1.1.3.2 Installing the DHUp. 317
13.9.1.1.4 Checking DHU/I-site [K110]p. 318
+13.10 Protective sensors, position sensors C5800p. 319
13.10.1 Overview, OCCp. 319
13.10.2 Maximum speed during cornering (OCC)p. 320
+13.10.3 Lift/lowering/reach movement sensor C5820p. 321
+13.10.3.1 Height sensorp. 321
13.10.3.1.1 Overview, height sensorp. 321
+13.10.3.1.2 Replacing the height sensorp. 322
13.10.3.1.2.1 Removing the height sensorp. 322
13.10.3.1.2.2 Installing a height sensorp. 323
+13.10.3.2 Low Speed when Low Forks (LSwLF) sensorsp. 324
13.10.3.2.1 Overview, LSwLF sensorp. 324
+13.10.3.2.2 Replacing LSwLF sensorsp. 325
13.10.3.2.2.1 Removing LSwLF sensor, LSwLF optionp. 325
13.10.3.2.2.2 Installing LSwLF sensor, LSwLF optionp. 325
+13.10.4 Safety probes/sensors C5830p. 326
+13.10.4.1 Emergency switch offp. 326
13.10.4.1.1 Overviewp. 326
13.10.4.1.2 Checking the emergency stop switchp. 326
13.10.4.1.3 Checking the emergency switch functionp. 327
+13.10.4.1.4 Replacing the emergency stop switchp. 327
13.10.4.1.4.1 Removing the emergency off switchp. 327
13.10.4.1.4.2 Installing the emergency off switchp. 328
+14 Hydraulics/Pneumatics C6000p. 333
+14.1 Descriptionp. 333
+14.1.1 Hydraulic hygienep. 333
14.1.1.1 Definitions – hydraulic partsp. 333
14.1.1.2 Inside cleaningp. 333
14.1.1.3 Packagingp. 333
14.1.1.4 Handlingp. 333
14.1.1.5 Storagep. 333
14.1.1.6 Work proceduresp. 333
14.2 Inspecting the hydraulic systemp. 334
+14.3 Quick change connectorsp. 334
14.3.1 Overview quick change connectorsp. 334
14.3.2 Removing female quick change connectorsp. 335
14.3.3 Removing female quick change connectorsp. 336
14.3.4 Installing female quick change connectorsp. 337
14.3.5 Removing a quick change connector (male)p. 338
14.3.6 Installing a quick change connector (male)p. 339
+14.4 Hydraulic unit C6100p. 340
14.4.1 Overviewp. 340
+14.4.2 Hydraulic oil tank C6110p. 340
14.4.2.1 Checking the hydraulic oil levelp. 340
+14.4.2.2 Oil changep. 341
14.4.2.2.1 Topping up with oilp. 341
14.4.2.2.2 Topping up with oilp. 341
+14.4.3 Filter, filter housing C6130p. 341
+14.4.3.1 Air filterp. 341
14.4.3.1.1 Inspecting the breather filterp. 341
+14.4.4 Pressure/flow/lowering valve C6170p. 342
14.4.4.1 Adjusting the pressure limiting valvep. 342
+14.4.5 Replacing the hydraulic unitp. 343
14.4.5.1 Removing the hydraulic unitp. 343
14.4.5.2 Installing the hydraulic unitp. 343
+14.5 Hydraulic cylinder C6600p. 344
+14.5.1 Main lift cylinders C6610p. 344
14.5.1.1 Inspect lifting cylinderp. 344
+14.6 Hydraulic unit tightening torquesp. 344
14.6.1 Hydraulic unit tightening torquesp. 344
15 Work function – lifting mast C7000p. 347
16 Auxiliary equipment, installation equipment C8000p. 351
+17 Optional equipment/Extra equipment C9000p. 355
+17.1 Other extra equipment C9500p. 355
17.1.1 Low speed with low forks (LSwLF)p. 355
+17.1.2 Fire extinguisherp. 356
17.1.2.1 Inspection of fire extinguisherp. 356
+17.1.3 Spider expansion unitp. 356
+17.1.3.1 Descriptionp. 356
17.1.3.1.1 Spider expansion unitp. 356
+18 Instructions for disposalp. 361
18.1 Recycling and transportp. 361
+18.2 Marking of plasticsp. 361
18.2.1 General marking of products and packagingp. 361
+18.2.2 Marking according to the manufacturer’s standardsp. 361
18.2.2.1 Abbreviationsp. 362
18.2.2.2 Marking examplesp. 362
+18.3 Pressure vesselsp. 363
18.4 Sorting categoriesp. 363
+19 Wiring diagramp. 367
19.1 Colour code tablep. 367
19.2 List of fusesp. 367
+19.3 Diagram [7654485 D – LWI160.1056]p. 368
19.3.1 Component listp. 368
19.3.2 General diagramp. 371
19.3.3 Detailed diagramsp. 372
+19.4 Diagram [7654487 D – LWI160.1056]p. 386
19.4.1 Component listp. 386
19.4.2 General diagramp. 388
19.4.3 Detailed diagramsp. 389
+20 Hydraulic diagramsp. 403
20.1 List of symbolsp. 403
20.2 Component listp. 405
+20.3 Diagramp. 406
20.3.1 Detailed diagramsp. 407
+21 Toolsp. 411
+21.1 Tools for electric connectorsp. 411
21.1.1 AMP connectorsp. 411
21.1.2 MQS connectorsp. 412
21.1.3 CPC connectorsp. 413
21.1.4 AMP Seal connectorsp. 413
21.1.5 Molex connectorsp. 414
21.1.6 Super Seal connectorsp. 414
21.2 Lubricating toolp. 415
21.3 Special toolsp. 416
+22 Service data and grease specificationsp. 425
+22.1 General tightening torquesp. 425
22.1.1 Galvanised, non-oiled screwsp. 425
22.1.2 Untreated, oiled screwsp. 425
22.2 Lubricants specificationp. 426
+23 Technical datap. 429
23.1 Truck Dimensionsp. 429
23.2 Truck datap. 430
24 Indexp. 431
Optimised Periodical Maintenancep. 433
That level of detail matters on a low-lifter because the same symptom can come from the motor control, the CAN bus, the battery management system or a sensor, and swapping parts until something works is expensive. Having the correct procedure and the correct specification in front of you is what keeps the truck safe, keeps the repair first-time, and keeps the machine out of the workshop.
The manual is delivered as an instant PDF download after payment. There is no shipping and no waiting. Open it on a laptop, tablet or phone in the workshop, print the pages you need for the job in front of you, and keep the diagrams to hand while you work.
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